MAN-10004933

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User Manual (Operation and Service)

MAN-10004933/C LIFT BAIL/TEST PLUG ASSY

Print Date: 17-Sep-15 of 45 TFO-10000357 Rev B

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1 HEALTH AND SAFETY .......................................................................................... 4

1.1 GENERAL ............................................................................................................... 5

1.2 SAFETY PRECAUTIONS AND WARNINGS .......................................................... 5

1.3 COMPETENCY OF PERSONNEL .......................................................................... 6

1.4 PERSONAL PROTECTIVE EQUIPMENT .............................................................. 7

1.5 PREPARATION OF THE WORKSITE .................................................................... 8

1.6 PRESSURE CONTROL SAFETY ........................................................................... 9

2 DESCRIPTION ...................................................................................................... 13

2.1 GENERAL DESCRIPTION.................................................................................... 14

3 SPECIFICTION AND FEATURES ........................................................................ 16

3.1 SPECIFICATIONS ................................................................................................ 17

3.2 STANDARD FEATURES ...................................................................................... 17

3.3 DESIGN STANDARDS AND REQUIREMENTS ................................................... 17

4 OPERATION ......................................................................................................... 19

4.1 FUNDAMENTAL RULES FOR PROPER OPERATION ........................................ 19

4.2 OPERATION ......................................................................................................... 19

4.1 FUNDAMENTAL RULES FOR PROPER OPERATION ........................................ 20

4.2 OPERATION ......................................................................................................... 20

5 ASSEMBLY INSTRUCTIONS .............................................................................. 23

5.1 TOOL LIST ............................................................................................................ 23

5.2 ASSEMBLY INSTRUCTIONS ............................................................................... 23

5.1 TOOL LIST ............................................................................................................ 24

5.2 ASSEMBLY INSTRUCTIONS ............................................................................... 25

6 MAINTENANCE AND TESTING .......................................................................... 32

6.1 ROUTINE MAINTENANCE ................................................................................... 32

6.2 MAJOR MAINTENANCE ...................................................................................... 32

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6.3 TESTING............................................................................................................... 32

6.4 TROUBLESHOOTING .......................................................................................... 32

6.5 MAINTENANCE RECORD SHEET ....................................................................... 32

6.1 ROUTINE MAINTENANCE ................................................................................... 33

6.2 MAJOR MAINTENANCE ...................................................................................... 35

6.3 TESTING............................................................................................................... 37

6.4 TROUBLESHOOTING .......................................................................................... 38

6.5 MAINTENANCE RECORD SHEET ....................................................................... 39

7 TRANSPORTATION, SPARES, ACCESSORIES AND DISPOSAL .................... 40

7.1 TRANSPORTATION ............................................................................................. 41

7.2 SPARES AND ACCESSORIES ............................................................................ 41

7.3 DISPOSAL ............................................................................................................ 42

8 DRAWINGS AND BILLS OF MATERIAL ............................................................. 43

8.1 GUIDE TO USE OF ELMAR DRAWINGS ............................................................ 44

8.2 IDENTIFICATION OF COMPONENTS WITHIN A UNIT ....................................... 44

9 EC DECLARATION OF CONFORMITY ............................................................... 45

Approvals

REV ECO PREPARED CHECKED APPROVED DATE Comments

C 12119 R. CHOUDHURY A.THOMSON P. MACDONALD 17/09/2015 SEE ECO-12119

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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 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 inwork 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 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 toequipment or its components. Follow the instructions carefully.

WARNING!

An instruction FOLLOWED by this WARNING highlights a danger or injury to the OPERATOR or otherPERSONNEL, or danger of serious damage to the equipment or other objects. Follow the instructionscarefully.

1.3 COMPETENCY OF PERSONNEL

All operation and maintenance of the Wellhead Pressure Control Equipment (WPCE)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 drugsshould not be allowed to operate WPCE.

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

have sufficient practical and theoretical knowledge of wellhead pressure controlequipment at that particular location;

have sufficient experience of the operation of wellhead pressure control

equipment in the environment in which it is used;

be able 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 firefighting and life support equipment at the location.

Elmar recommend that personnel involved in wellhead pressure operations have been

formally trained. Elmar can provide formal training courses which should be attended as

part of the achievement of operator competency.

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.

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;

4) Respiratory Protection (where conditions deem necessary);

5) Body Protection;

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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 WPCE shows no signs of

excessive damage or wear which may affect the safety of the equipment during use.

(Refer to Section 6 for inspection, examination and testing for WPCE 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 whenpressure 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 H ₂ S 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, advanced Detailed, 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, H ₂ S, CO ₂ , 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 (1

metre) 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, H ₂ S, 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 DESCRIPTION

2.1 GENERAL DESCRIPTION

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2.1 GENERAL DESCRIPTION

Elmar Lift Bail/Test Plug assemblies have been designed specifically for lifting Elmar

pressure control equipment at well sites and assembly shops. They are designed to allow

easy lifting and lowering of any wellhead equipment that has the relevant quick union

female box thread to match the Lift Bail/Test Plug’s Collar thread.

Each Lift Bail/Test Plug also features a test port that can be used for testing the wireline

string or BOP – typically ½” NPT for a Working Pressure less than or equal to 10,000 psi

and 9/16” AEHP for a greater Working Pressure.

Various quick union configurations can be supplied for the lower connection.

Whilst Elmar Lift Bail/Test Plug assemblies are capable of lifting and pressure testing

Elmar pressure control equipment, they are not intended to be used for these tasks

simultaneously.

The Lift Bail/Test Plug assemblies have been designed to be used in the following areas:

(1) Workshop facilities

(2) Lifts on board rigs

(3) On site at the wellhead

WARNING!

Do not lift pressure control equipment whilst under pressure.

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Figure 1: Typical set-up of a Lift Bail/Test Plug assembly

(Cross-section illustrates typical assembly of a Lift bail to a BOP body)

Lift Bail Body

BOP body union connection (partial section)

Collar

Internal/ExternalThread Interface

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3 SPECIFICTION AND FEATURES

3.1 SPECIFICATIONS

3.2 STANDARD FEATURES

3.3 DESIGN STANDARDS AND REQUIREMENTS

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3.1 SPECIFICATIONS

The exact specification of each Lift Bail/Test Plug will vary depending on the customer’s

individual requirements.

3.2 STANDARD FEATURES

Elmar Lift Bail/Test Plug assemblies have all the standard following features:

Lift Bail/Test Plug body rated for either H ₂ S or STD service depending on union

service designation;

Threaded Collar with Circlip retainer;

Lifting Eye and Shackle designed in accordance with various lifting standards;

Test Port;

Designed and manufactured in accordance with API 6A latest edition;

Designed and manufactured in accordance with NACE MR0175 latest edition (for

H₂ S service items only).

3.3 DESIGN STANDARDS AND REQUIREMENTS All Elmar Lift Bail/Test Plug assemblies have 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 H ₂ S service only;

Norwegian Petroleum Directorate, the Facilities Regulations, Sept 2001;

SI 289, 1974;

SI 913, 1996;

SI 2306, 1998 – PUWER.

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As standard each Lift Bail/Test Plug is designed to comply with the following requirements

within API 6A:

Working Pressure (refer to relevant assembly drawing for details); Service Temperature Classes P, S, T, U & V (-29 C to 121 C);

Manufacturing standards PSL 3;

Appropriate Material Class for relevant service conditions.

All Lift Bail/Test Plugs are supplied as standard with Nitrile elastomers for all sealing

elements. Other grades are available in seal kit form on request.

Elmar Lift Bail/Test Plug assemblies can also be designed to service temperature classes

L (-46 C) and X (180 C).

3.3.1 CE MARKED ASSEMBLIES

In addition to the aforementioned standards, Elmar CE marked assemblies have also been

designed in accordance with:

DNV 2.22 Lifting Appliances, 2013;

Norsok R-002 Lifting Equipment, 2012;

The Supply of Machinery (Safety) Regulations, 2008;

Lifting Operations and Lifting Equipment Regulations, 1998.

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4 OPERATION

4.1 FUNDAMENTAL RULES FOR PROPER OPERATION

4.2 OPERATION

THE WHOLE O F THIS PROCEDURE MUST B E READ THROUGH WITH THEAPPROPRIATE ASSEMB LY DRAW INGS BEFORE CARRYING OUT ANY OF

THE FOLLOWING ACTIONS

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4.1 FUNDAMENTAL RULES FOR PROPER OPERATION

The following fundamental rules apply to all operations with WPCE Equipment:

All equipment used for pressure control operations must be pressure rated, to adefined 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 WP rating, or outside its

temperature rating;

In a string of WPCE equipment, the WP of the weakest component gives the string

overall pressure rating;

All WPCE components holding pressure must have valid certification;

All WPCE components holding pressure must have a quality file;

All WPCE 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 WPCE equipment must be qualified to carry out pressure

operations;

4.2 OPERATION

Observe all safety considerations (Refer to Section 1 for general safety information) andsite rules.

Before operation of the Lift Bail/Test Plug, refer to Section 6, MAINTENANCE AND

TESTING to ensure the equipment has been fully serviced and the necessary ‘BEFORE

EVERY JOB ’ checks have been carried out. Do not assume that serviceable equipment on

the last job will be serviceable again.

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4.2.1 CONNECTING THE LIFT BAIL/TEST PLUG

Before connecting the Lift Bail/Test Plug, the threads on both the Lift Bail/Test Plug and

the piece of equipment to be lifted or pressure tested should be checked to ensure that

they are clean and free from debris.

Check the shackle moves freely in the lifting eye and the shackle pin is tight.

Tighten Lift Bail/Test Plug on to box thread of wellhead equipment, ensuring the thread is

fully engaged.

WARNING!

- Always use appropriate personal protective equipment when assembling the Lift Bail/Test Plug;

- Check that the Collar has not backed-off during rig-up.

4.2.2 LIFTING PROCEDURE

All lifting operations should be carried out under the supervision of the competent person,

and in accordance with an established safe working system.

Before lifting the wellhead equipment, the Lift Bail/Test Plug should be connected as per

the procedure in section 4.2.1. WARNING!

- Check the load rating of all lifting equipment and loose lifting gear before commencing a lifting

operation;

- Do not use equipment that is under-rated for the job at hand;

- Always clear the area of unauthorised personnel before commencing lifting operations;

- Ensure that no unauthorised personnel enter the lifting area during operations;

- Communication signals should be clarified and understood by all parties involved in the lifting

operation before commencement of lifting operations;

- Use a third person to assist in communications if the line of sight/communication is obscured.

Note!

Temporary tape barriers may prevent unauthorised personnel from entering the danger area.

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To use the Lift Bail/Test Plug for lifting:

connect the lifting line to the shackle of the Lift Bail/Test Plug

begin lifting the wellhead equipment

(note: if the load to be lifted is initially laid horizontally, it is permitted to lift the load

from the horizontal to the vertical position in the same lifting sequence).

To remove Lift Bail/Test Plug after lift is complete:

ensure Lift Bail load is in safe location on the ground

disconnect Lift Bail shackle from lifting line

disconnect Lift Bail from load

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5 ASSEMBLY INSTRUCTIONS

5.1 TOOL LIST

5.2 ASSEMBLY INSTRUCTIONS

THE WHOLE O F THIS PROCEDURE MUST B E READ THROUGH WITH THEAPPROPRIATE ASSEMB LY DRAW INGS BEFORE CARRYING OUT ANY OF

THE FOLLOWING ACTIONS

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5.1 TOOL LIST

- Clean work surface;

- Airline;

- Clean rags;

- Vice;

- O-ring pick;

- Grease brush;

- Pliers;

- Grease (Elmar Part No L-881720);

- Anti-seize compound (Nickelslip) (Elmar Part No L-8831028755);

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

- Punch (appropriate size for STD Collar make-up);

- 3” Circlip Pliers (for Collar Circlip).

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5.2 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.

WARNING!

The following instructions are typical examples only. Please ensure reference is also made to therelevant assembly drawing for specific details.

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5.2.1 ASSEMBLY INSTRUCTIONS FOR 5K WORKING PRESSURE LIFT BAIL/TEST

PLUG

Figure 2: Typical 5K Working Pressure Lift Bail/Test Plug

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NOTE!

Clean all parts thoroughly before beginning assembly.

STEP ACTION

1. O-Ring

To minimize damage to the O-ring during installation:

1) Check all components for cleanliness before installation;

2) Tape all threads over which O-rings might pass. O-rings should never be

forced over unprotected sharp edges;

3) Use an O-ring lubricator;

4) Double check O-ring to ensure correct size;

5) Don’t over stretch the O -ring;

6) Prevent the O-ring from rolling or twisting during assembly.

2. Coat all threads and seal surfaces lightly with grease.

3. Install O-Ring into the correct position on the Lift Bail/Test Plug Body.

4. Locate STD Collar onto the Lift Bail/Test Plug Body.

5. Fit Collar retaining Circlip using Circlip Pliers.

6. Locate and secure NPT plug.

7.Locate Shackle onto Lift Bail/Test Plug Body, ensure shackle nut is lockedwith cotter pin.

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5.2.2 ASSEMBLY INSTRUCTIONS FOR 10K WORKING PRESSURE LIFTBAIL/TEST PLUG


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NOTE!


STEP ACTION

1. O-Ring


1) Check all components for cleanliness before installation.




4) Double check O-rings to ensure correct size;

5) Don’t over stretch the O -rings;

6) Prevent the O-rings from rolling or twisting during assembly;

7) When only one back-up ring is used, it must be placed between the O-

Ring and the pressure face.


3. Install elastomers into the correct position on the Lift Bail/Test Plug Body.



6. Locate and secure NPT plug.

7. Locate Shackle onto Lift Bail/Test Plug Body Locate Shackle onto LiftBail/Test Plug Body, ensure shackle nut is locked with cotter pin.

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5.2.3 ASSEMBLY INSTRUCTIONS FOR 15K WORKING PRESSURE LIFTBAIL/TEST PLUG


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NOTE!


STEP ACTION

1. O-Ring


1) Check all components for cleanliness before installation.




4) Double check O-rings to ensure correct size;

5) Don’t over stretch the O -rings;

6) Prevent the O-rings from rolling or twisting during assembly;

7) When only one back-up ring is used, it must be placed between the O-

Ring and the pressure face.


3. Install elastomers into the correct position on the Lift Bail/Test Plug Body.



6. Locate and secure Plug and Gland.

7. Locate Shackle onto Lift Bail/Test Plug Body Locate Shackle onto LiftBail/Test Plug Body, ensure shackle nut is locked with cotter pin.

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6 MAINTENANCE AND TESTING

6.1 ROUTINE MAINTENANCE

6.2 MAJOR MAINTENANCE

6.3 TESTING

6.4 TROUBLESHOOTING

6.5 MAINTENANCE RECORD SHEET

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6.1 ROUTINE MAINTENANCE

NOTE!

Refer to Section 1 for general safety information before carrying out any maintenance and testingroutines.

NOTE!

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

NOTE!

Lift Bail/Test Plugs need to be carefully maintained to perform properly.

General rules for routine inspections:

- All components shall be thoroughly cleaned;

- All components shall be 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;

- After inspection and reassembly the equipment shall undergo a load test to

SWL and pressure test to Working Pressure.

6.1.1 BEFORE EVERY JOB

- Check the equipment service record to ensure the equipment has been fully

serviced and properly recorded by competent personnel;

- Inspect all loose lifting gear (Shackles, Slings, etc.) for damage;

- Inspect all structural aspects of the Lift Bail/Test Plug body for damage;

- Obtain details of any maintenance requirements identified during the last use of

the assembly from the last competent person to use the Lift Bail/Test Plug

assembly and undertake any necessary maintenance work;

- Obtain details of any maintenance requirements identified during the last

periodic inspection of the assembly from the last competent person to use the

Lift Bail/Test Plug assembly and undertake any necessary maintenance work;

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- Check all threads, seals and sealing surfaces for damage that might impair

sealing. Repair or replace as necessary;

- Verify that the well site test pressure does not exceed the Working Pressure

rating of that of the equipment;

- Complete the appropriate entrance in the maintenance records;

- Check that Seal Kits are available;

- Pressure test to Working Pressure.

NOTE!

If the user has any concerns over damage/corrosion/wear levels on their Lift Bail/Test Plug, theyshould return the assembly to Elmar for full dimensional inspection and review.

6.1.2 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 riskfrom corrosion.

NOTE!

Avoid steam cleaning any internal bores that have corrosion resistant coatings. Grease the internalbores using a cloth/swab.

These coatings are sacrificial and may need re-applied periodically.

- Dismantle and clean all parts;

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

back-up rings;

- Inspect all loose lifting gear (Shackles, Slings, etc.) for damage. Replace any

damaged items;

- Check all threads;

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NOTE!

If the job contained any of the following, then it is advisable to strip the assembly, replacing the sealsthat see well pressure:

- Extended Exposure (> 48 hours);

- H ₂ S;

- High pressure gas.

- Reassemble as per the assembly instruction in Section 5 and relevant assembly

drawing;

- Load test at SWL;

- Pressure test at working pressure.

6.2 MAJOR MAINTENANCE

All WPCE 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 when the WPCE has been subjected to extraordinary conditions, such as

rough handling, bending, accidental drops, corrosive fluids, unexpected H ₂ S or CO ₂ 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 WPCE

pressure containing equipment should undergo a major re-certification every five years

based on the following general procedures:

- Visual inspection;

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- Random thickness tests on risers, BOP, tool trap, ball check valve, tool catcher

and general bodies 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;

- Perform load test to proof load;

- Review of Quality Files.

All WPCE having undergone three 5 year major re-certifications should be retired before

the fourth re-certification is due (Refer to section 7.3) .

6.2.1 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) Perform load test to proof load;

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

6.5 for example Maintenance Record Sheet;

6) Third party agency to witness pressure test and load test.

6.2.2 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;

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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) Perform load test to proof load;

8) Third party certificate of final test.

6.3 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 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. Allwell 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.

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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. Ithas enough stored energy to separate parts with considerable force.

WARNING!

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

6.3.1 BODY PRESSURE TEST PROCEDURE

1) Locate the Test Cap on to the appropriate end;

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.

6.3.2 LOAD TEST PROCEDURE

1) Fix the Lift Bail/Test Cap assembly to a mating part suitable for the Proof Load

of the assembly;

2) Load test to Proof Load.

6.4 TROUBLESHOOTING

Problem Possible Cause Corrective Action

Leakage at theconnections.

(a) Damage to the O-Ringsand/or seal surfaces

(a) Replace faulty parts.

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6.5 MAINTENANCE RECORD SHEET

DatePeformed

Type ofmaintenance

Performedby

Verifiedby Comments

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7 TRANSPORTATION, SPARES, ACCESSORIES AND DISPOSAL

7.1 TRANSPORTATION

7.2 SPARES AND ACCESSORIES

7.3 DISPOSAL

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7.1 TRANSPORTATION

The Elmar Lift Bail/Test Plug assembly should always be stored with:

- any residual grease drained;

- quick union threads protected;

- protection from moisture ingress.

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

use. Care should be taken to ensure that the hydraulic fitting is left unobstructed and not

subjected to any loads or impacts.

7.2 SPARES AND ACCESSORIES

7.2.1 SPARES

Use only Elmar recommended spares.

For seal kit part numbers and spares parts, refer to the relevant Technical Illustration

supplied with the equipment.

All Lift Bail/Test Plug assemblies are 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 Elmar Sales Department for details.

Recommended spares:

- Seal Kit.

7.2.2 ACCESSORIES

Elmar can supply a range of accessories for handling, testing and assembling the Lift

Bail/Test Plug. 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 Stump/Cap;

- Test Stump Mounting Table;

- Male thread protector (steel or plastic);

- Grease (Elmar Part No L-881720);

- Grease Anti-seize – Nickelslip (Elmar Part No L-8831028755);

7.3 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. Elmar can assist if required.

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8 DRAWINGS AND BILLS OF MATERIAL

8.1 GUIDE TO USE OF ELMAR DRAWINGS

8.2 IDENTIFICATION OF COMPONENTS WITHIN A UNIT

For drawings specific to purchased equipment, refer to the drawing package supplied with

the equipment.

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8.1 GUIDE TO USE OF ELMAR DRAWINGS

IDENTIFICATION OF UNIT PART NUMBER

Most Elmar Lift Bail/Test Plug assemblies are identified by a part number beginning with L-970, e.g. L-9701003121.

Each unit also has a serial number which is suffixed to the part number, e.g. -012.

Part numbers and serial numbers can usually be found stamped on the Lift Bail/Test Plug

Body or on a label attached to the assembly if CE marked.

8.2 IDENTIFICATION OF COMPONENTS WITHIN A UNIT

Identify unit part number as described above, e.g. L-9701003121;

Look at the drawing with the same number, e.g. DD9701003121;

The Bill of Material for this drawing will show the part numbers for

individual components.

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9 EC DECLARATION OF CONFORMITY

EC Declaration of Conformity is available upon request where applicable.

The EC Declaration of Conformity is also available to NOV customers via

Cert Web through the NOV customer portal: myNOV.com.

MAN-10004933

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Transcript of MAN-10004933