~ - ;--
Basic Installation,Maintenance.
& Operating Instructions
For
71C0621
.)
SELF CONTAINEDSAFETY SYSTEM
. Issue Date: August 2006
,,
1,\.
August 2006 OPR MNL- 71 C0621
Halliburton
... ..
Basic Installation, Maintenance& Operating Instructions
For
71C0621
SELF CONTAINED SAFETY SYSTEM
Issue Date: August 2006
~
Halliburton
These instructions describe results from use of Halliburton Energy Service Equipment, but such results arenot guaranteed. Operation of equipment is subject to mechanical limitations and Halliburton EnergyServices shall only be liable for its merchandise and service as set forth in its General Terms and Conditions
.I
1.0
2.0
3.0
4.0
-'
Halliburton
TABLE OF CONTENTS
GENERAL
1.11.21.3
Description of ManualDesign FunctionDesign Specifications
SYSTEM INSTALLATION
2.1 Control CabinetlPanel
OPERATING INSTRUCTIONS
3.13.23.33.43.53.63.73.83.9
System Start-UpTo open master valve.To open wing valve #1.To open wing valve #2.To send pressure to choke valve #1.To send pressure to choke #2To close all valves one of the following should occurTo close the choke valve individuallyTo open the master valve, wing valve #1 manually with no air supply
MAINTENANCE & TROUBLESHOOTING
4.14.24.34.4
5.0
Control PanelPilot SensorTroubleshooting GuideSpecial Tools
DRAWINGS
Halliburton
GENERAL
1.0 General
This manual is written for the experienced operator to serve as a guide for systemoperation, general maintenance and as an aid in the location of the systemsmajorcomponents.
WARNING: THE OPERATORSHOULD THOROUGHLYFAMILIARIZEHIMSELF WITH ALL THE INFORMATIONCONTAINEDIN THIS MANUAL PRIOR TO OPERATINGTHE SYSTEM.
1.1 Description of Manual
This manual is written to cover several functions and areas of the basicSingle Well SafetyControl Panel.
1.2 Design Function
The Halliburton Energy Services 71C0621 Self Contained SafetySystem isdesigned to monitor systempressures and control the opening and closingof subsurface safety valves on producingwells. The system is designed tobe as maintenance free as possible by using high qualitycomponents in astainless steel cabinet.
,/
1.3 Design Specifications
Halliburton
The followinginfonnation is specific to the SingleWell Safety ControlPanel, 71C0621.
DESCRIPTIONSPECIFICATIONSITOLERANCES
Type:Installation:Service:Hydraulic Outputs:Pneumatic Outputs:Maximum Pressure Output (Psi):Individual Cont Sect (Per Well):
PilotSpecial Feature
Power Section:Pneumatic driven pumpManual overridePower Source Flow RateHydraulic Pressure, Primary (Psi)Pneumatic Pressure, Control (Psi)Reservoir Capacity (Gal)
Common Cont Sect (General):Emergency Shut down OutputFusible Plug OutputSpecial Feature
Engineering Data:Cabinet MaterialHeight (In)Width (In)Depth (In)Weight (Lbs)Temperature Range,AmbientTube FittingRepair Kit
Single WellEnd ItemStandard324,500
N/A
1125 Cu in/Min6,000 Max150 Max11.95 Gal
YesYes(3) Pilot outputRTU Shut-In
316L58.00 in34.50 in22.00 in250 Lb32° F - 120 ofSwagelokNone
2.0
Halliburton
System Installation
This section outlines general infonnation on the installation of the Single-WellSafety Control Panel's basic componentsand all connecting tubing and lines.
2.1 Control Cabinet/Panel
Installation of cabinet/other units shouldbe as shown in the systemdrawing. The cabinet should be locatedas space and safety conditionswillpennit.For approximate control cabinet dimensions,etc., refer to HalliburtonEnergy Services drawing and the design specifications in the Generalsection. The followingis recommendedfor cabinet and/or systeminstallation.
2.1.1 Cabinet should be properly securedat base if necessary,towithstand extremeweather conditions.
2.1.2 Hydraulic and pneumatic line between cabinet and safetyvalvesshould be properlycut and deburredbefore installation.
2.1.3 Attaching lines shouldbe routed to ensure easy access for trouble-shooting and safetyconsiderations.
All safety system hard line connectionsshould be properly torqued and leaktested to ensure a tight system.
Halliburton
3.0 OPERATING INSTRUCTIONS
3.1 Initial Start-up:
3.1.1 Properly mount the SafetySystem at the well site.
3.1.2 Properly connect the SafetySystembulkheads to the correct components atthe well site.
NOTE: THIS SAFETY SYSTEM USES WELL GAS IN THE CONTROLCIRCUIT. BE SURE TO PROPERLY PLUMB THE 'PLUMBEDEXHAUST' PORT TO A SAFE AREA.
3.1.3 Properly connect the electricalwiring to solenoid valve SV-1. Refer to theinstallation instructions for the solenoidvalve located in the 71C0621Manual.
3.1.4 Fill the reservoir Yzto % full.
3.1.5 Turn ball valve BV-3 to the closedposition. Turn all ofthe rest of the ballvalves to the open position.
3.1.6 Turn pressure regulator handlesR-I & R-2 fully counter-clockwise.
3.1.7 Push in on master valve handle PB-I.
3.1.8 Push in on pull & pin pilotedrelay valve handles PR-1, PR-2, PR-3, PR-4and PR-5.
3.1.9 Turn hydraulic control valvehandles CV-1, CV-2 and CV-3 fully counter-clockwise.
3.1.10 Apply air supply 80 to 100PSI to the safety system.
3.1.11 Slowly turn pressure regulatorhandle R-I clockwise andmonitor air supplypressure gauge G-I2. Stopturning regulator handle when you read 80 to100 PSI on pressure gauge0-12.
3.1.12 Slowly turn the handle on pressureregulator R-2 clockwise. Hydraulicpump should start to operate. Monitor hydraulic systempressure increaseon gauge G-13. Stop turningthe pressure regulator handlewhen you read4,000 PSI on pressure gauge 0-13.
Halliburton
3.0 OPERATING INSTRUCTIONS
3.1 Initial Start-up:
3.1.1 Properly mount the SafetySystem at the well site.
3.1.2 Properly connect the SafetySystem bulkheads to the correct components atthe well site.
NOTE: THIS SAFETY SYSTEM USES WELL GAS IN THE CONTROLCIRCUIT. HE SURE TO PROPERLY PLUMB THE 'PLUMBEJ)EXHAUST' PORT TO A SAFE AREA.
3.1.3 Properly connect the electricalwiring to solenoid valve SV-1. Refer to theinstallation instructions for the solenoid valve located in the 71C0621Manual.
3.1.4 Fill the reservoir ~ to % full.
3.1.5 Turn ball valve BV-3 to the closed position. Turn all of the rest ofthe ballvalves to the open position.
3.1.6 Turn pressure regulator handles R-1 & R-2 fully counter-clockwise.
3.1.7 Push in on master valve handle PB-1.
3.1.8 Push in on pull & pin piloted relay valve handles PR-1, PR-2, PR-3, PR-4and PR-5.
3.1.9 Turn hydraulic control valve handles CV-1, CV-2 and CV-3 fully counter-clockwise.
3.1.10 Apply air supply 80 to 100PSI to the safety system.
3.1.11 Slowly turn pressure regulatorhandle R-1 clockwise and monitor air supplypressure gauge G-12. Stop turning regulatorhandle when you read 80 to100 PSI on pressure gauge G-12.
3.1.12 Slowly turn the handle on pressure regulator R-2 clockwise. Hydraulicpump should start to operate. Monitor hydraulicsystempressure increaseon gauge G-13. Stop turning the pressure regulatorhandle when you read4,000 PSI on pressure gauge G-13.
Halliburton
OPERATING INSTRUCTIONSContinued
3.7 To Close All Valves One Of The Following Should Occur:
3.7.1 Sending an electrical signal to solenoid valve SV-1.3.7.2 Pushing in on the handle of relay valve PR-l.3.7.3 Pushing in on ESD valve handle PB-l.3.7.4 Flowline pressure exceeds the high/low pressure settings of pilots set #1 or
pilot set #2.3.7.5 Loss of pressure in ESD loop.3.7.6 Loss of pressure in fusible plug loop.3.7.7 Loss of pressure in annulus PSH loop.
3.8 To Close The Choke Valve Individually:
3.8.1 Push in on relay valve handle PR-5 for choke#1.3.8.2 Push in on relay valve handle PR-4 for choke #2.
3.9 To Open The Master Valve, Wing Valve #1, 'Ving Valve #2, ManuallyWith No Air Supply:
CAUTION: ALWAYS OPEN MASTER VALVE FIRST
3.9.1 Turn the handle of hydraulic control valve CV-I fully clockwise.3.9.2 Operate the hand pump option on hydraulicpump. You should see
hydraulic pressure increase on pressure gauges G-13 and G-l. Keepoperating the hand pump until you read full open hydraulic pressure for themaster valve on pressure gauge G-13 and G-l.
3.9.3 Turn the handle of hydraulic control valve CV-2 fully clockwise.3.9.4 Operate the hand pump option on the hydraulicpump. You should see
hydraulicpressure increaseon pressure gauge G-2. Keep operating thehand pump until you read full open hydraulicpressure for wing valve #1 onpressure gauge G-2.
3.9.5 Turn the handle of hydrauliccontrol valve Cv-3 fully clockwise.3.9.6 Operate the hand pump option on the hydraulicpump. You should see
hydraulicpressure increaseon pressure gauge G-3. Keep operating thehand pump until you read full open hydraulicpressure for wing valve #2 onpressure gauge G-3.
CAUTION: FOR THE SAFETY SYSTEM TO BE "IN SERVICE" THEPINS ON RELAY VALVES PR-l, PR-2, PR-3, PR-4 & PR-5MUST BE DISENGAGED AND THE HANDLES OF
HYDRAULIC CONTROL VALVES CV-l, CV-2 & CV-3MUST BE TURNED FULLY COUNTER-CLOCKWISE.
Halliburton
FOLLOWING IS THE LIST OF COMPONENTS FOR THEHALLIBURTON SINGLE WELL SAFETY SYSTEM -71C0621
71 CO 621 BILL OF MATERIAL
ITEM
1234567891011121314151617181920212223242526272829303132333435
801802
803
QTYDESCRIPTION
1135111104394126461111
AiRAiR
1011
AiRAiR311511
CABINET, PANEL, RESERVOIR ASSEMBLEY 316L SSHYDRAULICPUMP WITH MANUALOVERRIDE OPTION
HYDRAULICCONTROL VALVEPULL & PIN PILOTED RELAYVALVE3WNCPUSH I PULL VALVE 3WNO
SOLENOID VALVE2WNC VALVE24V DC E.P. INTRINSICALLYSAFE
PRESSURE REGULATOR300 PSI INN 0-100 PSI OUT
BALL VALVE 2 WAY 2,000 PSINOT USED
PRESSURE RELIEF VALVE 4,000 PSI TO 5,000 PSI ADJUSTABLEPRESSURE RELIEF VALVE 50 TO 350 PSI ADJUSTABLE
PRESSURE GAUGE 0-300 PSI2.5'F, FLANGE MOUNTED,GF,SSPRESSURE GAUGE 0-6,000 PSI 2.5'F, FLANGE MOUNTED,GF,SSFILTER MOUNTING BRACKETFLOW CONTROL VALVEORIFICE .015CHECK VALVE IN-LINE 3/8'TUBING ENDSCHECK VALVE IN-LINE 1/4"TUBINGENDSAIR FILTER WITH AUTO DRAIN 3/8"F NPTHYDRAULIC FILTER IN TANK 4" LONGTANK FILLER ASSEMBLYTANK PRESSURE RELIEF VALVE 1PSIMISCELLANEOUS ELECTRICALCOMPONENTSMISCELLANEOUS HARDWAREAND BRACKETSHALLIBURTON I.D. TAG SSNOT USED
PLACARD KIT DRAWINGOPERATING INSTRUTIONSAND SCHEMATIC DRAWING316 STAINLESS STEEL SEAMLESS TUBINGDUAL FERRULE TUBING FITTINGSAIR RECEIVERHALLIBURTON DECALBALL VALVE 2 WAY 1/4"FNPTPRESSURE REGULATOR 200 PSI IN AND 0-100 PSI OUTTANK SIGHT GAUGE ON 5" CENTERS
MARKING SPECIFICATIONTESTING SPECIFICTIONDOCUMENTAION
Halliburton
MANUFACTURER
KSIMAXIMATOR
SIGMABWBBWB
ASCONORGRENAPOLLO
NUPRONUPRO
STEWART-USASTEWART-USA
NORGRENDELTROLLORIMER
SWAGELOKSWAGELOKNORGREN
LHALHA
CIRCLE-SEALSUB-CONTRATORSUB-CONTRATOR
HALLIBURTON
HALLIBURTONHALLIBURTON
SUB-CONTRATORSUB-CONTRATOR
AIR-TECHHALLIBURTON
PARKERGO
LUBE DEVICES
HALLIBURTONHALLIBURTONHALLIBURTON
Halliburton
MAINTENANCE & TROUBLESHOOTING
4.0 Maintenance and Troubleshooting
Due to the design characteristicsof the well control system, the enclosed cabinets and useof cOITosiveresistant functional components,tubing and fittings, there is a minimum ofpreventative maintenancerequired for this unit. However, a scheduled inspection shouldbe made in the following areas to see that all operating equipmentis in good workingcondition and to ensure service life.
NOTE:THIS MAINTENANCE AND TROUBLESHOOTING INFORMATION ISDESIGNED FOR VARIOUS ASSEMBLIESfUNITS AND MAY CONTAIN MORECOMPONENTS THAN ARE ACTUALLY USED IN THE SYSTEM.MAINTENANCE AND TROUBLESHOOTING SHOULD BE PERFORMED AS
REQUIRED FOR THE INDIVIDUAL UNIT. A LOG SHEET IS LOCATED AT THEBACK OF THIS SECTION TO PROVIDE A RECORD OF ITEMS SERVICED ORREPAIRED.
4.1 Control Panel Maintenance
SERVICE FREQUENCY
4.1.1 System Fluid
A.B.
Check reservoir fluid
Fluid change outCheck monthly levelEvery 24 months under normal use.
4.1.2 Fluid Filters
A. Clean filter Every 12months under normal use.
4.1.3 Pneumatic Filters
A. Clean filter Every 12months under normal use.
4.1.4 Pneumatic Lubricators
A. Fill lubricator Every 6 months under normal use
4.1.5 Pneumatic Pumps
A. Lubricate air drive section Every 12months under normal use
4.1.6 Relief Valve
A. Verifyproper relief setting Every 12months
OPR MNL-71C0621 August 2006
Halliburton
MAINTENANCE & TROUBLESHOOTING - CONTINUED
SERVICE FREQUENCY
4.1.7 Pressure Regulator
A. Verify proper pressure setting Check monthly
4.1.8 Pilot Valves (Sensors)
A. Verify proper pressure setting Check monthly
4.1.9 Safety SystemPanel
A. Verifyproper control operation Check monthly
4.1.10 Component Maintenance
4.2
A. Individual components As required, refer to componentdata
Dial Pilot Maintenance
4.2.1 Control Panel
A. Verify proper separation Check monthly
4.2.2 Pressure Regulator
A. Verify proper setting Check monthly
4.2.3 Pneumatic Filter
A. Clean filter Clean every 12months under normalUse.
4.2.4 Dial Pilot Maintenance
A. Check accuracyof gaugepointer (black)Check accuracyofindicator limits (red)
Checkmonthly
B. Checkmonthly
NOTE:For complete information on the Dial Pilot, refer to Halliburton Energy ServicesDS Pilot Books OEC-5187and OEC-5188.
Halliburton
MAINTENANCE & TROUBLESHOOTING - CONTINUED
4.3 Troubleshooting
This general troubleshooting infonnation is designed for various units and may containmore components and operations than are actuallyused in this system. Corrective actiontaken during any type of systemmalfunction should be done on the followingprioritybasis to prevent any unnecessarymaintenance.
1.2.3.4.
Visual inspection of system.Component operation or adjustment.Component cleaning or replacement.Repair of component.
4.3.1 PNEUMATIC
SYMPTOM POSSIBLE CAUSE CORRECTIVEACTION
1. No supply 1.1 Nitrogen bottle 1.1.1 Replacepressure to emptybottlepanel asindicated on 1.2 Air compressor 1.2.1 Start up airgauge. is down compressor.
1.2.2 Repair air compressor;consult air compressortroubleshootingchart.
1.3 Isolation va1ve(s) 1.3.1 Locateclosedclosed. valve(s) and put in service.
1.4 Pneumatic filter(s) 1.4.1 Disassemble and
clogged repaIr.
2. No pneumatic 2.1 Regu1ator(s) not 2.1.1 Adjust regu1ator(s)pressure to properly adjusted. to desired setting.outlets.
3. Pneumatically 3.1 Regu1ator(s) not 3.1.1 Adjust regu1ator(s).driven pump properly adjusted.
3.2 Pump air driven 3.2.1 Consultpumpsectionmalfunc- maintenancetioning. manual and repair.
Halliburton
MAINTENANCE & TROUBLESHOOTING - CONTINUED
SYMPTOM POSSIBLE CAUSE CORRECTIVE ACTION
4. Mechanicallydriven pump
5. Hydraulicallydriven pumpwill not cycle.
4.3.2 II1{])~1J~I~
SYMPTOM
4.1 Power sourceinoperative.will not cycle.
4.1.1 Consult powersourcemanual for
repaIr
5.1.1 Consult pumpmanual for repair.
CORRECTIVE ACTION
1. When pump iscycling, hydraulicpressure willnot build up
1.7
5.1 Hydraulicpumpinoperative.
POSSIBLE CAUSE
1.1 Reservoir liquidlevel isextremelylow.
1.2 Block valve( s)open to reservoir.
1.3 Hydraulic leak,internal orexternal, tocontrol panelhas developed.
1.4 Hydraulic filter(s)clogged.
1.5 Relief valve
malfunctioning.
1.6 Check valves onpump are malfunc-tioning.
Hydrauliccontrolvalve(s)malfunc-tioning.
1.1.1 Fill reservoirapproximatelyhalf full.
1.2.1 Close valve(s)
1.3.1 Locate and repairleak
1.4.1 Clean filter(s)
1.5.1 Locate and repairor adjust relief valve.
1.6.1 Consultpumpmaintenance manualand repair.
1.7.1 Locate and repair
hydrauliccontrolvalve.
Halliburton
MAINTENANCE & TROUBLESHOOTING - CONTINUED
SYMPTOM POSSIBLE CAUSE CORRECTIVE ACTION
2.
4.3.3 ESD
1.
No hydraulicpressure tooutput valves
2.1 No hydraulicpressure available.
Regulator(s)notproperly adjusted.
Pneumatic relayvalve(s) not inservIce.
Solenoid valve(s)not functioningproperly.
SYMPTOM POSSIBLE CAUSE
2.1.1 Consult symptom 1
2.2.1 Adjust appropriateregulator.
2.3.1 Manually put valve(s). .m servIce
2.4.1 Supply electricalsignal to actuatevalve(s).
2.4.2 Repair or replacesolenoid.
CORRECTIVE ACTION
No pressureon ESD gauge.
SYMPTOM
1.1 ESD valve open 1.1.1 Locate and closeESD valve.
1.2.1 Replace plug.
4.3.4 DIAL PILOT CONTROL PANEL TROUBLESHOOTING
1.
2.2
2.3
2.4
1.2 Fusible plug out.
CORRECTIVE ACTION
No supplypressure topilot.
POSSIBLE CAUSE
1.1 Supply pressurenot available.
1.2 Pneumatic relayvalve which
suppliespilotnot in service.
1.1.1 Locate closed
valve and put. .m servIce.
1.2.1 Locatepneumaticrelay valve andtake necessarysteps to put inoperation.
Halliburtcm
MAINTENANCE & TROUBLESHOOTING - CONTINUED
SYMPTOM POSSIBLE CAUSE CORRECTIVEACTION
1.3 Control pressure 1.3.1 Check regulatorregulator not output gauge andproperly adjusted. adjust or repair
regulator.
1.4 ESD/fusible 1.4.1 Close ESD valvesloop not or replace fusiblepressurized. plugs. Check all
connectionsto ensureleaks are not present.
1.5 Orifice clogged. 1.5.1 Remove and clean.
1.6 Pressure sensing 1.6.1 Remove and cleanDS pilot not inlet filters.functioning For any adjust-properly. ments, consult
"HalliburtonEnergyServices Dial Pilot"92DS series guideto installation,adjustment,troubleshooting andtesting, pages 11 thru13, OEC Publication5187C.
2. No sensed 2.1 Sense line 2.1.1 Locate closedpressure on isolation valve valve and takeDS pilot. closed. necessary steps
to put it in operation.
Halliburton
MAINTENANCE & TROUBLESHOOTING - CONTINUED
4.4 Special Tools List
The following special tools are recommended for use during maintenance and servicingof the well control system.
TOOL DESCRIPTION SPECIFIC USE
1. 9/16" Open End Wrench 1/4"Tube Fitting
2. 11/16"Open End Wrench 3/8" Tube Fitting
3. 7/8" Open End Wrench 112"Tube Fitting
4. Hex Key Wrench 4/64" Pressure SensingPilot(1.57mm) Adjustment (Dial Pilot)
5. Screw Driver Blade Type Pressure SensingPilotBlade Width .12" (3.0mm) Adjustment(Dial Pilot)Maximum: Blade Thickness:.03" (.76mm)
6. Adjustable Wrench, 12" FlowlinePilot Sensor(0-1 3/8" Adjustment)Adjustment
<t I !
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Halliburton
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