OPERATIONS AND MAINTENANCE MANUAL

SIMPLE PRESSURE CONTROL

MAN-10001359
ASSEMBLIES

Example Illustration of X-Over

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OPERATIONS AND MAINTENANCE MANUAL
SIMPLE PRESSURE CONTROL
MAN-10001359
ASSEMBLIES

This document is applicable to all Simple Pressure Control Equipment, (such as

Flanges, PIS Assemblies, QTS Assemblies, X-Overs, Test Plugs, Test Caps,
Lubricators, Ball Check Valves & Side Entry Subs etc.) with a working pressure of
15,000 psi or below.

NOTE!
Simple Pressure Control Assemblies are defined as those that do not have any form of
hydraulic actuation.

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Originally Prepared by C. Wade
Edited by S. Trevaskis
Approved by C Wade
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Publication MAN-10001359
© 2013 Copyright National Oilwell Varco
The information is correct at the time of print
First Published in June 2007 by ASEP Elmar Engineering
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Approval and Issue

REV ECO PREPARED CHECKED APPROVED DATE COMMENTS

D 10496 S. Trevaskis P. Macdonald P. Macdonald 16/10/2013 Add Section 3.4

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1  HEALTH AND SAFETY ..................................................................................... 5 
1.1  GENERAL .......................................................................................................... 6 

1.2  SAFETY PRECAUTIONS AND WARNINGS ...................................................... 6 

1.3  COMPETENCY OF PERSONNEL ..................................................................... 7 

1.4  PERSONAL PROTECTIVE EQUIPMENT .......................................................... 8 

1.5  PREPARATION OF THE WORKSITE ................................................................ 9 

1.6  PRESSURE CONTROL SAFETY..................................................................... 10 

2  SPECIFICATIONS AND FEATURES ............................................................... 14 

2.1  SPECIFICATIONS ............................................................................................ 15 

2.2  DESIGN STANDARDS AND REQUIREMENTS............................................... 15 

3  OPERATION .................................................................................................... 17 

3.1  FUNDAMENTAL RULES FOR PROPER OPERATION ................................... 18 

3.2  OPERATION .................................................................................................... 18 

3.3  QTS OPERATING PROCEDURE ONLY .......................................................... 19 

3.4  SIDE ENTRY SUB ASSEMBLY........................................................................ 19 

4  ASSEMBLY INSTRUCTIONS .......................................................................... 20 

4.1  TOOL LIST ....................................................................................................... 21 

4.2  ASSEMBLY INSTRUCTIONS .......................................................................... 22 

4.3  ASSEMBLY PROCEDURE .............................................................................. 22 

5  MAINTENANCE AND TESTING ...................................................................... 23 

5.1  ROUTINE MAINTENANCE .............................................................................. 24 

5.2  MAJOR MAINTENANCE .................................................................................. 26 

5.3  TESTING .......................................................................................................... 27 

5.4  TROUBLESHOOTING...................................................................................... 30 

5.5  MAINTENANCE RECORD SHEET .................................................................. 30 

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6  TRANSPORTATION, SPARES, ACCESSORIES AND DISPOSAL................ 31 
6.1  TRANSPORTATION......................................................................................... 32 

6.2  SPARES AND ACCESSORIES ........................................................................ 32 

6.3  DISPOSAL ........................................................................................................ 33 

7  DRAWINGS AND BILLS OF MATERIAL ........................................................ 34 

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1 HEALTH AND SAFETY
1.1 GENERAL

1.2 SAFETY PRECAUTIONS AND WARNINGS

1.3 COMPETENCY OF PERSONNEL

1.4 PERSONAL PROTECTIVE EQUIPMENT

1.5 PREPARATION OF THE WORKSITE

1.6 PRESSURE CONTROL AND SAFETY

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 SAFETY IS EVERYONE'S RESPONSIBILITY

1.1 GENERAL
This manual should be consulted as a minimum requirement by all persons involved
in work on Wellhead Pressure Control Equipment. All other documents such as
assembly drawings, bill of materials etc, should be made available at the worksite.
Failure to consult the manual could result in a lack of knowledge that could result in
accidents involving injury to personnel or lead to damage to property and equipment.

This manual documents NOV ASEP Elmar's recommendations, but should not be
assumed to satisfy the requirements of legal regulations governing the region in
which the equipment is being used or additional company policy of the owner/user.

Additional measures must be put in place by owner/user to ensure that:

 the required competency of operators is defined, and that only competent

operators are permitted to operate the equipment;

 suitable additional workplace measures are defined, and adhered to, to

further reduce the residual risks associated with the use of the equipment;

 a suitable program for regular maintenance of the equipment is defined,

adhered to and recorded;

 a suitable program for periodic inspection, testing and examination of the

equipment is defined, adhered to and recorded.

1.2 SAFETY PRECAUTIONS AND WARNINGS

Operation and maintenance of wellhead pressure control equipment involves residual
risks which cannot be reduced by design lower than is reasonably practical. General
hazards and additional information to reduce these risks are provided in the form of
additional notes, cautions or warnings.

The following nomenclature is used throughout the manual. Its purpose is to make
the user aware of the potential hazards related to using pressure containing
equipment in general, and to allow the operator to minimise these risks by employing
safe working practices (refer also to 1.5, Preparation of the Worksite):
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 TIP!
An instruction with this indicator is a tip to make a task easier to carry out.

NOTE!
An instruction with this indicator is extra information that can prevent minor problems.

CAUTION!
An instruction FOLLOWED by this CAUTION highlights a hazard which could cause damage to
equipment or its components. Follow the instructions carefully.

WARNING!
An instruction FOLLOWED by this WARNING highlights a danger or injury to the OPERATOR
or other PERSONNEL, or danger of serious damage to the equipment or other objects. Follow
the instructions carefully.

1.3 COMPETENCY OF PERSONNEL

All operation and maintenance of the Wellhead Pressure Control Equipment (WHE)
should be planned and supervised by a competent person. The competent person
will normally be the person in charge of the worksite who should consider the safety
aspects of the work and the competency of the persons carrying out the operations.

WARNING!
Any persons who feel sick, tired, or are under the influence of medicines, alcohol, or other
drugs should not be allowed to operate WHE.

The legal requirements and owner/user requirements for operator competency may
vary between regions and between owner/users. The definition of operator
competency should, therefore, be defined and controlled by the equipment
owner/user.

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NOV ASEP Elmar recommend that the competent person must have, as a
minimum:

 Sufficient practical and theoretical knowledge of wellhead pressure control

equipment at that particular location.

 Sufficient experience of the operation of wellhead pressure control

equipment in the environment in which it is used.

 The ability to detect deficiencies and to assess their criticality in relation to

strength and performance, and to recommend remedial action to ensure
that conditions are appropriate for safe use.

 Understand and comply with Emergency Procedures and Instructions.

 Be able to describe the nature of principal hazards that could occur at the
particular location including the appropriate worksite precautions, test
methods and means of safe handling.

 Be able to locate, identify, describe functionality and operate all fixed and
portable fire fighting and life support equipment at the location.

 Other personnel involved in the operations should have a sound

knowledge of their part of the operation and have received instructions
from the competent person.

NOV ASEP Elmar recommend that personnel involved in wellhead pressure

operations have been formally trained. NOV ASEP Elmar can provide formal training
courses which should be attended as part of the achievement of operator
competency.

1.4 PERSONAL PROTECTIVE EQUIPMENT

Appropriate PPE should be worn specific to the job. As a minimum standard the
following is recommended:

1) Safety Helmets.

2) Eye Protection.

3) Hearing Protection.

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 4) Respiratory Protection (where conditions deem necessary).

5) Body Protection.

6) Hand Protection i.e. wearing of gloves or use a barrier cream if necessary.

7) Foot Protection.

1.5 PREPARATION OF THE WORKSITE

The competent person should not allow work to proceed until the thorough
examination and risk assessment of the work site and equipment has been carried
out, and that he is satisfied that it is safe to proceed. The risk assessment should be
carried out to identify hazards and assess their threat. This risk assessment should
be cascaded to all other persons involved in carrying out the work.

The examination should assess (as a minimum) the condition of the equipment
structure, the condition of all critical components, and ensure that the WHE shows no
signs of excessive damage or wear which may affect the safety of the equipment
during use. (Refer to Section 7 for inspection, examination and testing for WHE
details).

Hazards are identified and assessed through:

1) Experience/Judgement

 The knowledge of experienced staff provides a sound basis for

hazard identification and assessment.

2) Checklists

 These are a useful way of ensuring that known hazards have been
identified and assessed. They are normally drawn up from
operational experience and focus on areas where the potential for
mistakes is high or where problems have occurred in the past.

3) Hazards are assessed using any combination of:

 Engineering judgement, or.

 Comparison with good practice in the field.

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 4) At the completion of the of the risk assessment it should be possible to
document that:

 All hazards have been identified;

 The controls to manage potential causes are in place.

 The prepared measures to mitigate potential consequences have

been taken.

Remember….

 Do use eye protection when using power tools.

 Do wear gloves or use barrier cream to protect your hands.

 Do wear protective footwear.

 Keep loose clothing and long hair well out of the way of moving
mechanical parts.

 Do remove rings, wristwatch etc, before working.

 Do change out of oil-soaked clothes and do not keep oily rags in your
pocket.

 Do ensure that any lifting or jacking equipment has a safe working load
rating adequate for the job.

 Do get someone to check periodically that all is well if working alone.

1.6 PRESSURE CONTROL SAFETY

1.6.1 BASIC SAFETY

 Pressure Control Equipment is used to safely perform operations when

pressure is present or is likely to develop at the wellhead.

 A routine pressure job does not exist. Potential safety hazards always
exist during any operation performed under pressure.

 Well trained personnel and well maintained equipment are a fundamental

requirement for a safe pressure job.

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  All personnel should wear adequate safety clothing, for example safety
glasses, gloves, boots, hard hats and overalls.

 Special precautions are necessary if H2S may be present at the well site.

1.6.2 RESPONSIBILITY

 Safety is everyone’s responsibility. You are responsible for your own

safety and you have a duty of care to other personnel present on the rig or
well site.

1.6.3 BASIC SAFETY

 Never heat or weld any part of the pressure control equipment.

 Never tamper with equipment which is subjected to pressure.

 Never turn hose reels with pressure applied to hose.

 Never replace pressure fittings unless you are sure of the new parts
thread type, service type, and pressure rating.

 Never use any piece of equipment that does not have a Working Pressure
Rating.

1.6.4 PRE-DEPARTURE

 Detailed and advanced planning of a job is essential to ensure safe

operations.

 In order to gain details of possible hazards either visit the well site or call
the client. Points to discuss include:-

 Wellhead Pressure and Temperature;

 Production: gas, oil, H2S, CO2, chlorides, hydrates;

 Inhibitors, corrosive fluids, chemical injection;

 Rig: Height – BOP adapter flanges;

 Tubing, casing, restrictions, deviation;

 Wellhead crossover connection;

 Lifting equipment, cat lines, travelling blocks, cranes.

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  Select proper equipment depending on pressure and type of service.
Equipment is usually chosen to have a Working Pressure Rating of 1.2
times the maximum expected well pressure. Check the rating and
compatibility of all connections.

 Perform a complete system check.

 The pressure rating of a complete control system is equal to the rating of

the lowest rated individual item – the weakest link in the chain. This
includes the pressure fittings, needle valves, gauges, etc.

 Ensure that enough lubricators are available to cover the tool and allow 3ft
(1metre) clearance. This applies to fixed structures- not semi-submersible
rigs drilling rigs.

 Check spare parts box.

1.6.5 ON LOCATION

 Review all operational steps, possible safety hazards, open and shut-in
well procedures.

 Be aware of rig emergency procedures, including shut-in, fire, H2S,

abandon ship etc.

 Never fill riser or pressure test with diesel oil. Air in the riser can be
compressed and mixed with diesel vapour to cause a diesel explosion.

 Drill floors are dangerous places. Be more alert and take care of
necessary precautions when working on a rig floor.

1.6.6 RIGGING UP

 Clear area of unnecessary personnel.

 Ensure drill floor is free of mud and dirt.

 Rig up wellhead adapter, BOP and tool trap first.

 Secure all flow lines.

 Ensure drain lines are coupled to closed drain system or environmental

secure area.

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  Pressure test the complete set up to 1.2 times the expected wellhead
pressure. Hold pressure for 10 minutes and record. Use water or glycol to
test and NEVER diesel. Ensure that no air remains in the system during a
pressure test.

 Client representative controls the Christmas Tree master valves.

 Count the number of turns and tag the valve.

 Never tighten or loosen connections under pressure.

 Use a rope, NOT THE PRESSURE HOSES, to help align the grease head
and lubricator with the wellhead.

1.6.7 RIGGING DOWN

 Be aware that trapped pressure may exist in equipment even after it has
been rigged down and apparently bled down. A sure sign of trapped
pressure is an unusually tight union connection or a stiff hose.

1.6.8 AFTER JOB

 Perform maintenance. The time between the end of the job and
maintenance is when the equipment is most at risk from corrosion.

 Concentration is often low after the job is complete and this leads to
accidents. Please remember that the equipment is heavy and should still
be treated with care and attention.

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2 SPECIFICATIONS AND FEATURES
2.1 SPECIFICATIONS

2.2 DESIGN STANDARDS AND REQUIREMENTS

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2.1 SPECIFICATIONS
The exact specification of each Assembly will vary depending on the customer’s
individual requirements.

2.2 DESIGN STANDARDS AND REQUIREMENTS

2.2.1 DESIGN STANDARDS

The Pressure Control Equipment has been designed in accordance with the following
standards and given third party approval by Bureau Veritas:

 API 6A (Latest Edition)

 NACE MR 01 75 (Latest Edition) – for H2S service only

 Norwegian Petroleum Directorate, the Facilities Regulations, Sept 2001

 Schlumberger, Pressure Operations Manual

 SI 289, 1974

 SI 913, 1996

 SI 2306, 1998 - PUWER

As standard each piece of Pressure Control Equipment is designed to comply with

the following requirements within API 6A:

Working Pressure (refer to relevant assembly drawing for details)

 Service Temperature Classes P, R, S, T, U & V (-29C to 121C)

 Manufacturing standards PSL 3 and PR1.

 Material Class Refer to relevant assembly drawing for details.

All assemblies are supplied as standard with Nitrile elastomers for all sealing
elements. Other grades are available in seal kit form on request.

Assemblies can also be designed to service temperature classes L (-46C) and X

(180C).

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2.2.2 SPECIFICATIONS FOR ARCTIC USE
Our standard PCE range is designed to operate at a minimum temperature limit of -
29ºC (-20ºF) in accordance with API 6A temperature classes P to V. We can also
offer the option of arctic service assemblies which are designed for operation over a
wider range to include API 6A temperature classes L or K where required. The
associated lower limits for this arctic equipment are as follows:

 API 6A temperature class L has a minimum temperature limit of -46ºC

(-50ºF)

 API 6A temperature class K has a minimum temperature limit of -60ºC

(-75ºF)

All pressure containing bodies and elastomers are made from materials specifically
selected for use in low temperature environments. Raw materials for metallic
pressure containing elements have undergone appropriate impact testing at the
lowest limit for the temperature class required, and HNBR o-rings are used in seal
kits.

Arctic assemblies are identified by an ‘ARC’ suffix, and associated seal kits have a
‘KA’ suffix.

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3 OPERATION
3.1 FUNDAMENTAL RULES FOR PROPER OPERATION

3.2 OPERATION

3.3 QTS OPERATING PROCEDURE ONLY

3.4 LUBRICATOR SIDE ENTRY SUB-ASSEMBLY

THE WHOLE OF THIS PROCEDURE MUST BE READ THROUGH WITH

THE APPROPRIATE ASSEMBLY DRAWINGS BEFORE CARRYING OUT
ANY OF THE FOLLOWING ACTIONS

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3.1 FUNDAMENTAL RULES FOR PROPER OPERATION
The following fundamental rules apply to all operations with WHE Equipment.

 All equipment used for pressure control operations must be pressure

rated, to a defined Working Pressure, WP and a Test Pressure, TP. For
high temperature applications a Temperature Rating must also be defined.

 Pressure control equipment shall never be used above its Working

Pressure (WP) rating, or outside its temperature rating.

 In a string of WHE equipment, the WP of the weakest component gives

the string overall pressure rating.

 All WHE components holding pressure must have valid certification.

 All WHE components holding pressure must have a quality file.

 All WHE equipment used on the well-site is qualified for its use by passing
annually a hydrostatic body test and an operation check at WP.

 A well-site pressure test must be carried out after set-up and before
opening the well on each job. The Maximum Allowable Working Pressure
during the job equals the well-site test pressure.

 All crews operating WHE equipment must be qualified to carry out

pressure operations.

3.2 OPERATION
Observe all safety considerations (Refer to Section 1 for general safety information)
and site rules.

Before operation of the Pressure Control Equipment refer to Section 5, Maintenance

and Testing to ensure the equipment has been fully serviced and the necessary
‘Before Job Checks’ have been carried out. Do not assume that serviceable
equipment on the last job will be serviceable again.

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3.3 QTS OPERATING PROCEDURE ONLY
1. A hose and pump with special fittings and suitable WP, should be
supplied with the QTS.

2. Make sure the valve on the side of the QTS is closed ( allen key turned
clockwise).

3. Connect the hose from the pump to the QTS, first test if the pump and
hose are holding pressure, then dump pressure at the pump.

4. Using an allen key open the valve (anticlockwise) then apply required
pressure with the pump, this will only take a few strokes as the volume
of hydraulic fluid required is minimal, as it is only filling the gap between
two ‘O’ rings.

5. After the test, dump the pressure at the pump.

IT IS VERY IMPORTANT THAT THE VALVE ON THE QTS IS NOW

CLOSED (CLOCKWISE)
This is because if during the wireline operation an ‘O’ ring inside the QTS did fail then well
pressure could well enter the hose and return into the hand pump.

3.4 SIDE ENTRY SUB ASSEMBLY

The NOV Elmar side entry sub sits on the WPCE lubricator string and allows the
introduction of tooling into the main well bore through the angled side connection.
The assembly consists of 3 individual adapters screwed into a single block allowing
the adapters to be easily changed out if required.

The adapters all feature elastomeric seals and the angled side connection is
designed to have the same through bore as the main body and vertical adapters.

There are no special operating procedures to be aware of when using this assembly.

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4 ASSEMBLY INSTRUCTIONS
4.1 TOOL LIST

4.2 ASSEMBLY INSTRUCTIONS

4.3 ASSEMBLY PROCEDURE

THE WHOLE OF THIS PROCEDURE MUST BE READ THROUGH WITH

THE APPROPRIATE ASSEMBLY DRAWINGS BEFORE CARRYING OUT
ANY OF THE FOLLOWING ACTIONS

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4.1 TOOL LIST

 Clean work surface;

 Airline;

 Clean rags;

 Vice;

 O-ring pick;

 Grease brush;

 3M Scotchbrite (Elmar Part No L-893000);

 WD40 (Elmar Part No L-881740 – 5 litres);

 Grease (Elmar Part No L-881720);

 Anti-seize protective compound (Copperslip) (Elmar Part No L-882940);

 PTFE thread tape (Elmar Part No L-861900);

 Loctite 577 thread sealant (Elmar Part No L-862200);

 Punch (appropriate size for std collar/collar ring make-up)

 3” circlip pliers (for collar circlip)

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4.2 ASSEMBLY INSTRUCTIONS
Remember….

 Do use eye protection when using power tools.

 Do wear gloves or use barrier cream to protect your hands.

 Do wear protective footwear.

 Keep loose clothing and long hair well out of the way of moving
mechanical parts.

 Do remove rings, wristwatch etc, before working.

 Do change out of oil-soaked clothes and do not keep oily rags in your
pocket.

 Do ensure that any lifting or jacking equipment has a safe working load
rating adequate for the job.

 Do get someone to check periodically that all is well when working alone.

4.3 ASSEMBLY PROCEDURE

Refer to relevant assembly drawing for assembly procedure.

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5 MAINTENANCE AND TESTING
5.1 ROUTINE MAINTENANCE

5.2 MAJOR MAINTENANCE

5.3 TESTING

5.4 TROUBLESHOOTING

5.5 MAINTENANCE RECORD SHEET

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5.1 ROUTINE MAINTENANCE

NOTE!
Refer to Section 1 for general safety information before carrying out any maintenance and
testing routines.

WARNING
The Equipment can be heavy; check that the lifting and handling equipment can support this
load. Never position yourself under the suspended equipment.

NOTE!
Refer to build specific assembly drawings for equipment details, e.g seal kit part numbers and
service details.

NOTE!
Equipment needs to be properly maintained to perform properly.

General rules for routine inspections:

 All components shall be thoroughly cleaned.

 All assemblies shall be disassembled and components inspected for

damage or corrosion.

 All threads and sealing surfaces shall be checked for damage.

 Any elements showing cracks or surface defects shall be replaced.

 Where grease lubrication nipples exist, ensure grease is pumped until full.

 After inspection and reassembly the equipment shall undergo a function

test (if applicable) and pressure test to working pressure.

5.1.1 BEFORE EVERY JOB

 Check the equipment service record to ensure the equipment has been
fully serviced by competent personnel.

 Check all threads, seals and sealing surfaces for damage that might
impair sealing. Repair or replace as necessary.

 Lubricate through all grease nipples.

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  Function and pressure test to Working Pressure. (Function test may not be
applicable, check assembly drawing for details).

 Verify that the well site test pressure does not exceed the Working
Pressure rating of that of the equipment.

 Pressure test the complete hook-up.

 Check that Seal Kits are available.

5.1.2 AFTER EVERY JOB

NOTE!
Fully dismantling and cleaning all parts that have seen well fluids and debris will extend the life
of the product. The time between the end of the job and maintenance is when the equipment is
most at risk from corrosion.

NOTE!
Avoid steam cleaning any internal bores that have corrosion resistant coatings. Grease the
internal bores using a cloth/swab.
These coatings are sacrificial and may need re-applying periodically.

 Dismantle and clean all parts.

 Inspect all seals and sealing surfaces. Replace any damaged sealing rings
and back-up rings.

 Check all threads.

NOTE!
If the job contained any of the following, then it is advisable to strip the Assembly, replacing the
seals that see well pressure.
Extended Exposure (> 48 hours)
H2S
High pressure gas

 Reassemble as per the assembly drawing.

 Lubricate through all grease nipples.

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  Function test at working pressure.(if applicable)

5.2 MAJOR MAINTENANCE

All WHE shall be surveyed at regular intervals and at least once per year. An annual
survey usually consists of a visual inspection and dimensional checks for ovality of
tubulars and threads. For all jobs over 5,000 psi, the hydrostatic body test and
operational test shall not be older than 3 months. A verification procedure should also
be carried out after every job where the WHE has been subjected to extraordinary
conditions, such as rough handling, bending, accidental drops, corrosive fluids,
unexpected H2S or CO2 during standard service, or replacement of major parts.

All surveys and tests must be recorded in the equipment service record.

Renewal of certification requires a detailed survey and performance verification

carried out under the control of a certification agency. The need and frequency of
such certification renewal shall be determined by local regulations, but typically every
five years. All WHE pressure containing equipment should undergo a major re-
certification every five years based on the following general procedures:

 Visual inspection.

 Random thickness tests on all Pressure Control Assemblies using direct

measurements, ultrasonic or X-ray.

TIP!
Refer to Elmar Technical Bulletin TB-735
Procedure for finding minimum acceptable wall thickness on pressure control equipment.

 Dye penetration or MPI examination on threads or any damaged area

determined at visual inspection.

 Hydrostatic body test to Test Pressure.

 Function tests at Working Pressure. (if applicable).

 Review of Quality Files.

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All WHE having undergone three 5 year major re-certification should be retired
before the fourth re-certification is due (Refer to section 6.3).

5.2.1 TO BE CARRIED OUT ONCE A YEAR

1. Carry out Routine Maintenance procedure.

2. Discard all O-rings, inspecting all components and sealing surfaces for
corrosion or damage along the way.

3. Rebuild using seal kit and pressure test to Test Pressure.

4. Function test at Working Pressure. (if applicable)

5. Complete maintenance record sheet and affix dated chart. Refer to

Section 5.5 for example Maintenance Record Sheet

6. Third party agency to witness pressure test and function test.

5.2.2 TO BE CARRIED OUT EVERY 5 YEARS

1. Carry out Routine Maintenance procedure tasks.

2. Strip all component parts. Discard all O-rings and back-up rings.

3. Dimensional and thickness test.

4. Magnetic Particle Inspection (MPI) of all parts.

5. Rebuild using seal kit and any necessary new parts.

6. Hydrostatic body test to Test Pressure.

7. Function test at Working Pressure. (if applicable).

8. Third party certificate of final test and inspection and certificate of

conformity.

5.3 TESTING
The pressure rating of any item is expressed in pounds per square inch (psi) and it is
shown as a test pressure (TP) rating and a working pressure (WP) rating.

Every item of pressure control equipment has a particular pressure rating, and care
must be taken to ensure that no item is used in a situation that might cause its
working pressure to be exceeded. Although the test pressure rating is always higher
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than the working pressure rating, the difference between the two must never be
considered as a safety margin. This is because the actual use of the equipment
under field conditions involves forces that result from both well pressure and
mechanical stress. For this reason, all pressure control equipment must be handled
and secured in such a way that the external stresses are kept to an absolute
minimum.

The overall WP rating of the assembled equipment shall be equal to the rating of the
weakest component. All components used shall have a valid dated test record;
including a hydrostatic body test to TP. Equipment lacking a current test record shall
not be used. The well site TP shall never exceed the equipment WP rating.

The well site TP shall be 1.2 times maximum potential wellhead pressure (MPWHP).
If no wellhead pressure is expected, the equipment shall be tested at 25% of its WP
rating. All well site pressure testing and the pressure test values obtained shall be
noted on the equipment service report. The use of a pressure recorder (chart or film)
is recommended during well site pressure testing.

All adapters, flanges etc., shall be tested. It is recommended to test as much of the
equipment assembled together as possible. Valves must be in the partially open
position during the body test. Test plugs with a pressure rating equal to or higher
than the equipment that is being tested shall be used to cap open ended
components.

Adequate warning signs shall be displayed and all unnecessary personnel cleared
from the pressure testing location during the pressure test.

WARNING!
Trapped air requires considerable time to compress and when it is compressed is highly
dangerous. It has enough stored energy to separate parts with considerable force.

WARNING!
Clear the area of unnecessary personnel and ensure procedures are in force to prevent
personnel from entering the test area. Pressure testing should only be performed by competent
personnel.

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5.3.1 BODY PRESSURE TEST PROCEDURE
1) Locate the test plug and test cap/stump on to their appropriate ends.

2) Bleed off all air within the assembly.

3) Ensure all external surfaces are dry.

4) Pressure test to test pressure for 3 minutes.

5) Reduce pressure to zero and repeat test for 15 minutes minimum.

No Leakage acceptable.

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5.4 TROUBLESHOOTING

Problem Possible Cause Corrective Action

Leakage at the (a) Damage to the O-Rings (a) Replace faulty parts.
connections. and/or seal surfaces

5.5 MAINTENANCE RECORD SHEET

Date Type of Performed Verified
Comments
Peformed maintenance by by

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6 TRANSPORTATION, SPARES, ACCESSORIES AND DISPOSAL
6.1 TRANSPORTATION

6.2 SPARES AND ACCESSORIES

6.3 DISPOSAL

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6.1 TRANSPORTATION
The assembly should always be stored with:

 any residual hydraulic fluid, grease or well fluids drained completely;

 top and bottom quick union threads grease and thread protectors fitted;

 Inside diameter swabbed with grease;

 protection from moisture ingress.

Whenever possible, the assembly should be enclosed in a transport frame when not
in use.

6.2 SPARES AND ACCESSORIES

6.2.1 SPARES
Use only NOV ASEP Elmar recommended spares.

For seal kit part numbers and spares parts, refer to the relevant Technical Illustration
supplied with the equipment.

All Pressure Equipment is supplied as standard with Nitrile elastomers for all sealing
elements. A wide range of alternative compounds, for various service conditions, are
available on request. Contact the NOV ASEP Elmar Sales Department for details.

Recommended spares:

 Seal Kit

6.2.2 ACCESSORIES
NOV ASEP Elmar can supply a range of accessories for handling, testing and
assembling the Pressure Control Equipment. The use of any other accessories is
NOT recommended as this could lead to damage that may result in failure of the
equipment.

For accessories that do not have part numbers stated contact the Elmar Sales
Department for details. The part numbers for these accessories change depending
on the quick union being used.

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Recommended Accessories:

 Quick Union Test Plug

 Quick Union Test Cap

 Male thread protector (steel or plastic)

 Female Thread Protector (steel or plastic)

 Grease (Elmar Part No L-881720)

 Grease Anti-seize – Copperslip (Elmar Part No L-882940)

6.3 DISPOSAL
When the product approaches its twentieth service year it should be retired.

Ensure that the product is disposed of in a responsible manner and that any local
legislation is observed. NOV ASEP Elmar can assist if required.

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7 DRAWINGS AND BILLS OF MATERIAL
For drawings specific to purchased equipment, refer to the drawing package supplied
with the equipment

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