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ABC Guide to

Temporary Pipework
Practices to implement EP 2006-5393 Shell Global Standard for Temporary Pipework

I.E. Iyamu (SPDC EPG-PN-WS; B.A. Beltman (SIEP EPT-WN); G. Hampden-Smith (SUKEP EPE-T-WS)

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Wells ABC Guide to Temporary Pipework Practices to Implement EP 2006-5393 Shell Global Standard for Temporary Pipework by I. E. Iyamu (SPDC EPG-PN-WS); B. A. Beltman (SIEP EPT-WN); G. Hampden-Smith (SUKEP EPE-T-WS)

Sponsor: Reviewed by: Approved by: Date of issue: Period of work: Revised: ECCN number:

P. Sharpe (SIEP EPT-W) I. Duncan (SUKEP EPE-T-WS) D. Stewart (SIEP EPT-WX) December 2007 November 2007 February 2012 EAR 99

The information in this document is shared under the Research Agreement between SIRM and Shell Oil Company dated January 1, 1960, as amended unless indicated otherwise above. This document is classified as Restricted. Access is allowed to Shell personnel, designated Associate Companies and Contractors working on Shell projects who have signed a confidentiality agreement with a Shell Group Company. 'Shell Personnel' includes all staff with a personal contract with a Shell Group Company. Issuance of this document is restricted to staff employed by a Shell Group Company. Neither the whole nor any part of this document may be disclosed to Non-Shell Personnel without the prior written consent of the copyright owners. Copyright 2007 SIEP, Inc.

SHELL INTERNATIONAL EXPLORATION AND PRODUCTION INC., HOUSTON

Further electronic copies can be obtained from the Global EP Library, Houston

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Summary
This ABC Guide to Temporary Pipework is designed as a practical guide to create an awareness of the risks when using temporary pipework in the field. This guide covers: Flowline equipment Pressures and types of fluids involved Operational hazards Pipework connections and interfaces Hazard identification and mitigation Operational guidelines This guide shall be read and understood by all involved in temporary pipework operations. The guide shall be re-read prior to the commencement of each temporary pipework operation and also referred to during each step of that operation. If the correct procedure is unclear at any stage of the operation: Stop and Ask.

Figure 1 - Examples of temporary pipework

Keywords
Temporary pipework, Hammer Union, Hub Connection, Hoses, Restraints.

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Revision History
Revision 4
Section 5.1.3 Details Replaced charts in the section and expanded on commercial options for restraining pipework.

5.1.4

Removed revision 3 content and replaced with selection and installation of Polyester Round Sling Restraints.

5.1.5

Removed revision 3 content and replaced with information on the WeirSPM FLSR system.

5.1.6

Removed revision 3 content and replaced with information on FMC TPR system

Appendix 3

Restraint Charts using ASME B 30.9 Polyester Roundslings

Revision 5
Section 2.10 Details Added section. Direction of flow through Hammer Unions.

4.4

Amended some text to include the use of NPT and linepipe threads.

4.4.3

Added this section to specify the conditions for using NPT and line pipe threaded connections > 1/2.

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Contents
Summary Keywords Revision History I I II

Revision 4 Revision 5
1 Introduction

II II
1

1.1 1.2 1.3

2

What is Temporary Pipework Pipework or Flowline Equipment Equipment Boundaries

1 2 2
5

Hammer Unions and Operational Hazards

2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9

Origins of Hammer Unions Female/Male Subs or Union Parts Pressure Stored Energy Dynamic Loading Vibration Bending Forces Shock Loading Hazardous Fluids

5 5 6 8 8 8 9 10 10 10
10

2.10 Conventional Hammer Union Pipework Hook-up Direction of Flow

3 Loss of Containment

3.1 3.2 3.3 3.4 3.5

Leaks - Erosion H2S Catastrophic Failure Energy Release Polymers Elastomers and Thermoplastics - suitability

11 12 12 13 13

3.6

3.5.1 Elastomers 3.5.2 Thermoplastics Historic Incidents

16 17 18

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Pipework Connections and Interfaces

21

4.1

Hammer Union Mismatches

21

4.2 4.3 4.4

Mismatching the Same-Size Hammer Unions Mismatching Pipe Pressure Ratings Mismatching Wing Nuts Mismatching Components Mismatching Non-Detachable and Detachable Components 4.1.6 Connecting a Hammer Union Male Sub from one manufacturer to the Female Sub from a different manufacturer Mismatching Swivel Joint Components
Mating Hub Connector Components from different manufacturers Threaded Connections

4.1.1 4.1.2 4.1.3 4.1.4 4.1.5

21 24 25 25 26

26 27
27 28

4.5

4.6
5

4.4.1 Non-Pressure Sealing Thread (NPST) & Pressure Sealing Thread (PST) Line Pipe and NPT 4.4.2 Line pipe, NPT, NPTF 4.4.3 Pressure Sealing Threaded (PST) Connections greater than 1/2 Flexible Pipes - Hoses 4.5.1 Suitability of hoses connected in the high pressure (> 285 psi) side of the process. 4.5.2 Handling, Storage and Maintainance of Flexible Pipe Equipment Interfaces & Equipment Repair and Maintenance

29 32 38 40 40 41 42
43

Hazard Identification and Mitigation

5.1

Mitigation Methods

43

5.1.1 Checklists 5.1.2 No-Go areas 5.1.3 Restraints for Temporary Pipework using Polyester Roundslings 5.1.4 Installation Steps for Polyester Round Slings 5.1.5 WeirSPM FSR System 5.1.6 FMC Technologies TPR System

43 46 47 51 56 57

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Avoiding Injury

58

6.1 6.2
7 8

Hammering Unions Positioning of Body

58 59
60 63

Completing the Connection Interface Diagram Walking the Lines

8.1
9

Example walkthrough

63
65

Awareness of Safety Initiatives

9.1

Truncated 2 in. FIG 602 Female Sub

65
66

10 EP 2006-5393 Temporary Pipework Standard Compliance

10.1 Gap Analysis and Corrective Action Checklist

References Appendix 1

66
67

Different Hammer Union Male and Female Sub mating arrangements. 68 Piping Schedules Restraint Charts using ASME B 30.9 Polyester Roundslings. 72 70

Appendix 2 Appendix 3

List of Figures
Figure 1 Figure 2 Figure 3 Figure 4 Examples of temporary pipework Temporary pipework / permanent pipework Typical temporary pipework set-ups Equipment interface boundaries, welltest and pumping examples Some typical temporary pipework Temporary pipework connections Female sub and male sub of hammer type union I 1 2

3 3 4 5

Figure 5 Figure 6 Figure 7

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Figure 8 Figure 9

6 7 9 9 10 11 12

Figure 10 Vibration in Temporary Pipework Figure 11 Bend is being straightened due to internal pressure Figure 12 Direction of Flow in Conventional Hook-up Figure 13 Erosion point in a short radius bend Figure 14 Erosion of common equipment

Figure 15 Demonstration of energy involved in Catastrophic Failure 13 Figure 16 Example of Hammer Union Seals incorporating anti extrusion rings Figure 17 Mismatch of hammer union end connections Figure 18 Using the Go No-Go gauge Figure 19 Mismatching of wing union components

16 22 23 24

Figure 20 Mismatch caused by misidentification - standard male sub 25 Figure 21 Mismatch caused by misidentification - detachable male sub Figure 22 Misapplication of wing nuts Figure 23 Another misapplication of wing nuts Figure 25 Mating Hub Connectors Figure 24 Dangers of mismatching swivel joint components Figure 26 NPT in poor condition due to corrosion and with insufficient make-up Figure 27 NPST vs. LPT Figure 28 FMC NPST Hammer Union Subs with groove 0.38 from ends Figure 29 FMC NPST Retrofitted-groove schematics

25 26 26 27 27

28 29

30 31

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Figure 30 Line pipe connections which parted under rapid pressure increase and violent transverse movement Figure 31 NPT thread gauging Figure 32 NPT thread gauging and engagement - high pressure (>6000 psi) fittings Figure 33 Example of split female connections Figure 34 Leakage path through NPT threads Figure 35 Clock wise wrapping procedure Figure 36 Minimum bending radius of flexible pipe Figure 37 Hose installing concept for long spans Figure 38 Dynamic loading and selection guide of EN 1492-2 round sling restraints for liquid pressurised piping Figure 39 Dynamic loading and selection guide of EN 1492-2 round sling restraints for gas pressurised piping Figure 40 Condition of lugs on hammer union wing nuts Figure 41 Safety iron Figure 42 Safety hammer Figure 43 Gauge positioned directly above a pressurised pipe connection Figure 44 Sand Filter and Dataheader showing NPT connections Figure 45 CID toolbox guide Figure 46 CID toolbox video tutorial Figure 47 P & ID showing connections marked-up for walking the lines Figure 48 Example things to consider during walking the lines Figure 49 Truncated 2 in. Fig 602 Female Sub - new engineering design

32 34

35 36 36 37 41 42

48

49 58 58 59

59 59 60 61

62 64

65

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List of Tables
Table 1 Elastomer Selection Guide Table 2 Thermoplastic Selection Guide Table 3 Historic Incidents Table 4 Hammer Union Mismatches To Avoid Table 5 Indicative Torques for High Pressure (> 6000 psi) NPT fittings 14 17 18 21

34

Table 6: Allowed threaded connection working pressures for different pipe sizes 38 Table 7 Normal pressure < 6000 psi NPT nominal sizes and thread engagement data.

39

Table 8 Example of Pre-Mobilisation Temporary Pipework Checklist 44 Table 9 Pre-Pressure Test Temporary Pipework Checklist 45

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1
1.1

Introduction
What is Temporary Pipework

Temporary pipework consists of the conduits and equipment for directing fluids (liquids or gasses): From a pump to a Xmas Tree. A high pressure point to a lower pressure point. Fluids directed to outlets ending with plugs on which sensors are mounted.
Temporary pipework Permanent pipework

To temporary pipework system

Pipework part of original design (e.g. production facilities)

Figure 2 - Temporary pipework / permanent pipework

Temporary pipework is piping and flowline equipment that is mobilised to the wellsite for connecting or hooking up equipment for the following operations: General pumping operations (transfer of fluids, mud/brine mixing operations, (reverse) circulating well fluids, etc. Pressure testing of downhole equipment (casing, packers, tubing, plugs, valves, accessories). Cementing. Well killing. Well stimulation. Nitrogen pumping. Well clean-up (Flowbacks). Well testing. Under balanced drilling operations. Managed pressure drilling operations.

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Temporary pipework can be both hard and flexible pipe.

Figure 3 - Typical temporary pipework set-ups

1.2

Pipework or Flowline equipment

Pipework runs (straights), pup joints, elbows. T-pieces. Laterals (Y-pieces). Swivel joints. Treating loops. Crossovers. High pressure hoses. Flanges, blinds, plugs, tappings for sensors, sample points etc.

The equipment involved can include:

1.3

Equipment Boundaries

Pipework components contained within pumping or flowing packages: e.g. manifolds, pumping units, separator tanks are excluded where these are manufactured to a code or standard. The pipework connections or interfaces to the equipment are included.

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Interfaces included
Equipment D e.g. Steam Heat Exchanger Equipment C e.g. MSRV

Interfaces included

Equipment excluded Interfaces included

Equipment A e.g. Surface Test Tree

Equipment excluded
Equipment B e.g. Choke Manifold

Interfaces included

Blender

Equipment excluded

Interfaces included

Equipment excluded

Pump Truck

Treatment Manifold

Xmas Tree

Interfaces included

Figure 4 - Equipment interface boundaries, welltest and pumping examples

Pipework

Swivel Joint

Treating loop

Tee

Typical Coflexip Line

Figure 5 - Some typical temporary pipework

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The pipework connections referred to in the guide are known as: Hammer-type connections. Hub-type connections. Flange connections. Pipe body to pipe body (welded) or pipe body to Sub. - gas welded - friction welded Thread Pipe body to Sub - NPST (no pressure seal on thread) - PST (pressure seal on thread)
Hammer-type union Hub-type connection

Flange connection Welded connection

Figure 6 - Temporary pipework connections

In summary, temporary pipework (chiksan, flowline equipment) comprises such fittings as straights or pup joints, T-pieces, elbows, crosses, crossovers, blinds, plugs, swivel joints and plug, loops, and check valves.
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Hammer Unions and Operational Hazards

As previously described, temporary pipework operations involve the transport of fluids under pressure from one point to another. Due to the typical pressures and flow rates involved, temporary pipework systems contain a lot of stored energy which can cause vibration, bending forces, and shock loading on the system. The fluids being flowed can be hazardous or erosive, and can also attack the integrity or strength of the system. It is therefore vitally important that all equipment used in a temporary pipework operation set-up is: Mechanically sound and has been properly inspected prior to use. Of suitable material, particularly where seals are concerned; this applies both to working pressure rating and to the fluid type being flowed (e.g. Sour Service). Made up correctly at all connections and unions as per the recommendations of the operational design. Secured with engineered restraints attached to strong anchor points in the system. In order to better understand these requirements, we will now look at some of the physical aspects of temporary pipework.

2.1

Origins of Hammer Unions

Pipework connected by hammer unions is used in chemical process plants, the mining industry, on dredging vessels, and in the oil industry. It is an old design (early 1950s) created by the Well Equipment Company (WECO) which was acquired by FMC Technologies.

2.2

Female/Male Subs or Union Parts

The identification of the female and male parts of a hammer type union is show in the picture below.

Female Sub

Male Sub

Wing ut

Figure 7 - Female sub and male sub of hammer type union

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The union parts are called out using a Nominal pipe size, a FIG designation and a code e.g.1502. For example: 3 in. FIG 1502 The 3 in. is the nominal diameter and is close to the inside diameter. The meaning of FIG is probably an abbreviation of figure meaning drawing, and 1502 is a code for the working pressure rating 15 referring to 15,000 psi. The addition of H2S pipework has led to the designation becoming corrupted. 3 in. Fig 1502 H2S service pipework ordered from the major flowline equipment providers has a cold WP rating of 10,000 psi. The last two digits in the designation of hammer unions generally refers to the sealing arrangements. 02 refers to a square gasket seal; 06 refers to an o-ring seal.

1502 Square gasket seal

206 O-ring seal

Figure 8 - 3in. 1502 and 3 in. 206 connections

[See Appendix 1 showing different Hammer Union types]

2.3

Pressure

Pressure is the term for measuring the force per unit area, the units typically used for measuring pressure are pounds per square inch, which is abbreviated psi. A familiar example is the air pressure in a tyre, which is typically around 30 psi for a car. What this means is that a force of 30 pounds is exerted on each and every square inch of the inside of the tyre. There are a lot of square inches on the inside surface of a tyre, and because of this, the force exerted on that tyre is very large. Every square inch is pushed on with a force of 30 pounds. In temporary pipework operations, low pressure is often used for values of around 300 psi (that is 10 times that of a car tyre) and the operational pressure
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may be above 10,000 psi, that is, 10,000 lbs exerted on every square inch of the inside of piping, unions, swivel joints, crossovers, etc., in the system.
Units of Pressure Pounds per square inch (or pounds-force per square inch) is still the most widely used oilfield unit for pressure. Other common units are the SI (or metric) unit which is the Pascal (Pa), the Atmosphere (atm), and the Bar (bar). The Pascal is a very small unit, 1 Pa being only about 1/7000th p.s.i. 1 Atm and 1 Bar are approximately 15 p.s.i.

High

10,000 psi pressure

High pressure

10,000 psi

~6000 psi (ASME B31.3)

Normal Operating Pressure

285 psi
Low Pressure

30 psi

Car Tyre

Figure 9 - Relative Pressure Comparison

Thinking about the forces involved, it should be clear why it is vital to ensure there are no weak points in the system. Any improper use of equipment such as mismatching pressure ratings or using poorly conditioned equipment can have devastating consequences.
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2.4

Stored Energy

Stored energy is the capacity of a volume of pressured fluid to do work if allowed to expand. An example of this work would be a volume of pressurised gas expanding and pushing a piston. The greater the stored energy of the fluid, the greater the force with which the piston would be pushed and the greater the amount of work that piston could perform. The danger associated with stored energy in temporary pipework is that the stored energy is typically very large, and any weak point in the system will allow this energy to discharge with potentially catastrophic results.
Yield strength: - Pipework - Cannon comparison Yield Strength is the stress a material can withstand without permanent deformation. Typical minimum yield strengths for pipework range from 75,000 to 115,000 psi A liner comprising of steel tubing with 0.375 in. wall thickness and 85,000 psi yield strength is what is required to line the bore of 8-pounder cannons to make them safe for re-enactments of the American Civil War.

2.5

Dynamic Loading

When pipe fails the strain on any restraint when it snaps tight to restrain the pipe is called the dynamic loading by process engineers. The rule-of-thumb used to work out this dynamic loading is twice that due to the static force on the pipe arising from internal pressure.

2.6

Vibration

Vibration can be a significant risk to pipework integrity, leading to mechanical failure, fluid release, and potentially serious safety implications. Common areas of vibration in Temporary Pipework are: Long pipe runs. Piping fixtures and instrumentation such as gauges. Equipment such as valves, chokes, etc. Pumps. Common causes of vibration include: Excessive pulsation (from pumps for example). Mechanical natural frequencies. Inadequate supports and/or support structure.

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Common effects of vibration include: Loosening of bolts. Compromising of mechanical joints (backing-off of wing nuts). Movement or slackening of tie downs and restraints.

Figure 10 - Vibration in Temporary Pipework

2.7

Bending Forces

Temporary pipework is commonly subjected to bending forces due to fluid velocity and internal pressure of the pipe. Bending force occurs at junctions or bends in the pipework where it effectively tries to straighten out the bend.
Internal pressure attempts to straighten out the corner bend and forces the pipe outwards straining the connections

Figure 11 - Bend is being straightened due to internal pressure

Such bending forces are then transferred along the pipework and result in additional strain on connections. Improperly made-up connections (e.g., worn or mismatched components, wrong pressure rating, etc.) not able to cope with this increased load can fail catastrophically.
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2.8

Shock Loading

A significant change in the flowrate, or pressure, during an operation (such as the emergency closure of a valve) causes a sudden extra load or jolt on the system. The temporary increase of load on the system usually imposes increased pressure, vibration, and bending forces on the system. During this period of Shock Loading, any sub-standard part of the system (inferior pipe, worn connections, mismatched connections, wrong pressure rated equipment) can fail with potentially disastrous consequences.

2.9

Hazardous Fluids

While there are many physical factors (such as pressure, temperature, and flowrates) that must be considered when dealing with temporary pipework, chemical factors such as hazardous fluids must also be taken into account. Many fluids used in operations (such as brines or acids) are corrosive to temporary pipework and will cause a reduction in wall thickness. It is important that all pipework and connections used have been properly maintained, inspected, and certified before use. Standard Service components shall not be used on Sour Service wells (wells where Hydrogen Sulphide, H2S, is present), as this will cause stress corrosion cracking, and pitting in the metal as well as destroying any elastomer seals in unions, etc. These factors can lead to premature failure under pressure of components in the system.

2.10 Conventional Hammer Union Pipework Hook-up Direction of Flow

By convention, the flow enters the pipe work on the female sub side and circulates from the female sub to the male sub. All testing services equipment is manufactured to adhere to this convention and it should be followed whenever possible. However, there is no technical requirement for this convention and under certain circumstances, such as in a complex rig up or due to crossover availability, it may be required to rig up a line where the direction of flow is reversed. Any such line where the direction of flow is reversed must be clearly marked as to the true direction of flow.

Figure 12 - Direction of Flow in Conventional Hook-up

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3
3.1

Loss of Containment
Leaks - Erosion

Erosion takes place in flow systems where turbulence occurs, typically in pipe bends (e.g., elbows), tube constrictions (e.g., chokes or valves), and other structures that alter flow direction such as laterals or tees. Specific erosion points within these components can vary depending on the fluid velocity and size of any suspended particles. With typically sized sand grains, the erosion point in a bend is usually past the mid-point of the bend, and it is for this reason that wall thickness is measured at the 80-90 degree point as well as at 45 degrees.

~80o

Erosion point

Figure 13 - Erosion point in a short radius bend

Erosion can lead to leakage and a rapid failure, and it is therefore important that the layout is designed, where possible, to minimise bends and constrictions and that such areas are inspected regularly. Examples where erosion can be accelerated are: Connections downstream of the choke. Points where the flowline is re-directed. Protection is afforded by using Target Ts and log sweep bends. Intrusion into the flow path can cause vortices to be created and shed. The local fluid speed within the vortex can be much greater than the average fluid speed in the pipe. Local pipe erosion, in an area as small as inch square, can arise where the vortex makes contact with the equipment or pipe wall. Since the pipe thickness can be otherwise within operational limits, workshop personnel should be vigilant when making visual inspections.

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Flow

Flow Maximum erosion Maximum erosion

Standard elbow (r/D=1.5)

Plugged tee

Flow Maximum erosion

Predicted erosion rates for standard elbow, plugged tee and long-radius elbow. Areas shown in red and yellow have maximum erosion

Long-radius elbow (r/D=5.0)

Figure 14 - Erosion of common equipment

3.2

H 2S

When H2S is present, the system is known as Sour and Sour Service equipment shall be used. For working pressure above 6000 psi, Sour Service equipment has a significantly lower rated cold working pressure than the equivalent Standard Service equipment and it is therefore important to avoid mixing Standard and Sour Service equipment in the same operation.

3.3

Catastrophic Failure

When flow lines fail, whether it is due to excess pressure; faulty connections; worn components; damage to the piping connection; or other reasons, the results can be devastating and catastrophic to both equipment and personnel. The metal components that were previously being subjected to up to 15,000 p.s.i. of internal pressure are suddenly and instantly forced to relieve their stored energy. In such a failure there could be hundreds or even thousands of pounds of iron pipe flailing around. In that scenario, there is a high likelihood of severe personal injury or death. As we will cover later, restraint systems can help reduce this risk of damage or injury but they cannot eliminate it fully. Preventing the failure from occurring in the first place is the only truly safe method.
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3.4

Energy Release

The following sequence of pictures were taken from a Service Company demonstration video showing the failure of a 15,000 p.s.i. unrestrained line. In this catastrophic failure the energy release occurs in a very short period of time - a fraction of a second in fact, and the damage and risk to personnel would have been severe.

Test manikins 15,000 psi line

Line ruptures

Pup joint flies off and lands 200 yards away Test manikins destroyed

Piece of loop flies outward

Figure 15 - Demonstration of energy involved in Catastrophic Failure

3.5

Polymers Elastomers and Thermoplastics - suitability

Polymer is the name given to the class of chemical compounds that are moulded to make the elements of a sealing system. The elastomers comprise the deformable sealing element and the thermoplastics comprise the hard, nondeformable elements that limit the extrusion of the elastomers under pressure. In selecting the elastomers and thermoplastics, consideration must be given to the pressure, temperature, fluids and duration to which the polymers are exposed along with the mechanics of the leak path which the sealing arrangement cutsoff. The selection of suitable o-ring, seal and back-up ring polymers, as environmental conditions become more extreme, is challenging. It is difficult to be prescriptive on elastomer selection. Different grades or compounds of the same material type extend its range of use, but generally in one direction - to only one end of the temperature range: Elastomers compounded for very high temperature are not generally suitable for very low temperatures and vice versa.

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Table 1 has been compiled by James Walker in consultation with Shell. Generic elastomer compounds are identified in this table. It is intended to guide Wells Supervisors and persons responsible for preparing equipment for Wells operations as to the conditions where they should seek advice (from the Seal manufacturer in the first instance) on the suitability of the seal etc. type and to where seal qualification may be appropriate.
Table 1 - Elastomer Selection Guide
Key 1 = excellent, 2 = good, 3 = poor, C = consult
FR10/80 & FR10/95 Elast-OLion 280LF FR58/90* Elast-OLion 101 Elast-OLion 985 Elast-OLion 280 Chem-OLion LR5853* LR6316* FR25/90 AF69/90 AF85/90 Kalrez 3018 PB 80

James Walker grade

(Note: alternative materials are available)

FKM-GFLT

(hydrogenated nitrile)

(hydrogenated nitrile)

(hydrogenated nitrile)

(hydrogenated nitrile)

(fluorocarbon)

(fluorocarbon)

(fluorocarbon)

(fluorocarbon)

(fluorocarbon)

FKM-GLT

Special

(perfluoroelastomer)

FKM-B

FKM-A

FKM-F

HNBR

HNBR

HNBR

HNBR

FEPM

FEPM

FFKM

(Aflas)

(Aflas)

(nitrile)

NBR

Material type
Weak mineral Acids Strong mineral Weak carboxylic Strong carboxylic Alcohols except methanol Aliphatic hydrocarbons Aromatic hydrocarbons LD Ca/Na chloride Brines HD Na/Ca bromide HD Zn bromide Alkaline Na OH/KOH Biocides Carbon dioxide Corrosion inhibitors Crude oil, sweet <2000 ppm H2S Crude oil, sour 2000 ppm to 5% H2S 5% to 40% H2S Diesel based Drilling mud Ester based Mineral oil based Silicate based Sweet gas Rapid Gas Sour gas Decompression High CO2 Fire fighting media Glycols Hydrogen sulphide Wet Dry Amine based Potassium carbonate Dilute Concentrated

1 1 1 2 1 1 2 1 1 1 1 1 2 2 1 1 2 1 1 1 2 2 1 1 1 1 2 2 1 1 1

1 1 1 2 1 1 2 1 1 1 1 1 2 2 1 1 2 1 1 1 2 2 1 1 2 2 2 2 1 1 1

1 1 1 3 1 1 1 1 1 1 3 1 3 3 3 3 1 2 3 3 2 3 1 2 3 3 3 1 1 3 3

1 1 1 3 1 1 1 1 1 1 3 1 3 2 3 3 1 2 3 3 2 3 1 2 1 2 3 1 1 3 3

1 1 1 3 1 1 1 1 1 1 3 1 3 2 3 3 1 1 2 3 2 3 1 2 1 2 3 1 1 3 2

1 1 1 3 1 1 1 1 1 1 3 1 3 3 2 3 1 2 3 3 2 3 1 2 3 3 3 1 1 2 2

1 1 1 3 1 1 1 1 1 1 2 1 3 3 2 3 1 2 3 3 2 3 1 2 3 3 3 1 1 2 2

2 3 1 3 1 1 C 1 2 3 1 1 3 1 1 2 1 1 2 3 1 3 1 1 1 1 1 3 1 2 1

2 3 1 3 1 1 C 1 2 3 1 1 3 1 1 2 1 1 2 3 1 3 1 1 3 3 3 3 1 2 1

2 3 1 3 1 1 C 1 2 3 1 1 3 1 1 2 1 1 2 3 1 3 1 1 3 3 3 3 1 2 1

2 3 1 3 1 1 C 1 2 3 1 1 3 1 1 2 2 2 2 3 1 3 1 1 1 2 1 3 1 2 1

2 3 1 3 1 1 3 1 3 3 2 1 3 1 3 3 2 3 3 3 2 3 1 2 3 3 3 3 1 3 3

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 3 3 3 1 1 1 1

1 1 1 1 1 1 1 1 1 1 2 1 1 3 1 2 1 1 2 3 2 2 1 2 3 3 3 1 1 1 1

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Key 1 = excellent, 2 = good, 3 = poor, C = consult

FKM-GFLT
(hydrogenated nitrile) (hydrogenated nitrile) (hydrogenated nitrile) (hydrogenated nitrile) (fluorocarbon) (fluorocarbon) (fluorocarbon) (fluorocarbon) (fluorocarbon)

FKM-GLT

Special

(perfluoroelastomer)

FKM-B

FKM-A

FKM-F

HNBR

HNBR

HNBR

HNBR

FEPM

FEPM

FFKM

(Aflas)

(Aflas)

(nitrile)

NBR

Material type

Phosphate ester (HFD) Hydraulic fluids Oil/water (HFA) Water/glycol (HFC) Mineral oil based Mercaptans Methane 100% Methanol With water With hydrocarbons Mineral lubricants Synthetic lubricants Salt water Toluene Solvents Steam Scale inhibitors/ dissolvers Wax dissolvers General Water Produced Treated Mechanical strength Friction Abrasion resistance Flex resistance Maximum, C Temperature capability Minimum, C Maximum, F Minimum, F <5% and <40C / 104F >5<10% and <40C / 104F >10% and/or >40C / 104F Acetone MEK

3 1 1 1 1 1 1 1 1 1 2 1 2 3 3 1 1 1 3 2 1 1 1 1 2 2 2 205 5 400 41

3 1 1 1 1 1 1 1 1 1 2 1 2 3 3 1 1 1 3 2 1 1 1 1 2 2 2 200 5 392 41

1 3 1 1 3 1 3 1 1 1 2 1 1 3 3 3 2 3 3 1 2 3 3 2 2 2 2 200 18 392 0

1 3 1 1 3 1 3 1 1 1 1 1 1 3 3 3 2 3 3 1 1 2 2 2 2 2 2 200 30 392 22

1 3 1 1 2 1 3 1 1 1 1 1 1 3 3 3 1 3 3 1 2 3 3 2 2 2 2 210 12 410 10

1 2 1 1 2 1 1 1 1 1 1 1 1 3 3 1 1 2 3 1 1 2 2 2 2 2 2 230 0 446 32

1 2 1 1 2 1 1 1 1 1 1 1 1 3 3 1 1 2 3 1 1 2 2 2 2 2 2 205 29 400 20

3 1 1 1 2 1 1 1 C 1 1 1 3 3 3 2 1 1 3 2 1 1 1 1 2 1 1 160 25 320 13

3 1 1 1 2 1 1 1 C 1 1 1 3 3 3 2 1 1 3 2 1 1 1 1 2 1 1 150 10 302 14

3 1 1 1 2 1 1 1 C 1 1 1 3 3 3 2 1 1 3 2 1 1 1 1 1 1 1 150 10 302 14

3 1 1 1 1 1 1 1 C 1 1 1 3 3 3 2 1 1 3 3 1 1 1 1 2 1 1 150 40 302 40

3 2 1 1 2 1 1 1 C 1 2 2 3 3 3 3 3 3 3 3 1 2 2 1 3 2 2 110 25 230 13

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 2 280 5 550 41

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 3 1 1 1 1 2 2 2 2 205 10 400 14

All temperatures quoted relate to performance in air. Low temperature limits are quoted at standard atmospheric pressure.
* These fluorocarbon compounds are based on Viton polymers from DuPont Performance Elastomers. WARNING: Please note that, due to the complexity of making a material selection for any given duty, all information provided in this document on chemical compatibility is intended only as a guide. For example, a compound compatible at low temperatures may show considerable deterioration at high temperatures; also, combinations of chemicals in a fluid medium may have detrimental effects. If any doubt exists, please seek advice from James Walker. TRADEMARK ACKNOWLEDGEMENTS: Aflas - Asahi Glass; Kalrez & Viton - DuPont Performance Elastomers. All other names bearing the symbol are registered trademarks of James Walker.

Table courtesy of James Walker Website: www.jameswalker.biz/jwco/index/html

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3.5.1 Elastomers
Hammer union connection seals which are exposed to high pressure or high temperature should be replaced with seals having an integral back-up / antiextrusion ring. This is essential for obtaining reliable seal performance under adverse and challenging conditions.

Courtesy of WeirSPM

Figure 16 - Example of Hammer Union Seals incorporating anti extrusion rings

[Note: The metal band if made of stainless steel is a Viton seal (H2S), the green dot on this black seal signifies sour service. A brass band denotes a Buna Nitrile seal (STD) in this example.]

Anti-extrusion union seals are recommended for the following applications: Applications with combined high pressure (exceeding 10,000 psi) and elevated temperature (exceeding 130F ). Applications involving excessive side loading. Applications where the pipework is in service for a long time e.g. extended well test. Applications where periodic maintenance checks (to verify union tightness or seal status) are required but cannot be conducted. Applications involving pumping aggressive fluids which may chemically attack union seals, leading to softening of the composition and possible extrusion. (This is especially important in applications in which the suitability of the union seal material is marginal).

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3.5.2 Thermoplastics
Table 2 has been compiled with significant input from MERL Ltd. It is intended to guide Wells Supervisors and persons responsible for preparing equipment for Wells operations as to the conditions where they should seek advice (from the Seal manufacturer in the first instance) on the suitability of the seal etc. type and to where seal qualification may be appropriate.
Table 2 - Thermoplastic Selection Guide
Environment
Min / Max temperature (F) Min / Max temperature (C) Crude Oil Hydrocarbons Methane Gas Water H2S CO2 Gas Water Based Muds Oil Based Muds Brine Completion Fluid Sea Water Zinc Bromide Amine Inhibitors HCl Acid Methanol Glycol Steam

PTFE
500 260 OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK

PEEK
480 249 OK OK OK OK UP TO 356F / 180C OK OK OK OK OK OK OK OK, (NOT if concentrated) UP TO 392F/200C OK

PPS
464 240 OK UP TO 392F/200C OK OK UP TO 356F / 180C OK OK OK OK OK OK OK OK UP TO 356F/180C

PVDF homopolymer (flexible pipes)

285 141 OK UP TO 170F/ 77C OK OK UP TO 275F/135C DRY UP TO 220F/104C WET OK OK OK OK OK UP TO 150F NO OK UP TO 77F/ 25C No info

No information, pretty inert OK

Note: Legal Disclaimer: The information given above has been compiled by MERL Ltd and is given in good faith, but MERL can accept no responsibility for the information. Normal screening procedures should be operated before any material is selected for service. NOTES 1) Teflon is a brand name using PTFE 2) Coflon is a brand name using PVDF. 3) Where the thermoplastic is used as the pressure sheath in a flexible hose, the temperature limit can be considerably reduced. 4) Information on the lower temperature limits for thermoplastics is not easily avaiable and must be sought from the product supplier.

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3.6

Historic Incidents
Operation Pressure Testing Pressure Testing Event Chiksan elbow parted at swivel at 4800 psi WECO union pressure sensor connection on rig floor ripped off. A 2 inch WECO union with a swivel connection made up hammer tight, became unscrewed while tubing (onto which the union was connected) was being made up. The swivel assembly fell 10 meters on to a floor-man resulting in severe injury leading to death. Female hammer union plug end dislodged from a side outlet of a sand filter, with a pressure of 3,500 psi, while the injured party was operating a valve. This resulted in multiple injuries leading to death. Vapour release from connection Immediate cause Snap Rings and Ball Plugs were missing Mismatch between standard 2 in. 1502 WECO Union and rigs 2 1002 WECO union Hammer unions can back-off under unusual make-up conditions

Table 3 - Historic Incidents

Equipment chiksan Hammer Union

Hammer Union / Chiksan connection

Making up pipe

Hammer Union Plug End

Well Test

Mismatch in connection between 602 female and 1502 hammer wingnut.

Hammer Union Seal

Well Cleanup Operation

During operation, flowing temperature went below -20oC (4oF) of the rating of the seal.

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- 19 Operation Clean-up of Wellhead and BOP prior to pressure testing. Event While circulating through a standpipe manifold, a section of chiksan line was blown from its connection on the drain line manifold. Mud escaped onto rig floor and over drilling equipment. Multiple failure of Hammer unions due to poor make-up. 2 in. flexible hose terminated in a 1502 chiksan male/female connections failed in service.

EP2007-3153 rev 5

Equipment Hammer Union

Immediate cause Mismatch in connection between male 2 in. 1502 hammer union and a 2 in. 1002 female stub on the standpipe.

Hammer Unions and Swivel Joints Flexible Hose

General

Hammer lugs tend to deform and thereby reduce the efficiency of hammer blows. Deficient inspection programme.

In Service

Hammer Union

Equipment Testing Incident occurred during water flow test through a Mud Line Cellar Bit. Make-up Inspection

Shortly after pumping started, a 2 in. 602 hammer union on the pump stand pipe separated. An Assistant Driller was struck and fatally injured by the male half while reading a gauge. On inspection a number of NPT fittings made up to several hose connections appeared to not be fully made up.

Mismatch of 2 in. 602 female and 1502 male. IP was in line of fire.

NPT Tape Threaded Fittings

Investigation confirmed that these fittings were outside acceptable tolerance standards.

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- 20 Operation Pressure Venting Event During pressure venting after transfer of bulk chemicals, a 4 in. flexible hose was lowered over side of vessel into the sea to prevent dust clouds during venting. It was kept submerged by using an old valve and ballast chain on the outboard end and had a 4 m length of rope to aid recovery. A sudden release of compressed air occurred when a vent valve in the engine room was opened and caused the vent hose to whip out of the sea onto the deck of the vessel where a crewman was struck on the head and fatally injured. Accumulation of solids in the line downstream of the separator to the production gas header caused a rapid build-up of pressure, to 2050 psi, which was relieved by the operation of the burst disc and relief valve on the separator. On discharge at the separator the separator which was stationed on a trailer moved down, causing the line to whip about 6 inches and separate at the threaded connections. Pipework was dropped off at location for pump to come later. The drill crew hooked up pipework to their 602 connection on their own pump. Driller was struck by pipe and killed.
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Equipment Flexible Hose

Immediate cause The hose was not adequately secured to prevent whipping onto the deck and the method used was not a safe or recommended practice.

Threaded connection on pipe run to production gas header

Coil tubing operation

The down movement of the separator and lack of engagement of the threads threads not stripped.

Hammer Union

Pressure Testing

Mismatch between standard 2 in. 1502 WECO union and rigs 2 1602 WECO union

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Pipework Connections and Interfaces

In earlier sections, it has been shown how important the quality of pipework connections and interfaces is to the integrity of the system. Improperly fitted, rated, or sized connections repeatedly prove to be the weak point of the system when exposed to operating conditions.

4.1

Hammer Union Mismatches

Mismatches in hammer unions are severe mechanical hazards to the integrity of the temporary pipework system. They are weak points that may fail under pressure and can result in serious personal injury, death, and/or property damage. Such Mismatches occur in 5 main categories: Mismatching the same size. Mismatching the pressure ratings. Mismatching of wing nuts. Mismatching of components. Mismatching of non-detachable and detachable components. Avoiding these mismatches is of prime importance in all aspects of temporary pipework operations. To further illustrate this, each mismatch is covered more fully in the sections below

4.1.1 Mismatching the Same-Size Hammer Unions

These mismatches refer to connecting hammer unions having the same size, but different figure numbers. The Wing Half of the 2 in. Fig 1502 can accept a female 2in. Fig 602 or 2 in. Fig 1002. This connection can appear to make-up will hold some pressure, but will fail due to lack of thread engagement. The following Hammer union mismatches have the same threads:
Table 4 - Hammer Union Mismatches To Avoid

Size 1 in. 5 in.

Union Figure Nos 600, 602, 1002 400, 1002

The 2 in. 602 and 2 in. 1002 unions are banned in Shell. They must be identified by contractors and installations and systematically removed and replaced with 2 in. 1502 unions.

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Hazardous!!!
Improperly Made-Up Acme Thread - as little as 0.10in. Thread Flank contact per Side 2 1502 Nut
2 1502 Segments

2 1502 Male (Detachable Type)

Seal Ring

2 602 Female Mismatched!!!

MIS-MATCH!
Never connect products with hammer union end connections that are not positively identified as to the manufacturer and that are not identified to have identical union figure number, size and pressure rating. Mismatched connections may fail under pressure, which can result in serious personal injury, death and/or property damage.

Figure 17 - Mismatch of hammer union end connections

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4.1.1.1 Use of the Go No-Go Gauge

The Go No-Go Gauge shall be used to be sure you have a 1502 Female Sub. The gauge will be No-Go on a 1502 sub but will be a Go on a 602 sub.
2 in. Fig 1502 Female - NO-GO 2 in. Fig 602/G/Sealomatic/607 Female - GO

This go/no-go gauge can be purchased from either: FMC at 800-772-8582 (Select 1, then 1 for Flowline Customer Service) or Wood Machine Company, Tulsa, OK (Part number 477990000) at 918-438-2412 or email: wood14201@aol.com 2 in Fig 1502 2 in Fig 602 2 in Kemper Fig G, Guiberson Sealomatic & Best Fig 607 2 in American Block Fig 602

4.109 in.

3.812 in.

3.938 in.

3.922 in.

No-Go interference Varying clearances between gauge and female stubs

Figure 18 - Using the Go No-Go gauge

It is important that the inside diameter of the GO NO-GO ring reflects the NOGO of the 2 in. 1502 rather than GO on the 2 in. 602. There are 2 in. 602 female subs which are not replicas of the original WECO 2 in. 602, having larger diameters. The flat gauge ring ID should have 4.000 inch (101.6mm) opening so it will GO on these proprietary replica unions but still NO-GO on the 2 in. 1502 female sub thread. The 2 in. 1502 union thread is 4.109 inch (104.4 mm) minimum OD.

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4.1.2 Mismatching Pipe Pressure Ratings

This type of mismatch refers to connecting hammerlug union products having different pressure ratings but with end connections of the same size and figure number. This occurs when mixing sour gas pipe with standard service pipe or when unions are welded to pipe with a working pressure lower than that corresponding to the union. The use of Sour Service pipework in Standard Service applications (but not the other way round) is allowed, but discouraged. In these instances, it is imperative that the working pressure of the Sour Service pipework is not exceeded.

15,000psi WP

10,000psi WP

2 in. 1502 Standard Female Sub

2 in. 1502 Sour Service Male Sub and Wing Nut

MIS-MATCH!
Wing union components that cannot be positively identified with regard to manufacturer, size, figure number, pressure rating and type of service must never be used. Incorrectly identified components will lead to hazardous assemblies, which can fail under pressure and result in serious personal injury, death and/or property damage.
Figure 19 - Mismatching of wing union components

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4.1.3 Mismatching Wing Nuts

This mismatch occurs when the wing nut of one size and figure number is mounted on the male sub of another size and figure number. There is only a small amount of engagement of the male sub in the wing nut and therefore the connection will not safely hold typical working pressures.

MIS-MATCH!
Never assemble any combination of male sub, wing nut or segments that are not positively identified to assure that union figure number, size, pressure rating and manufacturer are identical. Mismatched components will result in hazardous connections, which may fail under pressure, which can result in serious personal injury, death and/or property damage.

3 in. 1502 Wing Nut

3 in. 602 Standard Male Sub

Figure 20 - Mismatch caused by misidentification - standard male sub

4.1.4 Mismatching Components

Mismatching of components occur when segments and nut of one figure number are made up to a detachable male sub with a different figure number. This results in a small amount of engagement of the male sub with the segment engaging the wing nut. This will not hold pressure safely during typical operations.

MIS-MATCH!
Never assemble any combination of male sub, wing nut or segments that are not positively identified to assure that union figure number, size, pressure rating and manufacturer are identical. Mismatched components will result in hazardous connections, which may fail under pressure, which can result in serious personal injury, death and/or property damage.

3 in. 1502 Wing Nut

3 in. 602 Detachable Male Sub

Figure 21 - Mismatch caused by misidentification - detachable male sub

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4.1.5 Mismatching Non-Detachable and Detachable Components

This mismatch is caused by the assembly of non-detachable nuts on detachable male subs. The detachable wing nuts require a longer thread length to compensate for the segments between the wingnut and the sub shoulder. Use of a non-detachable wing nut in a detachable union results in a lack of thread engagement and an insufficient engagement between of the male sub shoulder with the wing nut ID.

MIS-MATCH!
The misapplication of standard, non-detachable style wing nuts on 2 in., 3 in. and 4 in. Figure 602 and 1002 detachable nut connections will result in an unsafe connection leading to separation when under pressure. Failure to avoid this condition may result in death, serious personal injury and severe property damage.

4 in. 1002 non-detachable nut inappropriately used in a detachable union assembly. Notice the resulting lack of thread engagement with the female sub.

Figure 22 - Misapplication of wing nuts

MIS-MATCH!
The misapplication of standard, non-detachable style wing nuts on 2 in., 3 in. and 4 in. Figure 602 and 1002 detachable nut connections will result in an unsafe connection leading to separation when under pressure. Failure to avoid this condition may result in death, serious personal injury and severe property damage.

4 in. 1002 non-detachable nut inappropriately assembled to a detached male sub end. Notice the excessive play between the ID of the nut and male sub OD behind the shoulder.

Figure 23 - Another misapplication of wing nuts

4.1.6 Connecting a Hammer Union Male Sub from one manufacturer to the Female Sub from a different manufacturer.
The practice of mating connection components from different manufacturers where no industry standard exists for the design and manufacture of the connection is generally not allowed. In the case of Hammer Unions, the acme thread is specified by ASME B 1.5, 1.8, but not the sealing arrangement. The male sub (all components from one manufacturer) can be mated with the female sub from another manufacturer if there is an operational history of mating integrity.
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4.2

Mismatching Swivel Joint Components

Because of similarities in design, it is physically possible to erroneously assemble a male race end of a SPM 3 in. HD-LR component into the female race end of an FMC 3 in. TSi component. The assembly would not be structurally sound.
Gap in 3 in. ball race No step between second and third race Male race interferes with female end

SPM 3 in. HD-LR male ball race end

FMC 3 in. TripleStep female ball race end

FMC 3 in. TripleStep male ball race end

SPM 3 in. HD-LR female ball race end

Dangerous Mismatch to be Avoided

Do not mix components from different manufacturers

Figure 24 - Dangers of mismatching swivel joint components

4.3

Mating Hub Connector Components from different manufacturers

The issue arises as the patent for Grayloc has expired and Grayloc will not endorse the integrity of the connection with components copies from another manufacturer. The mating of hub connector components from two different manufacturers (only) is allowed if: The components are dimensionally the same and mechanically equivalent. The hub connector face shall be from one manufacturer and all the other connector components shall be supplied by the other manufacturer. The assembled connector integrity has been validated at temperature, 1 Hub Connector Face pressure and side-loading by the from Manufacture A manufacturer supplying the majoriFigure 25 - Mating Hub Connectors ty of the components. If these conditions cannot be ascertained, a crossover should be manufactured with the sealing faces from the respective manufacturers on opposite ends to avoid mixing the connector components.
Wells All other components from Manufacturer B

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4.4

Threaded Connections

The requirement limiting NPT and line pipe pressure sealing threads (PST) to 1/2 connections has been amended to allow larger nominal sizes, subject to strict QC criteria. (See section 4.4.3). The issues with pressure sealing threaded connections are illustrated below:

Should be made up to this point

2 NPT connection (Pressure Sealing Thread) Hammer lug Weco union to 2 nipple engaged by 6 -7 threads only (Normal engagement requires 8 - 9 threads)
Figure 26 - NPT in poor condition due to corrosion and with insufficient make-up

In Figure 26 the pressure containing equipment with 2 NPT (Pressure Sealing Threads) provides a false sense of security - one cannot tell the condition of the threaded connection as it can be corroded by well or pumped fluids, or been fully made up.
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4.4.1 Non-Pressure Sealing Thread (NPST) & Pressure Sealing Thread (PST) Line Pipe and NPT
The NPST connection was developed in order to isolate the tubing thread from the contained fluid.
Tubing thread Male sub Seal ring Wing nut Tubing thread

Well Fluids

Bakerlok Female sub

NPST Connection Allowed (seal made by elastomer)

Male sub Line pipe thread

Seal ring Line pipe thread Wing nut Female sub

Well Fluids

PST Connection - Banned for use above 285 psi (seal made by thread)
Figure 27 - NPST vs. LPT

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Differentiation of NPTS from PST hammer union connections. Made-up pipework with NPST hammer union male and female connections cannot often be distinguished, viewed externally, from made-up pipework with PST connections. A solution to distinguish between the two has been introduced by FMC. NPST hammer union subs will be identified by a groove 0.38 from the end of the subs and shown in the pictures below.

Groove

Groove

Figure 28 - FMC NPST Hammer Union Subs with groove 0.38 from ends

A viable method of retrospectively adding grooves to the NPST hammer union subs is proposed below. 1) Pipework Deployed on Current Operations. Obtain confirmation from Supervisors that the Hammer union connections are NPST, a) from records if the pipework is already made-up, b) from internal visual inspection of the subs - internal threading on the sub is visible if it is a PST connection. Remove and replace any PST connections. 2) Pipework going through maintenance. When pipework is pulled for maintenance, cut the grooves on the subs on both ends of the pipe.

Figure 29 shows the dimensions and position, relative to the end of the subs, of the grooves (one each end). The copied email (green text) from FMC gives information on the grinder that can be bought for cutting the grooves on the subs. The grinder is mobile, so the grooves can be cut in the Service Providers'
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workshops. According to FMC it takes about 10 mins per end. You need an adapter for this grinder which FMC have designed. They will provide details - see below.
Following are the components that FMC purchased to cut the grooves on the NPST pups in the field. 1. Motorized Tubing Cutter, manufactured by Mathey Dearman p/n 03-0100-M00 (operates off of 110V AC) 2. Heavy Duty Die Grinder, manufactured by Milwaukee Electric Tool p/n 5192 (operates off of 110V AC) 3. Die Grinder Tip, manufactured by SGS p/n 12100, Tool SC-13, 1/8" shank, 5/32" Diameter Bur Tool. One additional item, an adapter, is required to attach the Die Grinder to the Tubing Cutter. FMC Manufacturing Engineering Dept. designed and built this adapter for their use, but would be willing to share this information with anyone needing it in the future. Please let FMC know if you need additional information.
Male Sub

Female Sub

Figure 29 - FMC NPST Retrofitted-groove schematics

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4.4.2 Line pipe, NPT, NPTF

4.4.2.1 Tapered Pipe Connections/Fittings - General

Tapered Pipe Fittings are prone to leakage because they are torque-sensitive. Over-tightening can distort the threads too much and create a leakage path. Also, tapered pipe threads are prone to loosening when exposed to high vibration and wide temperature variation. Repeated assembly and disassembly only aggravates the leakage problem by distorting the threads further. Tapered pipe threads should not be used for mechanically joining components in a system where load would be placed perpendicular to the pipe axis. This weight will further weaken the sealing joint. In light of its sealing mechanism (described below), assembly restrictions and design limitations, pipe thread connections are optimal only when the following conditions exist: Minimum hydraulic shocks or vibration. The fitting/connection is limited to few re-uses (makes and breaks). For NPT fittings, few operating cycles for higher pressure service. Connections are made-up by competent personnel. Line pipe and NPT are pressure sealing threads (PST). Line pipe and NPT threads for the same nominal pipe size are very similar, having the same taper, threads per inch and thread height.
4.4.2.2 Line Pipe

To ensure that line pipe threaded connec-tions are leak-tight, the connections need to be made up power-tight after apply-ing thread compound. Note that after the first make-up of line pipe threads power-tight, the threads may not necessarily gauge. These threads are not designed to be made-up power-tight and broken many times and still remain pressure tight.

Bent linepipe nipple

Figure 30 - Line pipe connections which parted under rapid pressure increase (pipework blockage) and violent transverse movement

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For the above reasons line pipe pressure sealing threaded (PST) pipework is forbidden on the high pressure side (> 285 psi) of the process.
4.4.2.3 NPT and NPTF - Similarities and Difference

NPTF (ANSI/ASME B1.20.3) threads are derived from the NPT (National Pipe Taper ANSI/ASME B1.20.1) thread form adjusted to achieve metal-to-metal contact at the root and crest of the threads when they are assembled. The connection is known as a dryseal connection notionally it does not require any sealant in order to be leak-tight. The applications for this connection are where it is necessary for preventing the process fluid becoming contaminated by the sealant or the process fluid is corrosive. The crests and roots of NPT never meet, even when torqued up, but NPTF crests and roots are the first point of contact. As the connection is torqued the crests deform until the thread flanks meet. NPT threads always require a sealing compound to block the helical leak path. NPTF threads should seal if they are clean and perfectly formed, but a lubricant is still required so sealing liquid should still be used. Consequently NPT fittings should not be mixed with NPTF connections. In fact NPT male can be used with NPTF female, not the other way around, but to avoid confusion it is best never to mix the threads at all. NPTF threads are common for small size steel couplings. Stainless fittings should always be NPT. Rolled threads vs cut threads Cut (machined) NPT or NPTF threads are sharp and clean, but rolled NPT threads have a rough texture on the crests of the thread due to the manufacturing process. This is normal and does not mean the thread will gall as only the thread flanks come into contact. One time make-up vs multiple use NPT, NPTF has a thread interference design that means as the fitting is tightened there is some deformation of the material. This means that technically NPT, NPTF is a one-time make-up connection. NPT, NPTF are not a multiple make up fittings. NPTF is more susceptible to failure compared to NPT as a result of multiple makeup/break-out. Gauging requirements are much more stringent for NPTF compared with NPT. The dominant thread type for Wells applications is NPT. For NPT and NPTF specifying torque values is unusual because with metal-tometal contact and the thread tolerances on the threads, torque values would be highly variable, especially for NPTF. Leak-tight specification of the connection is best done by number of exposed threads after the connection has been made wrench tight. However, some indication of torque values is given below.

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Table 5 - Indicative Torques for High Pressure (> 6000 psi) NPT fittings

Size - ins.
1/ 4 1/ 2

Torque N-M 40 90

ft-lbs 30 67

NPT On the high pressure side of operations using temporary pipework, only threaded connections up to in. are allowed for instrument or hose connections. At in. nominal size, the cold working pressure for an NPT connection is 10,000psi. NPT threads without the use of a sealant will not be leak-tight. The NPT thread gauging illustrated in the following pictures should be incorporated into the routine pipework maintenance.

Mark

OK thread gauge sticks up to mark

Not OK thread gauge passes mark when screwed tight

Ring Gauge

Plug Gauge

No. 1560 L1 Single End Plug

No. 1562 L1 Thin Ring

Figure 31 - NPT thread gauging

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- 35 Female nipple internal threads

Flush One turn large One turn small

EP2007-3153 rev 5
For gauging internal taper threads, the plug gage is screwed up tight by hand into the internal thread of the product. The thread is within the permissible tolerance when the gauging notch of the working plug gage is not more than 1 turn, large or small, from being flush with the end of the thread.

Plug Gauge

Optimal diameter

Maximum tolerance on diameter

Minimum tolerance on diameter

Male nipple internal threads

Ring Gauge

Flush

One turn large

One turn small

Optimal diameter

Maximum tolerance on diameter

Minimum tolerance on diameter

In gauging external taper threads, the ring gage is screwed up tight by hand on external thread of product. The thread is within the permissible tolerance when the gauging face of the working ring gage is not more than 1 turn, large or small, from being flush with the end of the thread.

NPT (ASME B1.20.1) Pipe OD Hand-tight engagement Threads/ turns 4.3 4.3 4.1 4.3 4.5 Wrench-tight make-up Threads/ turns 23/4 - 3 23/4 - 3 3 -3.1 3 3 Max length Wrench-tight makeup in. 0.11 0.11 0.17 0.17 0.21 mm 2.8 2.8 4.8 4.2 5.4

Nominal Size (in.)

Threads/ inch

in.
1/ 16 1/ 8 1/ 4 3/ 8 1/ 2

mm 7.9 10.2 13.7 17 21.3 27 27 18 18 14

0.31 0.4 0.54 0.67 0.84

Included in the standards for NPT threads are engagement lengths, both hand-tight and wrenched. For example, a 1/4 inch tapered pipe fitting should screw in 4.1 threads until finger tight and 3 threads for wrench makeup. One problem is the wide variance in quality of the fittings and threads. Few 1/4 inch fittings screw in 4.1 threads before they reach finger tight. As a general guideline, after hand-tight engagement, tighten 2 3/4 - 3 full turns for sizes up to 1/2 inch.

Figure 32 - NPT thread gauging and engagement - high pressure (>6000 psi) fittings

Gauges can be obtained from: http://www.kennametal.com/en-US/products_services/metalworking/tapping/ Greenfield_tap_die/Greenfield_tap_die_products.jhtml

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Sealing liquid vs thread tape Coupling and fitting suppliers commonly recommend using a liquid thread lubricant/sealant in place of sealing tape. A down side of sealing tape is the risk of applying too much or too little. If too much is applied, not enough turns will be engaged and the threads will not interlock completely. In the worst case the fitting could fail under pressure. If the fitting starts to tighten within one turn due to the excess tape, all the force will be concentrated in a small area and the female may split.
Split Split

Figure 33 - Example of split female connections: A combination of the female thread being slightly off-centre (but within tolerance) and using excessive Teflon tape on the male thread

If too little tape is used the voids may not be filled and the connection could leak, or there could be too little lubrication and an increased risk of thread galling.

Leakage path through NPT threads shown at red points. No matter how tight you make NPT threads, a leakage path still exists. It is the function of the sealant to block the path between the male and female thread

Figure 34 - Leakage path through NPT threads

Shell guidelines (3804-005 MIMS Plant and Equipment Guidance 1.002 Small Bore Tubing Installation) state that the sealant method chosen should be consistent with the design specification for the system. In other words, if liquid sealant is specified it must be used, but otherwise tape is acceptable.
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PTFE tape application and make-up The PTFE tape (to spec AA-58092 or Mil-T-27730A) should be selected appropriate to the pressures, fluid type and fitting material (stainless steel). High density tape (1.2 gm/cc) is recommended for sealing taper threaded connections against high pressure gas. Apply PTFE TAPE to male threads as close as possible to end of threads. Hold end of PTFE TAPE firmly and wind clock wise on standard threads. Stretch tape tightly as you wind. Continue to wind and stretch tape so the tape seats into threads. Wind once around on joints under 1 in. with 50% overlap, as shown in the picture above. Complete winding and overlap bottom end of male thread by about 1/2 in. Tear tape by pulling in same direction as you were winding. Smooth torn end by running fingers over it. Make-up the connection in usual manner.

B B

A B

Tape 50% overlap to give double layer covering

Figure 35 - Clock wise wrapping procedure

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4.4.3 Pressure Sealing Threaded (PST) Connections greater than 1/2

The following NPT and Line Pipe threaded connections for pressure containment for 10,000 psi and below:
Table 6 - Allowed threaded connection working pressures for different pipe sizes

Nominal Pipe Size (ins) Max. Rated WP (psi)

1/ , 3/ , 1/ 4 8 2

3/ , 4

1 1/4 to 6 * 2,500

10,000

5,000

*Maximum size 2 if thread is exposed to H2S. {Note: This table is more conservative than Table 1 in API SPEC 6A.}

The following conditions apply: i) ii) The NPT connections are manufactured according to ASME/ANSI B1.20.1 and the Line Pipe connections according to API Specification 5B. The minimum wall thickness of the connecting coupling in which the male thread makes up shall be not less than that of the unthreaded connected pipe/nipple wall thickness. (The coupling wall thickness being measured from root of thread to the minimum outside diameter.) Internal threaded components shall be at least equivalent in strength and toughness to the external threaded components. (The threaded connection has the same or higher service specification than that of the part/equipment to which it is assembled. Threads exposed to pressured or produced fluids shall be subject to 100% examination for finish and fit. Items with visible imperfections in thread finish or failure to meet gauging requirements in API Spec 5B or ASME B1.20.1, as applicable, shall be rejected. NPT and line pipe threaded connection make-up, requiring the application of sealing tape or sealing compound, is done by trained personnel. The sealant or lubricant used on threads shall be compatible with the fluid service. The connection threads are inspected, gauged, maintained and controlled within a Quality Management System. The threaded parts shall be marked with their maximum working pressure, thread type and their suitability for sour service.

iii)

iv)

v)

vi)

{Note 1: The calculation of wall thickness is made using the equations and allowable stresses from ASME B31.3 for the specified internal design pressure. (The use of more conservative equations, e.g. Barlow, is acceptable.) Note 2: The calculation of shear strength is made using the equations given in ISO TR 10400 or is based on empirical data.}

The following pressure sealing threaded connections are NOT allowed: i) Pressure sealing threaded connections cut on pipe body connected to hammer unions or to any threaded connector which requires hammering
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for its make-up or break-out. ii) Threaded connection sizes greater than 2 if exposed to sour fluids. iii) In conditions where the connections are subject to vibration, mechanical shocks, hydraulic shocks. iv) Threaded connections greater than 6 nominal pipe size.
{Note: ASME Pressure designations are: High Pressure > ~6000 psi; Normal Pressure <~6000 psi. Shell designations: High Pressure > 10,000 psi; 500 psi <Normal Pressure < 10,000 psi. Low Pressure <285 psi for threaded connections. Low pressure for pressure testing is ~200-500psi.}

Situations where pressure sealing threaded connections may be found on well testing equipment are: Dataheaders HP Separator, Fisher Controller Separator, Daniel orifice meter HP Separator Separator 5000 psi WP 2160 psi WP 1440 psi WP 3500 psi WP 1440 psi WP
3/ NPT (Thermowells). 4 1 1/2 NPT 3/ NPT drain 4 3/ NPT connections 4

1 NPT Isokinetic sampling point on gas line

Table 7 - Normal pressure < 6000 psi NPT nominal sizes and thread engagement data.
Pipe OD in. 1.05 1.315 1.66 1.9 2.375 2.875 3.5 mm 26.7 33.4 42.2 48.3 60.3 73.0 88.9 Handtight engagement Threads: Turns 4.75 4.6 4.8 4.8 5 5.5 6.1 6.6 6.75 7.5 7.7 Wrenchtight Max Length Wrenchmake-up tight makeup Threads: Turns 3 3 3 3 3 2 2 2 2 2 2 in. 0.21 0.26 0.26 0.26 0.26 0.25 0.25 0.25 0.25 0.25 0.25 mm 5.3 6.6 6.6 6.6 6.6 6.4 6.4 6.4 6.4 6.4 6.4

Nominal Max WP Size (in.) (psi) 0.75 1 1.25 1.5 2 2.5 3 3.5 4 5 6 5000 5000 2500 2500 2500 2500 2500 2500 2500 2500 2500

Threads per inch 14 11.5 11.5 11.5 11.5 8 8 8 8 8 8

4 101.6 4.5 114.3

5.563 141.3 6.635 168.5

Threaded connections (taper and straight) on hydraulic hoses and control lines used for control systems containing clean and non-corrosive fluids are allowed.
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4.5

Flexible Pipes - Hoses

4.5.1 Suitability of hoses connected in the high pressure (> 285 psi) side of the process.
The high pressure hoses that are used in temporary operations include: Hoses to direct well fluid from the test tree to the stand pipe or choke manifold - test lines. Hoses to direct fluids from the stimulation vessel to the frac head. Cementing hoses. Acid line. Nitrogen lines Chemical injection hoses. Kill lines. There are many standards for hoses which have been developed for specific industry applications. The standards for hose design and construction for application in temporary pipework operations include API 16C, API 17J (which is identical to ISO 13628-2). It is generally accepted that the brand for high pressure hoses is Coflexip (Technip). This hose design is classified as unbonded flexible pipe, the construction consisting of separate unbonded polymeric and metallic layers, which allows relative movement between the layers. (ISO 13628-10 covers bonded hoses; API 16C covers both unbonded and bonded hoses. API 16C gives rigorous requirements for the testing of flexible hoses and is not equivalent to ISO 13628-2.) Unbonded hoses are more suitable than bonded hoses in dynamic situations i.e. where there is relative movement between the hose ends. Unbonded hoses have a smaller bending radius in general for the same hose size and pressure rating. Other established manufacturers of hoses, e.g. Parker with their Polyflex products, comply with criteria taken from both API 16C and ISO 13268-2. Some propretary criteria e.g. testing of the hoses, can be more stringent than that required in the standards above or better reflect the conditions under which they will be used. The expectation of Shell for the supply of high pressure flexible hoses given the diversity of their engineering and the polymer materials available today is that: Their design and construction in the main should comply with ISO 13268-2 / API 17J (unbonded) or ISO 13268-10 (bonded). Where there are differences between the specification and the standards, they should be evaluated for suitability with the proposed application. The hose should have a reliable track record; or, if a new design is proposed, that the hose should have been validated at the extremes of its operational envelope with the stressing parameters (pressure, temperature, flexing, vibration, etc.) applied simultaneously.
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4.5.2 Handling, Storage and Maintainance of Flexible Pipe

Flexible pipes or hoses are resistant to bending, including frequent continuous flexure, however it is imperative that they are handled, stored and maintained correctly. In general: The preferred installation for a flexible line is with the pipe positioned in a J or U configuration, with the end fittings pointing up in a vertical position. Do not leave medium to longer lengths of horizontal pipe unsupported. Ensure flexible pipe is not bent over or resting on sharp edges - any vibration will cause damage at such points. Do not exceed the minimum bending radius of flexible pipe. [ As a rule of thumb, the minimum bending radius (MBR) is roughly 12 x the I.D. of the pipe].

d = (2 x MBR - OD) d is the minimum inside distance between two surfaces MBR

Figure 36 - Minimum bending radius of flexible pipe

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Support to maintain bending radius Anchor Soft strops with shackles

1 2

Cable SWL 5.7t

4 3

SF4 15m

PN

Cable anchor points Steel sling or soft Chain block strop SWL 5t Cable One shackle connection SWL 6t as cable is not long enough Deck beam Similar configuration for coflex on both ends

4 3

Figure 37 - Hose installing concept for long spans

4.6

Equipment Interfaces & Equipment Repair and Maintenance

Replacement parts for temporary pipework should be built from design and manufacturing files identical to the original parts and should have been validated at the extremes of the connection envelope:- pressure, temperature, side loading, etc. applied simultaneously.
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5
5.1

Hazard Identification and Mitigation

Mitigation Methods

5.1.1 Checklists
5.1.1.1 Pre-Mobilisation Check List

Equipment for temporary operations can be assembled over several days as it is released after maintenance. A final physical inspection when the package is complete will reduce the likelihood of incorrect equipment being installed in the field. A pre-mobilisation check is a specific activity independent of the ongoing checks made when all the equipment is assembled and shall include verification:that there are no mismatches of the types identified in this guide of the mating integrity of connections of the interfaces where equipment comes from different suppliers of critical dimensions (IDs, ODs). Where there is no categorical proof of the suitability of the equipment, physical checks shall be made.
5.1.1.2 Pre-Pressure Test Temporary Pipework Walk-the-Lines Check List

The purpose of the checklist is to ensure that the Temporary Pipework and equipment: Is hooked-up in compliance with the approved drawings and equipment lists. Can be operated as required by the Programme. To ensure the adequacy of the ratings of the interfaces and blanked-off outlets. Checklists are an orderly and sequential collection of best practices for confirming the configuration of temporary pipework for safe operations. Checking a temporary layout must often be undertaken amid a host of competing job priorities. Routine supervisory duties can interfere with walking-the lines resulting in failure to complete the checklist and confirm the correct configuration of the temporary pipework. The consequences of disrupted or interrupted checklists are varied and potentially serious and must be avoided.

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Table 8 - Example of Pre-Mobilisation Temporary Pipework Checklist

NAME GRADE DATE

CLIENT CONTRACT NO.

RIG WELL
SUPERVISOR SNR TECH DATE

COLLECT LATEST P&ID ESTABLISH EQUIPMENT TO BE SHIPPED MATCHES P&ID IF PROGRAMME/HAZ-OP AVAILABLE COMPARE WITH P&ID TO CHECK FOR INCONSISTANCIES IMPLEMENT CHANGES IF REQUIRED CHECK X-OVERS, ETC FOR ALL EQUIPMENT CHECK CHOKE MANIFOLD AND HEATER CHOKE FOR ALL NECESSARY EQUIPMENT AND THAT SPARES ARE AVAILABLE LIASE WITH LOGISTICS/CERTIFICATION DEPT. ABOUT STATUS OF HIRE EQUIPMENT IF FLOW CHECK VALVES ARE PRESENT ENSURE THEY OPERATE IN THE CORRECT DIRECTION OBTAIN & CHECK RIG VISIT REPORT TO CHECK RIG INTERFACES WITH X-OVERS DISCUSS WELLTEST DESIGN WITH OPERATIONS SUPERVISOR AND OPERATIONS SUPPORT TECHNICIAN LIASE WITH WORKSHOP SUPERVISOR AND DISCUSS EQUIPMENT STATUS CONFIRM VALVE HANDLES ARE PRESENT FOR ALL EQUIPMENT IF ACID IS EXPECTED ENSURE REQUIRED PPE IS PACKED CHECK SEPARATOR ORIFICE PLATES MATCHES SEPARATOR CHECK STANDARD SPARES LIST MATCHES PACKAGEREQUIREMENT CHECK SANDFILTER ELEMENTS SUIT PACKAGE IE. (GOLDEN SUPER), HIGH DIFF, FILTER CARRIERS CONFIRM PILOT SETTINGS CONFIRM ELEVATOR SIZES MATCH FLOWHEAD CONFIRM TEST CAPS ARE AVAILABLE FOR ALL EQUIPMENT CONFIRM STRING /WIRELINE X-OVERS ARE BEING SUPPLIED BY EXPRO, IF SO ARE THEY PRESENT? CONFIRM IF SUBSEA HAS INVOLVEMENT IN OPERATION, CHECK STATUS OF EQUIPMENT AND INTERFACES HAS BURNER BOOM INFORMATION BEEN CHECKED AND CONFIRMED WITH WORKSHOP? ARE ALL CREW MEMBERS SELECTED? ARE ANY OF THE CREW DUE TO GO ON ANNUAL LEAVE? DISCUSS RELIEF WITH CLIENT

SUPERVISOR
IS H2S OR CO2 EXPECTED? ARE ELASTOMERS ADEQUATE?

SNR TECH

DATE

HAS SHIPPING LIST BEEN ADEQUATELY FILLED OUT? DISCUSS OMISSIONS WITH ONSHORE OPS SUPERVISOR, ENSURE ANY OMISSIONS OR MISTAKES ON SHIPPING LIST ARE RECTIFIED. NOTE: DISCUSS AND REVIEW ANY SIGNIFICANT CHANGES TO THE EQUIPMENT OR OPERATION (DOES THE CHANGE AFFECT THE OPERATIONAL REQUIREMENTS?) WILL THERE BE/OR COULD THERE BE ANY LATE CHANGES TO ANY MAJOR ITEMS OF KIT? Eg. SEPARATOR, HEATER. IF SO, THE P&ID MUST BE CHANGED TO REFLECT THIS, CLIENT MUST ALSO BE INFORMED. HAZOP MAY HAVE TO BE RE-VISITED. ALL LATE CHANGES TO KIT MUST BE DISCUSSED WITH ONSHORE OPS SUPERVISOR AND RELEVANT INFO PASSED ONTO CLIENT

LIST OF ALL OUTSTANDING ITEMS - ADDITIONAL ITEMS, List all items that may be on order, are missing, or you are struggling to get hold of for the job. All items listed here should be passed onto Ops supervisor/workshop foreman for action.

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Table 9 - Pre-Pressure Test Temporary Pipework Checklist

Location/Well: Supervisors: Reference Drawing No. Job No. Programme: Date: Reference Equipment List(s):

Line Section:
Dispensations Requested for this line section: YES Item/ Description of Check Procedure
1. Check pressure rating of upstream interface connection and subsequent connections in the line by reference to banding. 2. Check pipework material for suitability for service. 3. Check that the number of swivels has been minimised. 3. Check/confirm that correct bolts and gaskets are installed at all mechanical joints and bolt engagement. (Bolts shall extend completely through the nut with at least one thread exposed at each end. Confirm that bolting has been made up to the correct torque with calibrated torque wrenches.) 4. Check sealant on screwed connections is as per specification. 5. Check/confirm elastomers in hammer unions are compatible with fluids/service. 6a. Confirm that vessel/equipment outlets, not in the flow path and potentially subject to being pressured are appropriately blanked. Where the blanking comprises a male or female hammer union confirm the FIG no. and service is compatible with the vessel/equipment specification. 6. Check for correct flow through filters and strainers, traps, check valves, globe valves and control valves. 7. Check that the valve positions are tagged (open/closed) and are correctly lined up for the pressure testing. Where a valve is required to be locked open or closed, ensure that the locking system is sufficiently robust, preventing it from being simply overridden. Note those valves the position of which needs to be altered for the first operation. 8. Check that all chain wheels and extended spindles required for specified valves have been installed 9. Check that orifice flanges have required upstream and downstream clearances. 10. Check that all vents and drains are installed. The drains should be at the lowest points and vents at the highest points. Check for proper slope (e.g. flare lines). 11. Check all instrument thermowells installed. Check that welded nipples are properly installed. Threaded nipples shall be checked for engagement, Check that they have not been seal-welded. 12. Confirm the setting of pressure pilots, and sizing of pressure reliefs. 13. Confirm the safety of electrical instruments. 14. Check that all pipe supports, anchor point, clamps and restraints are adequate. (Confirm that expansion allowance has been provided. Confirm that there is no excessive bending moment resulting from lack of support or overloading from tugger lines on the pipework.) 15. For items marked No, raise outstanding works list and ensure that it is completed prior to pressure testing. Count/Eq No.

NO
Reason

N/A

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The key points are: 1. The Wells Supervisor (WS) and the Contractor Services Supervisor (CSS) are jointly responsible for ensuring that the Temporary Pipework is hookedup as required by the approved P&ID or Process Flow Diagram. 2. Any deviation in the Temporary Pipework hook-up from the requirements of the Standard for Temporary Pipework (EP 2006-5393) needs a Dispensation. 3. A confirmation that all temporary pipework has been certified (maintained and tested) according to Contractors procedures (endorsed via contract awarded by Shell). Specifically that no equipment is derated or below the minimum wall thickness allowed. 4. The checks may be carried out Line Section by Line Section determined by specification (pressure) breaks progressing from high pressure to low pressure. 5. Refer to EP 2006-5393 Appendix 3 for specific hammer union mismatches and restraint dynamic loads. (Note specifically: Both male and female 2 in. Fig 402, 2 in. Fig 602 and 2 in. Fig 1002 unions are banned in all configurations e.g. vessel outlets, burner boom piping). 6. Where appropriate, record the number of connections inspected (Count) or equipment identification number (Eq. no.) in the tick column and if NO is ticked, the Reason.

5.1.2 No-Go areas

During pressure testing keep at least 2 pipe run lengths away from the line under pressure. Keep out of line-of-sight of pressured plugged outlets, instrument connections on vessels and flowline equipment.

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5.1.3 Restraints for Temporary Pipework using Polyester Roundslings

The installation of temporary pipework restraints is mandatory where fluids are pumped or flowed through the pipework. The forces reacting on pipework when fluids at high pressure are discharged through a rupture are large. A restraint system acts like a shock absorber. In order to absorb the kinetic energy of the pipe, the weakest part of the restraint system must have at least twice the strength (this is the dynamic force, or dynamic load) generated by the reactive force acting on the parted pipe. The maximum theoretical (corroborated by other calculation methods and lower limit tests) dynamic forces generated in wire ropes, roundslings, fibre ropes, etc. used to restrain pipe when the pipe ruptures are given in the charts Fig. 38, Fig. 39 for the pipe IDs and pressures in question. When pumping non-energised liquid and the pipe runs are constrained from swinging or from becoming projectiles, should a pipe section rupture, by the rig structure (for example, pipe runs from an offshore cement unit) the installation of a restraint system may be waived, subject to a suitable risk assessment. Where pipework is boxed-in and cannot whip, become projectiles or indeed move (for example, boxed-in Compact Well Test equipment pipe runs between vessels mounted on the same skid) installation of a restraint system around individual pipe sections is not required.
Restraint Installation using Polyester Rounslings - General

The method for hitching round slings to pipework is similar to that which was used for wire rope. It is assumed that the restraint installation requirements are straightforward enough and the results obvious enough (when walking-the-lines) that the installation of roundslings as restraints can be performed competently by a person using these instructions. The roundsling restraint installation will generally start after all the temporary pipework is hooked up, prior to pressure testing. It is expected that the planning process will have identified the range (total lengths, individual lengths and WLLs) of the slings required and mobilised for the operation. It is not possible to prescribe restraint installation for every conceivable flow or pumping layout. It is expected that there is enough information in the following instructions for the method to be applied to unusual pipework arrangements.

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Chart indicating the dynamic loading on, and selection of EN 1492-2 round sling restraints in the event of pipe rupture for a range of ID's, the pipe being pressured with oil,sea water (liquids)
Maxoperating pressure(Liquid)

70.0

1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 11000 12000 13000

60.0

50.0

Roundslings(workingloadlimit) EN14922 (safetyfactor7:1) Colourcodes

40.0

14000
15000 16000 17000 18000 19000 20000

Dy ynamic Load (mT)

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30.0

Figure 38 - Chart indicating dynamic loading and selection guide of EN 1492-2 round sling restraints for liquid pressurised piping
1 1.5
2" 2 2.375"OD

Wells
2.5
3" 3 3.5"OD

2Tonne 3 Tonne 4 Tonne 5 Tonne 6Tonne 8 Tonne 10Tonne 12Tonne

20.0

10.0

40Fto194F 40Cto90C

0.0 3.5

12 10 8 6 5 4 3 2 4" 4 4.5" OD

Roundslingrestraints Max load(Tonnes) Hitchedtopipe

0.5

4.5

Pipe ID (ins)

6" 5.5 6.625"OD

6.5

8" 7.5 8.625"OD

EP2007-3153 rev 5

JoiningShackle

ReefKnot

Half Hitch

JoinbetweenhitcheswithExample howtousechartfor:Processsteps: Reef Knotorshackle:Maxpressure5000psi(oil)1. Drawverticallineupfrom3.152"fromhorizontal 4.75T for2,3,4WLLrestraintsFlowedorpumped. Axistomeet5000psicurve. 6.5T for6,7,8WLLrestraints4"602pipescheduleXXS2.Frompointofintersection,drawahorizontalline 8.5T for9,10WLLrestraintsIDofschXXS=3.152" tomeetroundslingsbars. 3.Thefirstbarintersectedgivestheroundsling WLL.Hitchpipewith6T(brown)sling.

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Chart indicating the dynamic loading on, and selection of EN 1492-2 round sling restraints in the event of pipe rupture for a range of ID's, the pipe being pressured with gas
Maxoperating pressure(gas)

70.0

1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 11000 12000 13000

60.0

50.0

Roundslings(workingloadlimit) EN14922 (safetyfactor7:1) Colourcodes

40.0

14000
15000 16000 17000 18000 19000 20000

Dynamic Load (mT)

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Figure 39 - Chart indicating dynamic loading and selection guide of EN 1492-2 round sling restraints for gas pressurised piping
1 1.5
2" 2 2.375"OD

Wells
2.5
3" 3 3.5"OD

30.0

2Tonne 3 Tonne 4 Tonne 5 Tonne 6Tonne 8 Tonne 10Tonne 12Tonne

20.0

10.0

40Fto194F 40Cto90C

0.0 3.5

12 10 8 6 5 4 3 2 4" 4 4.5" OD

Roundslingrestraints Max load(Tonnes) Hitchedtopipe

0.5

4.5

Pipe ID (ins)

6" 5.5 6.625"OD

6.5

8" 7.5 8.625"OD

EP2007-3153 rev 5

JoiningShackle

ReefKnot

Half Hitch

JoinbetweenhitcheswithExample howtousechartfor:Processsteps: Reef Knotorshackle:Maxpressure5000psi(oil)1. Drawverticallineupfrom3.152"fromhorizontal 4.75T for2,3,4WLLrestraintsFlowedorpumped. Axistomeet5000psicurve. 6.5T for6,7,8WLLrestraints4"602pipescheduleXXS2.Frompointofintersection,drawahorizontalline 8.5T for9,10WLLrestraintsIDofschXXS=3.152" tomeetroundslingsbars. 3.Thefirstbarintersectedgivestheroundsling WLL.Hitchpipewith5T(red)sling.

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To use the charts: Enter the horizontal axis with the pipe ID. Draw a vertical line up from the ID to intersect the maximum internal pipe pressure. Draw a horizontal line to intersect the vertical axis and read the dynamic loading in tonnes. (This first coloured vertical column that this line intersects just before meeting the vertical axis is the colour coding and strength of the lowest safe roundsling restraint). Note (1). Two charts are needed, giving the maximum dynamic loading on restraints for open-ended pipe for: a. energised liquids, or non-energised liquids pressured from an infinite source (oil reservoir), b. gasses. The steady-state reactive force generated by the discharge is proportional to the density of the fluid being discharged, thus liquid discharge, as indicated in the charts, produce a greater reactive force on the pipe (and a corresponding greater dynamic loading on the restraints) than gas discharge. Note (2). Although the restraints use lifting equipment technology, the SWL (Safe Working Load) or the WLL (Working Load Limit) of this equipment has no direct relevance for their use as pipework restraints, except to indicate the breaking strength of the restraints, be it wire rope or roundslings. In the case of roundslings manufactured to EN 1492-2, the slings are designated by their WLL and the standard (1492-2) requires that their breaking strength under specific pull conditions is 7 times the WLL. Note (3). Where Polyester roundslings are manufactured to ASME B 30.9 (US Standard), different Selection Charts apply. These are shown in Appendix 3.

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5.1.4 Installation Steps for Polyester Round Slings

PRIOR TO PRESSURE TESTING STEP 1 Selection of the round slings corresponding to line sizes

1. Verify the size and maximum pressure of the line sections to be restrained. 2. Use the chart to select restraints suitable for the pipework being restrained. 3. Layout the slings required, checking the tags in addition to the colour coding.

STEP 2

Pick anchor points

[Note: The following Anchor Point steps demonstrate restraint installation using red (5T WLL) round slings.]

Identify an anchor point on the equipment/rig, avoiding a pressured line, selecting a structural member without square edges. Try to pick the anchor point to minimise the freedom for potential movement between the point and the first half-hitch on the pipework. Attach the roundsling restraint to the structural member/anchor point with a choke-hitch and tighten.

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STEP 3

Hitching roundslings around the pipe away from the anchor point.

Make a half-hitch (illustrated with 3T WLL roundslings) around the nearest joint of pipework in the process flow on the backside of a connection and remove any slack by pulling away from the anchor point and working and taking out any slack via the half-hitch.

AN

CH

OR

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STEP 4

Joining two slings and connecting to the end anchor point

Warning: Slings must not be joined across connections (that is with the join,

shackle or reef-knot, positioned between the half-hitches either side of a union or swivel connection). 1. Continue with the hitching away from the starting anchor point. The roundslings can be joined by forming a reef-knot: pass one end of the sling to be joined through the free end of the restraining sling already installed and pull the free end back through itself.

Continue with hitching the roundsling to the pipework. 2. On reaching the anchor point, it will not be possible to make a choke hitch around a structural member. There are two possibilities illustrated here with a 5T WLL roundsling, tieing off a roundsling to the structure on a separator: a) Wrap remaining slack around the member/bar/stiffener etc. and then use a suitable shackle to tie-off.

b) Altenatively tie-off

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3. Where the restraints have been attached to anchor points at either end of the pipe run, it will not be possible to join their free ends together with a reef-knot. The join can be made with a shackle of suitable size. (See Appendix A). (The roundslings may be additionally hitched either side of the shackle in order to take up slack).

4. Pipe runs which are not connected (anchored) by equipment at the ends,
e.g. discharge lines, diversion lines, venting pipe runs, pressure relief lines, must be tied down to anchor points or solid structure with restraints. The 4 deluge water diversion line shown right could rotate about any of the connections (shown by orange arrows) injuring by contact with or discharging the line contents at a person opening the valve (yellow arrow).

The discharge line should be reconfigured in the manner shown below and restrained:

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- 55 Encountering Swivels, Tees and Valves in the line

EP2007-3153 rev 5

STEP 5

1. SWIVEL JOINT. On encountering a swivel joint in the line, a half-hitch must be made across each breakable section of the swivel and across the connecting unions.

2a. TEE 180 DEGREE BRANCH. On encountering a TEE-180 degree branch, continue with restraint installation as if the TEE were a straight, half-hitching either side of the connection.

2b. 90 DEGREE BRANCH. If the TEE is encountered along the 90 degree branch or a start to the installation of the restraints made from the 90 degree branch, the connection should be made as follow: pass the roundsling around the 180 degree branch and thread it through itself to make a choke-hitch. Continue with half-hitches either side of the connection on the branch as they are encountered.

3. VALVE. On encountering a valve, when restraining pipework, half-hitch the restraint either side of the valve connections as shown.
STEP 6 Inspection of completed installation Walk-the-Lines to verify that the sling installation has captured every connec-tion and that there is no looping slack in the restraints.
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5.1.5 WeirSPM FSR System

Flow Line Safety Restraint System (FSR) At a Glance

The Flow Line Safety Restraint System, or FSR, is the first and most utilized engineered restraint system specifically designed to reduce the area of danger around high-pressure flow line disengagements. Now, the FSR System is available in two styles: the original Medium Duty FSR and the new Light Duty FSR.

Features of the Weir SPM FSR System: Rental packages available Extreme high strength and reliability Flexible & lightweight Easy to install Corrosion resistant Works in both fluid and gas pumping operations Water resistant exterior covers Uniquely identifiable colors and labeling Available Full-Service Assistance in the field Ten years of proven, successful utilization

Inspection / Rejection Criteria: Easy visual inspection process which can be performed in the field by competent personnel. Any damaged items must be taken out of service immediately. For more detailed inspection information visit the website below to view the FSR Operations Manual.

Medium Duty FSR Color Code: Rib - Red Spine - Blue

Light Duty FSR Color Code: Rib - Yellow Spine - White Available in offshore and onshore rental packages.

Medium Duty FSR Ratings: 2" Iron - 20,000 psi 3" Iron - 15,000 psi 4" Iron - 10,000 psi

Light Duty FSR Ratings: 2" Iron - 15,000 psi 3" Iron - 7,500 psi 4" Iron - 5,000 psi

Medium Duty FSR Weights: (weight per foot of length) Rib - .85 lbs. / ft. Spine - 1.7 lbs. / ft.

Light Duty FSR Weights: (weight per foot of length) Rib - .64 lbs. / ft. Spine - 1.00 lbs. / ft. Training and full service support available.

For more information please visit the Weir SPM products page at

www.weiroilandgas.com
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5.1.6 FMC Technologies TPR System

The FMC Technologies Temporary Pipeworks Restraint (TPR) System incorporates important safety and operational benefits for tough operating environments and demands for handling pressurized fluids. The TPR System is designed to restrain potential separation of pipework at rated pressure for temporary pipework up to 4 Figure 1502. The design also takes into consideration the maximum fluid bore areas after material loss due to erosion. There are only two components in the TPR System: R-Links and C-Links. The R-Links are the restraining components of the system, which are wrapped tightly to pipework. This installation technique minimizes the strike zone, eliminates the need for anchor lines and minimizes tripping hazards. The C-Links are employed to connect the ends of two R-Links together. The C-Links have an integrated hitch pin to keep the assembly intact during pipework handling and line vibrations. The simplicity of the TPR System facilitates the fastest possible installation, removal for access to leaking connections and decommissioning. TPR System components can be quickly inspected on-site before or after each job through the application of the following inspection features: The fiber optic system, which will not pass light when internal yarn damage due to crushing, cutting or chemical attack has occurred, even when the outer cover is intact. The External Warning Indicator, which disappears under the cover to indicate that the component had been misused or otherwise subjected to very high loads. A red undercover, which facilitates easy detection of damage to the outer cover. In most cases, TPR System components which have been rejected due to the above inspection methods are repairable through a refurbishment and recertification service provided by FMC. TPR System components employ the very best in high strength, chemically resistant fiber technology. The two-layer cover is sized to reduce the amount of moisture that can be absorbed. The TPR System is available in three models covering the broad range of pipework sizes and pressure ratings. To learn more about the TPR System, see the link below: http://www.fmctechnologies.com/FluidControl/Flowline/RestraintSystem.aspx
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6
6.1

Avoiding Injury
Hammering Unions

In order to minimise the risk of injury while hammering unions, the following are suggested: The hammer heads and lugs on the Hammer Union Wing Nut should be in good condition.

M I N
6

<> 1/ 4
mm

Acceptable

Unacceptable

Figure 40 - Condition of lugs on hammer union wing nuts

The hammer shaft, if wood, should be in good condition. Preferably the hammer shafts should be made of composite material. Consideration should be given to using WeirSPM Safety Iron or Hub connections where possible.

Figure 41 - Safety iron

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Where hammer unions cannot be avoided then the WeirSPM Safety Hammer should be considered.

ote: the picture shows a union with threaded makeup to the pipe body. This is banned in Shell

Figure 42 - Safety hammer

6.2 Positioning of Body

When reading gauges or working on pressured pipework, keep body out of line of fire of all connections.
Sandfilter
1/ " 2

NPT plug, ejected

at 10,000 psi has more than twice the

Gauge

PT Plugs

energy of a 0.22 calibre rifle bullet. A 1/2" NPT plug projectile is potentially lethal even if the pres-

Connection

sure behind it is just 1000 psi and can cause serious injury if ejected at any lower pressure.

Figure 43 - Gauge positioned directly above a pressurised pipe connection

Dataheader

PT Connections

Figure 44 - Sand Filter and Dataheader showing NPT connections

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EP2007-3153 rev 5

Completing the Connection Interface Diagram

In order to mitigate against the safety and operational risks associated with incorrect connections in temporary pipework, a toolbox has been introduced to standardise the construction of Completion Interface Diagrams (CIDs). The objectives of this toolbox are: To create a consistent standard for representation of temporary pipework connections. To simplify layouts to remove unnecessary or confusing information. To make identification of critical connections easier. To mitigate against incorrect connections at pipe interfaces. The procedure begins with a layout drawing or P&ID and, with the use of a MS Word templates or Visio templates (Visio is much easier to use), aides the construction of a clear layout design. A guide to using this toolbox along with a video tutorial have been prepared and should be reviewed before attempting the construction of the CID for your operation.

Constru

ction and

3. CID Ke
Software

Implem

entation

y Featur

es

of Connec tion Inte

rface Diag rams

Shell Exp

loration and

Production

All existing CIDs hav versions of this soft e been created in Microso ware pac is advisab ft kage that le, are availabl Word. They sho should mak but not necessa uld be read e. All new ry, to use e the crea able and CID the tion and editable Microso editing pro most recent vers s should be crea in most ft Wo ted in Mic ion of this cess mor rosoft Wo e simple. of this guid rd has been cho software rd. It sen e, users that is avai will be fam over other pac that it and lable as kages due this iliar with they can to its alm produce the draw ost univ the desired Figure 1 ing method ersa shows a l use on results in s used in complet PCs. By terms of are desc the packag ed CID the end ribed as nea e t, for and clea follows; Well Tes r and con will be con ting Tem sistent CID fident porary Pipe s. work. The key features of this diag ram

Platform

ion and Construct ion x for the ct ne on C A Toolbo of tation Implemen Diagrams Interface
Comprising part of the Guidance to the Tem porary Pipe work Stan dard

Figure 1 - Well Testing

CID

June 2006

Rev. 1

Shell

Explora

tion and

Producti on Nex

us Consult

ing, 200

6 Page 4

Figure 45 - CID toolbox guide

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Figure 46 - CID toolbox video tutorial

The completed CID for an operation will be used as a check when walking the lines to confirm that it is safe to test. Alternatively, Piping and Instrument Drawing (P and ID) can be used to show the connections and their interfaces and as reference when walking the lines.

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EXAMPLE: P and ID Marked-up showing Connection Interface To be used when "Walking-the-Lines" prior to pressure testing. All blanked-off outlets on vessels must be identified.
Example of marking up P and ID

Female - Male X-Over 4" 602 x 4" 206

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3" 1502 3" 1502 4" 602 4" 602 3" x 2" 1502 X-over

Figure 47 - P & ID showing connections marked-up for walking the lines

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2" 1502

4" 602
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Walking the Lines

Prior to pressure testing, the flowing or pumping lines shall be 'walked' and checked against the Hook-up schematic to confirm that it is safe to proceed, there being no connection mismatches, that the pipework restraint arrangements have been installed as planned, and that suitable pressure test safety precautions such as valves being in the correct position, air bleed points, and barriers - are all in place. Items of equipment that cannot be individually restrained, such as hammer union blanking plugs on process equipment outlets shall be specifically identified and checked for compatibility with the mating union and process equipment rating.

8.1

Example walkthrough

Some things to look out for, in addition to those previously mentioned, include:

Insufficient restraints

All connections and long runs of pipework should be suitably restrained

Earthing Point corroded

Insufficient/inappropriate support Wells

Pipework and connections must be adequately supported

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NPT thread showing some corrosion

Flange bolts do not fully penetrate nuts

Flange bolts should extend completely through the nut with at least one thread exposed

2 in. Threaded Connections 2 in. Fig 200 Male Sub Crossover with the potential to be used elsewhere 2 in. Fig 200 Female Sub

Inlet to Atmospheric Tank

2 in. Fig 602 Female Sub

2 in. Fig 602 Wing Nut 2 in. Fig 602 Male Sub

2 in. Fig 200 Wing Nut

Figure 48 - Example things to consider during walking the lines

Also confirm that the design is not flawed e.g. check-valve reversal!
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9
9.1

Awareness of Safety Initiatives

Truncated 2 in. FIG 602 Female Sub

To prevent the female 2 in. FIG 602 sub mating with the 2 in. FIG 1502 male sub, a modification to the female 2 in. FIG 602, 1002 is proposed. The truncation of the FIG 402, 602, and 1002 female subs, reducing the thread diameter by ~ 30/1000th of an inch prevents the make up of these subs with the 2 in. FIG 1502 male sub. This modification has been endorsed by API in API RP 7HU1 (in draft currently) and the comparison with the old design is shown below.

Current design

New design

Figure 49 - Marked raised shoulder on new engineering design is illustrated by comparing the original geometry (on right with no raised shoulder) to the new geometry (on left with raised shoulder and size/figure markings)

Since there is no compromise on the banning of 2 in. FIG 602 unions, the truncated 2 in. FIG 602 subs are not allowed on Shell installations, even though their construction prevents mismatched make-up.

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10

EP 2006-5393 Temporary Pipework Standard Compliance

GAP (Y/N/ TBD)

10.1 Gap Analysis and Corrective Action Checklist

EP 2006 5393 Reference Temporary Pipework Standard Requirement Gap Comments Proposed Corrective Actions

The requirements have been extracted from EP2006-5393 and the gaps in compliance noted and the action taken to remedy then planned.

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References
Iyamu, I., Beltman, B., and Hampden-Smith, G. (2006), Shell Global Standard for Temporary Pipework, Shell International Exploration and Production bv (SIEP), Rijswijk, EP 2006-5393. Hampden-Smith, G. (2009), Restraint Investigation Report (stored in Livelink).

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Appendix 1- Different Hammer Union Male and Female Sub mating arrangements.

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[Note: The threaded connections to make-up on the pipe are not allowed. The purpose is to show the different Hammer Unions and sizes]
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Appendix 2 - Piping Schedules

A certain pipe schedule is often established for certain services. This is dictated by the classification of the piping system, based on the need and the application. A pipe schedule to be used serves as the basic specification for the pipe thickness and dimensions. Industrial pipe thicknesses follow a set formula, expressed as the "schedule number" as established ANSI. The schedule numbers that are available for use: 5, 10, 20, 30, 40, 60, 80, 100, 120, 140,160, and double extra-heavy (XXS or XXH). The schedule number is defined as the approximate value of the expression:

Schedule Number = 1,000*(P/S) Where, P = the internal working pressure, psig S = the allowable stress (psi) for the material of construction at the conditions of use.

For example, the schedule number of 4 (nominal) steel pipe having an allowable stress of 50,000 psi for use at a working pressure of 5,000 psig would have: Schedule Number =1,000*(5,000)/50,000) = 100 (indicating 120)
Pipe Size (Nominal) 1.00 1.00 1.00 1.00 1.00 1.00 1.25 1.25 1.25 1.25 1.25 1.25 2.00 2.00 2.00 2.00 2.00 Schedule 40 STD XS 80 160 XXS 40 STD XS 80 160 XXS 40 XS 80 160 XXS OD ins 1.315 1.315 1.315 1.315 1.315 1.315 1.66 1.66 1.66 1.66 1.66 1.66 2.375 2.375 2.375 2.375 2.375
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ID ins 1.049 1.049 0.957 0.957 0.815 0.599 1.38 1.38 1.278 1.278 1.16 0.896 2.067 1.939 1.939 1.687 1.503

Wall Thickness ins 0.133 0.133 0.179 0.179 0.25 0.358 0.14 0.14 0.191 0.191 0.25 0.382 0.154 0.218 0.218 0.344 0.436

Wt/ft lbs 1.679 1.679 2.172 2.172 2.844 3.659 2.273 2.273 2.997 2.997 3.765 5.214 3.653 5.022 5.022 7.462 9.029

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Pipe Size (Nominal) 3.00 3.00 3.00 3.00 3.00 3.00 3.50 3.50 3.50 3.50 3.50 4.00 4.00 4.00 4.00 4.00 4.00 4.00 5.00 5.00 5.00 5.00 5.00 5.00 5.00 5.00 5.00 6.00 6.00 6.00 6.00 6.00 6.00 6.00 8.00 8.00 8.00 8.00 8.00 8.00 8.00 8.00 8.00 8.00

Schedule STD 40 XS 80 160 XXS STD 40 XS 80 XXS STD 40 XS 80 120 160 XXS 5 10 STD 40 XS 80 120 160 XXS STD 40 XS 80 120 160 XXS STD 40 60 XS 80 100 120 140 160 XXS

OD ins 3.5 3.5 3.5 3.5 3.5 3.5 4 4 4 4 4 4.5 4.5 4.5 4.5 4.5 4.5 4.5 5.563 5.563 5.563 5.563 5.563 5.563 5.563 5.563 5.563 6.625 6.625 6.625 6.625 6.625 6.625 6.625 8.625 8.625 8.625 8.625 8.625 8.625 8.625 8.625 8.625 8.625

ID ins 3.068 3.068 2.9 2.9 2.625 2.3 3.548 3.548 3.364 3.364 2.728 4.026 4.026 3.826 3.826 3.625 3.438 3.152 5.345 5.295 5.047 5.047 4.813 4.813 4.563 4.313 4.063 6.065 6.065 5.761 5.761 5.5 5.187 4.897 7.981 7.981 7.813 7.625 7.625 7.437 7.187 7 6.813 6.875

Wall Thickness ins 0.216 0.216 0.3 0.3 0.438 0.6 0.226 0.226 0.318 0.318 0.636 0.237 0.237 0.337 0.337 0.438 0.531 0.674 0.109 0.134 0.258 0.258 0.375 0.375 0.5 0.625 0.75 0.28 0.28 0.432 0.432 0.562 0.719 0.864 0.322 0.322 0.406 0.5 0.5 0.594 0.719 0.812 0.906 0.875

Wt/ft lbs 7.576 7.576 10.25 10.25 14.32 18.58 9.109 9.109 12.51 12.51 22.85 10.79 10.79 14.98 14.98 19 22.51 27.54 6.349 7.77 14.62 14.62 20.78 20.78 27.04 32.96 38.55 18.97 18.97 28.57 28.57 36.39 45.35 53.16 28.55 28.55 35.64 43.39 43.39 50.95 60.71 67.76 74.69 72.42

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Chart indicating the dynamic loading on, and selection of ASME B 30.9 polyester round sling restraints in the event of pipe rupture for a range of ID's, the pipe being pressured with oil,sea water (liquids)
Maxoperating pressure(seawater)

150.0

1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 11000 12000 13000

140.0

10

TagNo.

130.0

120.0

110.0

100.0

90.0

10 9 8 7 6 5 4 3 2

Vertical Rated Capacity Klbf 40 31 25 21.2 16.8 13.2 10.6 8.4 5.3

80.0

70.0

Dynamic Load Klb-f

60.0

14000 000
15000 16000 17000 18000 19000 20000

50.0

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Appendix 3- Restraint Charts using ASME B 30.9 Polyester Roundslings.

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2.5
3" 3 3.5"OD

40.0

30.0

20.0

10.0

0.0 3.5
4" 4 4.5" OD

Roundsling 0.5 Selection

1.5

2" 2 2.375"OD

4.5

6" 5.5 6.625"OD

6.5

8" 7.5 8.625"OD

Pipe ID (ins)

JoiningShackle

ReefKnot

Half Hitch

JoinbetweenhitcheswithExample howtousechartfor:Processsteps: Reef Knotorshackle:Maxpressure5000psi(oil)1. Drawverticallineupfrom3.152"fromhorizontal 4.75T for2,3,4Tagrestraintsflowedorpumped. axistomeet5000 psicurve. 6.5T for6,7,8Tagrestraints4"602pipescheduleXXS2. Frompointofintersection,drawahorizontalline 8.5T for9,10TagrestraintsIDofschXXS=3.152" tomeetroundslingsbars. 3.Thefirstbarintersectedgivestheroundsling Note:AMSEB30.9Roundslingbreakingstrength=5xratedcapacity.Tagno.Hitchpipewiththisratedsling.

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Chart indicating the dynamic loading on, and selection of ASME B 30.9 polyester round sling restraints in the event of pipe rupture for a range of ID's, the pipe being pressured with gas
Maxoperating pressure(gas)

150.0

1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 11000 12000 13000

140.0

10

TagNo.

130.0

120.0

110.0

100.0

90.0

10 9 8 7 6 5 4 3 2

Vertical Rated Capacity Klbf 40 31 25 21.2 16.8 13.2 10.6 8.4 5.3

80.0

70.0

Dynamic Load Klb-f

60.0

14000 000
15000 16000 17000 18000 19000 20000

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1.5
2" 2 2.375"OD

50.0

40.0

30.0

20.0

10.0

0.0 2.5
3" 3 3.5"OD

Roundsling

0.5

3.5

4" 4 4.5" OD

4.5

6" 5.5 6.625"OD

6.5

8" 7.5 8.625"OD

Pipe ID (ins)

JoiningShackle

ReefKnot

Half

JoinbetweenhitcheswithExample howtousechartfor:Processsteps: Reef Knotorshackle:Maxpressure5000psi(oil)1. Drawverticallineupfrom3.152"fromhorizontal 4.75T for2,3,4Tagrestraintsflowedorpumped. axistomeet5000 psicurve. 6.5T for6,7,8Tagrestraints4"602pipescheduleXXS2. Frompointofintersection,drawahorizontalline 8.5T for9,10TagrestraintsIDofschXXS=3.152" tomeetroundslingsbars. 3.Thefirstbarintersectedgivestheroundsling Note:AMSEB30.9Roundslingbreakingstrength=5xratedcapacity.Tagno.Hitchpipewiththisratedsling.

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SHELL

The information in this document is shared under the Research Agreement between SIRM and Shell Oil Company dated January 1, 1960, as amended unless indicated otherwise above. This document is classified as Restricted. Access is allowed to Shell personnel, designated Associate Companies and Contractors working on Shell projects who have signed a confidentiality agreement with a Shell Group Company. 'Shell Personnel' includes all staff with a personal contract with a Shell Group Company. Issuance of this document is restricted to staff employed by a Shell Group Company. Neither the whole nor any part of this document may be disclosed to Non-Shell Personnel without the prior written consent of the copyright owners. Copyright 2007 SIEP, Inc.

SHELL INTERNATIONAL EXPLORATION AND PRODUCTION INC., HOUSTON

Further electronic copies can be obtained from the Global EP Library, Houston

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