Well Engineering
Well Integrity Maintenance
Procedure
User Note:
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Keywords: WIT, Wellhead Integrity Test, SIT, Subsurface Integrity Test, Well Failure Model,
Well type, gas lift wells, steam injection wells, free flowing wells
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i Document Authorisation
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ii Revision History
The following is a brief summary of the 4 most recent revisions to this document. Details of all
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Note that changes made as part of Document Maintenance (correction of broken hyperlinks) will
not be recorded in this Revision Table.
TABLE OF CONTENTS
i Document Authorisation ......................................................................................................... 3
ii Revision History ..................................................................................................................... 4
iii Related Business Processes ................................................................................................. 4
iv Related Corporate Management Frame Work (CMF) Documents ........................................ 4
1 Introduction ............................................................................................................................ 7
1.1 Background ...................................................................................................................... 7
1.2 Purpose ............................................................................................................................ 8
1.3 Scope ............................................................................................................................... 8
1.4 Distribution/Target Audience ............................................................................................ 8
1.5 Review and Improvement ................................................................................................ 8
1.6 Step-out and Approval ..................................................................................................... 8
2 Procedure Description ........................................................................................................... 9
2.1 Wellhead Integrity Test (WIT) ........................................................................................ 10
2.1.1 Suspended Wells.......................................................................................... 10
2.1.2 Well Type 1 (High Pressure Wells or high GLR or H2S Wells) .................... 12
2.1.3 Well Type 2 (Free Flowing Low Pressure Oil Wells, < 20,000 kPa) ............ 20
2.1.4 Well Type 3 (Gas lift Wells) .......................................................................... 27
2.1.5 Well Type 4 (Steam Injection Wells) ............................................................ 33
2.1.6 Well Type 5 (Sub-hydrostatic, pumped wells) .............................................. 40
2.1.7 Well Types 6 and 7 (Water Injection/ Disposal wells with/ without tubing) .. 46
2.2 Subsurface Integrity Test (SIT) ...................................................................................... 52
2.2.1 Well Type 1 (High Pressure Wells or high GLR or H2S Wells) .................... 52
2.2.2 Well Type 2 (Free Flowing Low Pressure Oil Wells, < 20,000 kPa) ............ 63
2.2.3 Well Type 3 (Gas lift Wells) .......................................................................... 74
2.2.4 Well Type 4 (Steam Injection with Packer) .................................................. 85
2.2.5 Well Type 5 (Sub-hydrostatic, pumped wells) .............................................. 91
2.2.6 Well Types 6 and 7 (Water Injection/ Disposal wells with/ without tubing) 102
2.3 Subsurface Integrity Test (SIT), Maintenance ............................................................. 113
2.3.1 Well Type 1 (High Pressure Wells or high GLR or H2S Wells) .................. 113
2.3.2 Well Type 2 (Free Flowing Low Pressure Oil Wells, < 20,000 kPa) .......... 114
2.3.3 Well Type 3 (Gas lift Wells) ........................................................................ 115
2.3.4 Well Type 4 (Steam Injection with Packer) ................................................ 116
2.3.5 Well Type 5 (Sub-hydrostatic, pumped wells) ............................................ 117
2.3.6 Well Types 6 and 7 (Water Injection/ Disposal wells with/ without tubing) 118
2.4 Preventive Well Maintenance of Wellhead related Surface Equipment ....................... 119
2.4.1 Preventive Maintenance of OTIS Control Panels ....................................... 119
2.4.2 Preventive Maintenance of Beam Pumps .................................................. 119
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TABLE OF FIGURES
(Double-click to view in presentation mode)
Figure 2-1, Stem Packing with Check Valve ............................................................................. 141
Figure 2-2, Low Pressure Grease Fitting .................................................................................. 141
Figure 2-3, Explosion Drawing of Valve .................................................................................... 142
Figure 5-1, Valve Drawing Sealant and Body Filler Connections ............................................. 163
LIST OF TABLES
Table 1-1, Well Types and Colour Coding .................................................................................... 7
Table 2-1, SCSSSV Control line pressure Limits in kPa............................................................. 13
Table 2-2, SCSSSV Control line pressure Limits in kPa............................................................. 21
Table 2-3, Test Pressures for Annuli Tests ................................................................................. 53
Table 2-4, FLS Gate Valve, Description of Parts ...................................................................... 141
Table 4-1, Roles and Responsibilities ....................................................................................... 149
Table 5-1, Glossary of Terms, Abbreviations and Definitions ................................................... 150
Table 5-2, Related Business Control Documents and References .......................................... 151
LIST OF EQUATIONS
N/A
1 Introduction
1.1 Background
In April 2004 PDO introduced SP-2017, Well Failure Model as the Standard in which PDOs
Well Integrity related requirements are defined, this in line with CP-118, Well Life Cycle Integrity
Code of Practice (WLICoP).
Since then both these documents have been under continuous development incorporating ideas
and challenges brought forward by the members of the Well Integrity Working Group resulting in
new versions of these documents.
It should be noted that all legacy Well Maintenance related documents, notably PR-1037, PR-
1472, PR-1474, PR-1477, PR-1484 shall be deemed withdrawn with the official endorsement of
this Procedure.
The Well Failure Model distinguishes the following categories of well integrity related activities
and specifies these for 7 well types in terms of frequency and scope.
Well Integrity Testing (Preventive / Planned Maintenance)
Wellhead Integrity Test (WIT) (See Chapter 2.1 below)
Note: The WIT comprises the flow-wetted parts of the completion
Subsurface Integrity Test (SIT) (See Chapter 2.2 below)
Note: The WIT comprises all the flow-wetted parts of the completion.
WIT and SIT are intended to be interventionless. However it has
been recognized that, in order to acquire true knowledge of whether
or not a valve can be considered a barrier as per the definition given
in SP-1217, Well Control Barriers, there may be a need to set plugs
in the completion or the wellhead and pressure test against these to
establish their integrity. Such a test would be called a Pressure
Integrity Test, PIT. It is PDOs aim to move to interventionless
integrity testing using novel technologies.
Subsurface Integrity Test (SIT), Maintenance (Chapter 2.3)
Well Type 2
Free Flowing low pressure Oil Well - < 20,000 kPa
Well Type 3
Gaslift Well
Well Type 4
Steam Injection well
Well Type 5
Sub-hydrostatic pumped well, minimum one casing string with or
without packer
1
The Colour Coding was introduced to prevent the user from accidentally slipping into the wrong well type, this as the
procedures are similar yet different in the detail.
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Suspended Wells (not listed as separate Well Type in the Well Failure
Model)
1.2 Purpose
This Procedure sets out the standards which all Well Maintenance related operations have to
conform to.
It forms the framework from which detailed work practice procedures can be developed and
maintained by PDO and contractor companies who perform operations on behalf of PDO.
1.3 Scope
This Procedure is applicable to all Well Integrity related operations conducted either by PDO or
Contractor personnel on all PDO well equipment.
2 Procedure Description
Whenever a SIT is carried out it shall be combined with a WIT.
Where pressure exists for testing, a differential pressure shall be applied across the valve being
tested by blowing down the flow line or downstream fixed volume to the minimum pressure
practical. Where it is not possible to blow down the flow line fully, the minimum pressure
differential (P) at the start of test shall be 1.2 times the Allowable Leak Rate by valve size as
stated above.
Note : The reasoning behind this rule is that the purpose of leak testing valves is to assess their
likely performance in the worst case scenario; for a Christmas Tree valve this is isolation
of the well in case of a flow line rupture. In a failure situation, a greater pressure
differential would exist across the valve than under test conditions; so a pass under test
conditions demonstrates integrity. A fail under these conditions will also have occurred
before the valve has equalised; therefore this method is deemed to be a valid test
method.
Where no well pressure exists in lieu of testing, the valve shall be cycled and maintained in
accordance with manufacturers instructions; this shall be deemed a test Pass.
Note: Whenever a SIT is carried out in conjunction with a WIT, the valves will be tested using
applied pressure above LMV, if fitted, or UMV. The decision not to set a Two-Way Check
Valve below the tree (which would give information on the integrity of the lowest Master
Valve) is based on a Risk/ Cost/ Value judgement; the value of knowing the result of the
Master Valves status is outweighed by the effort/ cost of achieving a valid test. In risk
term this judgement leads to a rating of C2 on the PDO Risk Matrix.
In situations where CITHP is > 0 but corresponding to < 1.2 x Allowable Leak Rate, pressure
equalisation across the valve within the test period will be deemed a test Fail as it
demonstrates condition degradation.
The Pressure Measurement Method can be either by Pressure Build-up within an enclosed
volume or by Bleed-off from an enclosed volume.
Note: When a valve test is carried out it is vital to maintain a small positive pressure in the
cavity to be tested, this to ensure
a. that there is no zero error on the gauge
b. that the cavity to be tested is already filled with fluid
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2.1.2 Well Type 1 (High Pressure Wells or high GLR or H2S Wells)
The Testing Frequency is as per SP-2017, Well Failure Model
2.1.2.1 Safety Precautions
2.1.2.1.2 H2S
Well Type 1, High Risk Wells, comprises H2S wells. This Chapter highlights the particularities
relating to H2S wells and provides links to Reference Documents.
1) Comply with all items outlined in SP-1219, Drilling Specification Hydrogen Sulphide.
2) A calibrated pressure gauge fitted to the tree cap with bleed facility (in line with H2S
controls) maybe bled off to outside fence downwind of the work area.
5. The tests and the work to be carried out are defined, for each individual well type, in
the Well Failure Model, in the worksheet titled Well Integrity Testing/ Maintenance
Matrix (ensure work is carried out based on the approved version of the Well Failure
Model).
6. Tests must be carried out in the order stated below as the valve status is assumed
as left from the previous test
7. Valves must not be greased before testing. Valve maintenance will be carried out
after the initial test, not before (irrespective of whether the test results is a pass or
fail), this to allow the condition as found to be analysed in terms of failure rates for
both as found and as left conditions. 2
Table 2-1, SCSSSV Control line pressure Limits in kPa
Minimum Pressure to activate flapper to open
3.5, 13.7 lbs/ft Completion String Minimum pressure to activate the flapper to open = expected CITHP
+ 12,500 kPa (Flapper Opening Pressure) + 3,500 kPa (Safety Factor for
Equalization)
3.5, 10.2 lb/ft Completion String Minimum pressure to activate the flapper to open = expected CITHP
+ 16,900 kPa (Flapper Opening Pressure) + 3,500 kPa (Safety Factor for
Equalization)
4.5, 16.9 lb/ft Completion String Minimum pressure to activate the flapper to open = expected CITHP
+ 15,200 kPa (Flapper Opening Pressure) + 3,500 kPa (Safety Factor for
Equalization)
The maximum pressure for the control line used in PDO under SAP # 1000004564 is
182,000 kPa.
2.1.2.4 Testing
2.1.2.4.1 WIT Task Carry out External Leak Test
WELL TYPE 1 WIT
TASK CODE ELCW /CAPW
TASK DESCRIPTION Carry out external leak check
1) Check all gaskets, flanged, bolted connections and packings for leakage and rectify as
required.
2) Measure and record all annulus pressures and the closed in tubing pressure (CITHP).
Note: Pressure within bolted or flanged connections must be bled off prior to attempting
to pull up any minor weeps
2 If the number of tests performed and recorded in WIMS equals 1 the condition as found can be concluded to have
been within limits. The data obtained in this manner will allow analysis of valve performance with a view to establishing
the appropriate long-term reliability based maintenance frequency.
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2.1.2.4.3 WIT Task Function/ leak-off test Flow Wing Valve (Inner or only)
WELL TYPE 1 WIT
TASK CODE FWVIW/ FWVOW
TASK DESCRIPTION Function / leak-off test Flow Wing Valve (Inner or only)
Note: This method assumes that a combination of LMV and UMV provides a leak-tight
seal.
1) Shut in production at the choke and close HIPPS valve (to be done remotely by Production
Operations).
2) Zero check the methanol line or flow line pressure gauge, ensuring the line to the gauge
is open.
3) Zero check the Swab Valve Pressure Gauge, ensuring that the Swab Valve and the line to
Gauge are open.
4) Close LMV and UMV.
5) Open FWV.
6) Bleed off pressure between HIPPS, where fitted, or Location and wellhead through KWV.
7) Close KWV and FWV.
8) Replenish Tree Cavity pressure by either pumping or cycling LMV and UMV.
9) Record Test Start pressure at the swab pressure gauge in the WIMS Checklist.
10) Measure the pressure drop in the enclosed tree cavity over 10 minutes using a gauge
known to be accurate.
a. Monitor the pressure rise in the enclosed flow line section between the HIPPS and
the FWV, using the methanol line or flow line Pressure Gauge.
Note: If the pressure rise observed on the monitoring gauge exceeds the pressure
rise corresponding to the Allowable Leak Rate, specified in the Well Failure
Model (Allowable leak rate sheet), the FWV is recorded as a Fail; such a
result also suggests that the combination of UMV/ LMV is also a Fail. In this
instance, grease all valves and re-test FWV. If the result is the same then
the Well Services Supervisor or the Asset Well Integrity Engineer must be
3All Harweel well sites are equipped with permanent H2S and noise monitors which may trigger
audible alarms and HIPPS / SSV closure.
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2.1.2.4.5 WIT Task Function/ Leak-off test Kill Wing Valve Inner (or only)
WELL TYPE 1 WIT
TASK CODE KWVIW
TASK DESCRIPTION Function / Leak-off test Kill Wing Valve Inner (or only)
1) Close KWVI if not already closed.
2) Bleed down KWVI downstream cavity and install a pressure gauge and double block and
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2.1.2.4.6 WIT Task Function/ Leak-off test the Upper Master Valve UMV
WELL TYPE 1 WIT
TASK CODE UMVW
TASK DECRIPTION Function/ Leak-off test Upper Master Valve
1) Close UMV
2) Open SV or KWV (dependent on where the measurement will be taken)
3) Open the bleed facility to bleed down the Tree Cavity to as near zero as possible maintain
some positive pressure on the gauge.
4) Close in the bleed point.
5) Record the test Start pressure in the WIMS Checklist.
6) Measure the pressure build-up in the Tree Cavity over 10 minutes.
7) Record the test Finish pressure in the WIMS Checklist.
8) If the test result is within the Allowable Leak Rate for the tested valves size then record the
result as Pass with Start and Finish pressures in the WIMS WIT Checklist; record the
number 1 in the Number of Tests done field.
9) If the test results in a Fail on the first attempt, grease and cycle the valve and re-test it until
a Pass test result is achieved or no improvement in results is seen.
a. Flush the Valve Cavity after two failed tests using flushing liquid.
10) Record the final test (last test carried out) result in the WIMS WIT Checklist including Start
and Finish pressure and number of tests done.
2.1.2.4.7 WIT Task Function/ Leak-off test the Lower Master Valve LMV
WELL TYPE 1 WIT
TASK CODE LMVW
TASK DECRIPTION Function/ Leak-off test Lower Master Valve
1) Close LMV.
2) Open UMV.
3) Open the bleed facility to bleed down the Tree Cavity to as near zero as possible; maintain
some positive pressure on the gauge.
4) Close in the bleed point.
5) Record the test Start pressure in the WIMS Checklist.
6) Measure the pressure build-up over 10 minutes.
7) Record the test Finish pressure in the WIMS Checklist.
8) If the test result is within the Allowable Leak Rate for the tested valves size then record the
result as Pass with Start and Finish pressures in the WIMS WIT Checklist; record the
number 1 in the Number of Tests done field.
9) If the test results in a Fail on the first attempt, grease and cycle the valve and re-test it until
a Pass test result is achieved or no improvement in results is seen.
a. Flush the Valve Cavity after two failed tests using flushing liquid.
10) Record the final test (last test carried out) result in the WIMS WIT Checklist including Start
and Finish pressure and number of tests done.
2.1.2.4.8 WIT Task Function/ Leak-off test the Down-Hole Safety Valve
WELL TYPE 1 WIT
TASK CODE SSSVW/ APRW/ CLA
TASK DECRIPTION Function/ Leak-off test Down-Hole Safety Valve e.g. SCSSSV/ ICV/
Storm Choke or Plug
1) Open the LMV, record the CITHP.
2) Close the SCSSSV by trip function locally.
3) Open the FWV.
4) Using the choke, bleed off the pressure above the closed SCSSSV in stages to flow line
pressure.
5) Close FWV.
6) Bleed off the remaining pressure through the flexiline, hooked up to the KWV.
7) Close in the bleed point.
8) Record the A annulus pressures at the start of the test.
9) Record the test Start pressure in the WIMS Checklist.
10) Measure the pressure build-up in the tubing and the Tree Cavity over 30 minutes using a
gauge known to be accurate; use the Well Failure Model Leak Rate Equation to determine
if the leak rate is acceptable.
11) Record the test Finish pressure in the WIMS Checklist.
12) Record the A Annulus pressure at the end of the test.
13) Whilst conducting the above build-up survey, confirm (e.g. by looking, listening and feeling)
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2.1.3 Well Type 2 (Free Flowing Low Pressure Oil Wells, < 20,000 kPa)
The Testing Frequency is as per SP-2017, Well Failure Model
2.1.3.1 Safety Precautions
4 If the number of tests performed and recorded in WIMS equals 1 the condition as found can be concluded to have
been within limits. The data obtained in this manner will allow analysis of valve performance with a view to establishing
the appropriate long-term reliability based maintenance frequency.
2.1.3.4 Testing
2.1.3.4.1 WIT Task Carry out External Leak Test
WELL TYPE 2 WIT
TASK CODE ELCW /CAPW
TASK DESCRIPTION Carry out external leak check
1) Check all gaskets, flanged, bolted connections and packings for leakage and rectify as
required.
2) Measure and record all annulus pressures and the closed in tubing pressure (CITHP).
Note: Pressure within bolted or flanged connections must be bled off prior to attempting
to pull up any minor weeps
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2.1.3.4.4 WIT Task Function/ leak-off test Flow Wing Valve (Inner or only)
WELL TYPE 2 WIT
TASK CODE FWVIW/ FWVOW
TASK DESCRIPTION Function / leak-off test Flow Wing Valve (Inner or only)
Note: This method assumes that a combination of LMV and UMV provides a leak-
tight seal.
1) Shut in production at the choke (if fitted), close the ESD Valve or the FWV and close the
Location Valve.
2) Zero check the flow line pressure gauge (if fitted), ensuring the line to the gauge is open.
3) Zero check the Swab Valve Pressure Gauge, ensuring that the Swab Valve and the line to
the gauge are open.
4) Close UMV and LMV, if fitted.
5) Open FWV.
6) Bleed off pressure between the Location Valve and the Wellhead through the fixed flexible
bleed line.
7) Close KWV and FWV.
8) Replenish Tree Cavity pressure by either pumping or cycling UMV and LMV, if fitted.
9) Record Test Start pressure at the swab pressure gauge in the WIMS Checklist.
10) Measure the pressure drop in the enclosed tree cavity over 10 minutes using a gauge
known to be accurate.
a. Monitor the pressure rise in the enclosed flow line section between the FWV and
the Location Valve using the Flow line Pressure Gauge.
Note: If the pressure rise observed on the monitoring gauge exceeds the pressure
rise corresponding to the Allowable Leak Rate, specified in the Well Failure
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2.1.3.4.6 WIT Task Function/ Leak-off test Kill Wing Valve Inner (or only)
WELL TYPE 2 WIT
TASK CODE KWVIW
TASK DESCRIPTION Function / Leak-off test Kill Wing Valve Inner (or only)
1) Close KWVI if not already closed.
2) Bleed KWVI downstream cavity and install a pressure gauge and double block and bleed
system.
3) Re-pressurize the tree body if required by the chosen method and allow the pressure in the
tree body to stabilize.
4) Close in the bleed point.
5) Record test Start pressure in the WIMS Checklist.
6) Measure the pressure build-up downstream of the KWVI over 10 minutes using the installed
pressure gauge.
7) Record the test Finish pressure in the WIMS Checklist.
8) If the test result is within the Allowable Leak Rate for the tested valves size then record the
result as Pass with Start and Finish pressures in the WIMS WIT Checklist; record the
number 1 in the Number of Tests done field.
9) If the test results in a Fail on the first attempt, grease and cycle the valve and re-test it until
a Pass test result is achieved or no improvement in results is seen.
a. Flush the Valve Cavity after two failed tests using flushing liquid.
10) Record the final test (last test carried out) result in the WIMS WIT Checklist including Start
and Finish pressure and number of tests done.
2.1.3.4.7 WIT Task Function/ Leak-off test the Upper Master Valve UMV
WELL TYPE 2 WIT
TASK CODE UMVW
TASK DECRIPTION Function/ Leak-off test Upper Master Valve
1) Close UMV
2) Open SV or KWV (dependent on where the measurement will be taken)
3) Open the bleed facility to bleed down the Tree Cavity to as near zero as possible maintain
some positive pressure on the gauge.
4) Close in the bleed point.
5) Record the test Start pressure in the WIMS Checklist.
6) Measure the pressure build-up in the Tree Cavity over 10 minutes.
7) Record the test Finish pressure in the WIMS Checklist.
8) If the test result is within the Allowable Leak Rate for the tested valves size then record the
result as Pass with Start and Finish pressures in the WIMS WIT Checklist; record the
number 1 in the Number of Tests done field.
9) If the test results in a Fail on the first attempt, grease and cycle the valve and re-test it until
a Pass test result is achieved or no improvement in results is seen.
a. Flush the Valve Cavity after two failed tests using flushing liquid.
10) Record the final test (last test carried out) result in the WIMS WIT Checklist including Start
and Finish pressure and number of tests done.
2.1.3.4.8 WIT Task Function/ Leak-off test the Lower Master Valve LMV
WELL TYPE 2 WIT
TASK CODE LMVW
TASK DECRIPTION Function/ Leak-off test Lower Master Valve (if fitted)
1) Close LMV.
2) Open UMV.
3) Open the bleed facility to bleed the Tree Cavity to as near zero as possible; maintain some
positive pressure on the gauge.
4) Close in the bleed point.
5) Record the test Start pressure in the WIMS Checklist.
6) Measure the pressure build-up over 10 minutes.
7) Record the test Finish pressure in the WIMS Checklist.
8) If the test result is within the Allowable Leak Rate for the tested valves size then record the
result as Pass with Start and Finish pressures in the WIMS WIT Checklist; record the
number 1 in the Number of Tests done field.
9) If the test results in a Fail on the first attempt, grease and cycle the valve and re-test it until
a Pass test result is achieved or no improvement in results is seen.
a. Flush the Valve Cavity after two failed tests using flushing liquid.
10) Record the final test (last test carried out) result in the WIMS WIT Checklist including Start
and Finish pressure and number of tests done.
2.1.3.4.9 WIT Task Function/ Leak-off test the Down-Hole Safety Valve
WELL TYPE 2 WIT
TASK CODE SSSVW/ APRW/ CLA
TASK DECRIPTION Function/ Leak-off test Down-Hole Safety Valve e.g. SCSSSV
1) Open the LMV or UMV, record the CITHP.
2) Close the SCSSSV by trip function locally.
3) Open the FWV.
4) Using the choke, bleed off the pressure above the closed SCSSSV in stages to flow line
pressure.
5) Close FWV.
6) Bleed off the remaining pressure through the secured flexiline.
7) Close in the bleed point.
8) Record the A annulus pressures at the start of the test.
9) Record the test Start pressure in the WIMS Checklist.
10) Measure the pressure build-up in the tubing and the Tree Cavity over 30 minutes using a
gauge known to be accurate; use the Well Failure Model Leak Rate Equation to determine
if the leak rate is acceptable.
11) Record the test Finish pressure in the WIMS Checklist.
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7. The tests and the work to be carried out are defined, for each individual well type, in
the Well Failure Model, in the worksheet titled Well Integrity Testing/ Maintenance
Matrix (ensure work is carried out based on the approved version of the Well Failure
Model).
8. Tests must be carried out in the order stated below as the valve status is assumed
as left from the previous test
9. Valves must not be greased before testing. Valve maintenance will be carried out
after the initial test, not before (irrespective of whether the test results is a pass or
fail), this to allow the condition as found to be analysed in terms of failure rates for
both as found and as left conditions. 5
2.1.4.4 Testing
2.1.4.4.1 WIT Task Carry out External Leak Test
WELL TYPE 3 WIT
TASK CODE ELCW /CAPW
TASK DESCRIPTION Carry out external leak check
1) Check all gaskets, flanged, bolted connections and packings for leakage and rectify as
required.
2) Measure and record all annulus pressures and the closed in tubing pressure (CITHP).
Note: Pressure within bolted or flanged connections must be bled off prior to attempting
to pull up any minor weeps
5 If the number of tests performed and recorded in WIMS equals 1 the condition as found can be concluded to have
been within limits. The data obtained in this manner will allow analysis of valve performance with a view to establishing
the appropriate long-term reliability based maintenance frequency.
2.1.4.4.4 WIT Task Function/ leak-off test Flow Wing Valve (Inner or only)
WELL TYPE 3 WIT
TASK CODE FWVIW
TASK DESCRIPTION Function / leak-off test Flow Wing Valve
1) Shut in production at the choke (if fitted) and the FWV.
2) Isolate the gas lift supply by closing the annulus valves.
3) Close the Location Valve.
4) Zero check the flow line pressure gauge (if fitted), ensuring the line to the gauge is open.
5) Zero check the Swab Valve Pressure Gauge, ensuring that the Swab Valve and the line to
the gauge are open.
Note: Monitoring CITHP during FWV test makes test pressure decay noticeable.
6) Bleed off pressure between the Location Valve and the Wellhead through a fixed flexible
bleed line into a portable waste drum.
7) Record Test Start pressure at the flow line pressure gauge in the WIMS Checklist.
8) Measure the build-up in the flow line between the FWV and Location valve using the flow
line Pressure Gauge.
Note: If the integrity of the FWV is suspect continue the Integrity test with the
Master Valve.
9) Record Test Finish pressure in the WIMS Checklist.
10) If the test result is within the allowable leak rate for the tested valves size, record the test as
a Pass with Start and Finish pressures in the WIMS WIT Checklist; record the number 1
in the Number of Tests done field.
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2.1.4.4.6 WIT Task Function/ Leak-off test Kill Wing Valve Inner (or only)
WELL TYPE 3 WIT
TASK CODE KWVIW
TASK DESCRIPTION Function / Leak-off test Kill Wing Valve Inner (or only)
1) Close KWVI if not already closed.
2) Bleed KWVI downstream cavity and install a pressure gauge and double block and bleed
system.
3) Close in the bleed point.
4) Record test Start pressure in the WIMS Checklist.
5) Measure the pressure build-up downstream of the KWVI over 10 minutes using the installed
pressure gauge.
6) Record the test Finish pressure in the WIMS Checklist.
7) If the test result is within the Allowable Leak Rate for the tested valves size then record the
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2.1.4.4.7 WIT Task Function/ Leak-off test the Upper Master Valve UMV
WELL TYPE 3 WIT
TASK CODE UMVW
TASK DECRIPTION Function/ Leak-off test Upper Master Valve
1) Close UMV
2) Open SV or KWV (dependent on where the measurement will be taken)
3) Open the bleed facility to bleed down the Tree Cavity to as near zero as possible maintain
some positive pressure on the gauge.
4) Close in the bleed point.
5) Record the test Start pressure in the WIMS Checklist.
6) Measure the pressure build-up in the Tree Cavity over 10 minutes.
7) Record the test Finish pressure in the WIMS Checklist.
8) If the test result is within the Allowable Leak Rate for the tested valves size then record the
result as Pass with Start and Finish pressures in the WIMS WIT Checklist; record the
number 1 in the Number of Tests done field.
9) If the test results in a Fail on the first attempt, grease and cycle the valve and re-test it until
a Pass test result is achieved or no improvement in results is seen.
a. Flush the Valve Cavity after two failed tests using flushing liquid.
10) Record the final test (last test carried out) result in the WIMS WIT Checklist including Start
and Finish pressure and number of tests done.
2.1.4.4.8 WIT Task Function/ Leak-off test the Lower Master Valve LMV
WELL TYPE 3 WIT
TASK CODE LMVW
TASK DECRIPTION Function/ Leak-off test Lower Master Valve (if fitted)
1) Close LMV.
2) Open UMV.
3) Open the bleed facility to bleed the Tree Cavity to as near zero as possible; maintain some
positive pressure on the gauge.
4) Close in the bleed point.
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8. Tests must be carried out in the order stated below as the valve status is assumed
as left from the previous test
9. Valves must not be greased before testing. Valve maintenance will be carried out
after the initial test, not before (irrespective of whether the test results is a pass or
fail), this to allow the condition as found to be analysed in terms of failure rates for
both as found and as left conditions. 6
2.1.5.4 Testing
2.1.5.4.1 WIT Task Carry out External Leak Test
WELL TYPE 4 WIT
TASK CODE ELCW /CAPW
TASK DESCRIPTION Carry out external leak check
1) Check all gaskets, flanged, bolted connections and packings for leakage and rectify as
required.
2) Measure and record all annulus pressures and the closed in tubing pressure (CITHP).
Note: Pressure within bolted or flanged connections must be bled off prior to attempting
to pull up any minor weeps
6 If the number of tests performed and recorded in WIMS equals 1 the condition as found can be concluded to have
been within limits. The data obtained in this manner will allow analysis of valve performance with a view to establishing
the appropriate long-term reliability based maintenance frequency.
2.1.5.4.4 WIT Task Function/ leak-off test Flow Wing Valve (Inner or only)
WELL TYPE 4 WIT
TASK CODE FWVIW
TASK DESCRIPTION Function / leak-off test Flow Wing Valve
Note: This method assumes that the Master Valve provides a leak-tight seal.
1) Shut in production at the choke (if fitted) and the FWV.
2) Close the Location Valve.
3) Zero check the flow line pressure gauge (if fitted), ensuring the line to the gauge is open.
4) Zero check the Swab Valve Pressure Gauge, ensuring that the Swab Valve and the line to
the gauge are open.
Note: Monitoring CITHP during FWV test makes test pressure decay noticeable.
5) Bleed off pressure between the Location Valve and the Wellhead through a fixed flexible
bleed line into a portable waste drum.
6) Record Test Start pressure at the flow line pressure gauge in the WIMS Checklist.
7) Measure the build-up in the flow line between the FWV and Location valve using the flow
line Pressure Gauge.
Note: If the pressure rise observed on the monitoring gauge exceeds the pressure
rise corresponding to the Allowable Leak Rate, specified in the Well Failure
Model (Allowable leak rate sheet), the FWV is recorded as a Fail; such a
result also suggests that the Location Valve is also a Fail. In this instance,
grease all valves and re-test FWV. If the result is the same then the Well
Services Supervisor or the Asset Well Integrity Engineer must be informed
before taking any further action.
8) Record Test Finish pressure in the WIMS Checklist.
9) If the test result is within the allowable leak rate for the tested valves size, record the test as
a Pass with Start and Finish pressures in the WIMS WIT Checklist; record the number 1
in the Number of Tests done field.
10) If the test results in a Fail on the first attempt, grease and cycle the valve and re-test it until
a Pass test result is achieved or no improvement in results is seen.
a. Flush the valve Cavity after two failed tests using flushing liquid.
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2.1.5.4.6 WIT Task Function/ Leak-off test Kill Wing Valve Inner (or only)
WELL TYPE 4 WIT
TASK CODE KWVIW
TASK DESCRIPTION Function / Leak-off test Kill Wing Valve Inner (or only)
1) Close KWVI if not already closed.
2) Bleed KWVI downstream cavity and install a pressure gauge and double block and bleed
system.
3) Close in the bleed point.
4) Record test Start pressure in the WIMS Checklist.
5) Measure the pressure build-up downstream of the KWVI over 10 minutes using the installed
pressure gauge.
6) Record the test Finish pressure in the WIMS Checklist.
7) If the test result is within the Allowable Leak Rate for the tested valves size then record the
result as Pass with Start and Finish pressures in the WIMS WIT Checklist; record the
number 1 in the Number of Tests done field.
8) If the test results in a Fail on the first attempt, grease and cycle the valve and re-test it until
a Pass test result is achieved or no improvement in results is seen.
2.1.5.4.7 WIT Task Function/ Leak-off test the Upper Master Valve UMV
WELL TYPE 4 WIT
TASK CODE UMVW
TASK DECRIPTION Function/ Leak-off test Upper Master Valve
1) Close UMV
2) Open SV or KWV (dependent on where the measurement will be taken)
3) Open the bleed facility to bleed down the Tree Cavity to as near zero as possible maintain
some positive pressure on the gauge.
4) Close in the bleed point.
5) Record the test Start pressure in the WIMS Checklist.
6) Measure the pressure build-up in the Tree Cavity over 10 minutes.
7) Record the test Finish pressure in the WIMS Checklist.
8) If the test result is within the Allowable Leak Rate for the tested valves size then record the
result as Pass with Start and Finish pressures in the WIMS WIT Checklist; record the
number 1 in the Number of Tests done field.
9) If the test results in a Fail on the first attempt, grease and cycle the valve and re-test it until
a Pass test result is achieved or no improvement in results is seen.
b. Flush the Valve Cavity after two failed tests using flushing liquid.
10) Record the final test (last test carried out) result in the WIMS WIT Checklist including Start
and Finish pressure and number of tests done.
2.1.5.4.8 WIT Task Function/ Leak-off test the Lower Master Valve LMV
WELL TYPE 4 WIT
TASK CODE LMVW
TASK DECRIPTION Function/ Leak-off test Lower Master Valve (if fitted)
1) Close LMV.
2) Open UMV.
3) Open the bleed facility to bleed the Tree Cavity to as near zero as possible; maintain some
positive pressure on the gauge.
4) Close in the bleed point.
5) Record the test Start pressure in the WIMS Checklist.
6) Measure the pressure build-up over 10 minutes.
7) Record the test Finish pressure in the WIMS Checklist.
8) If the test result is within the Allowable Leak Rate for the tested valves size then record the
result as Pass with Start and Finish pressures in the WIMS WIT Checklist; record the
Printed 05/09/16 PR-1047, Well Integrity Maintenance Procedure Page 37
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2.1.5.4.9 WIT Task Function/ Leak-off test Downhole Plugs (if fitted)
WELL TYPE 4 WIT
TASK CODE SSSVW/ APRW/ CLA
TASK DECRIPTION Leak-off test Down-Hole Plug (if fitted)
1) Open the LMV or UMV, record the CITHP.
2) Open the FWV.
3) Using the choke, bleed off the pressure above the closed SCSSSV in stages to flow line
pressure.
4) Close FWV.
5) Bleed off the remaining pressure through the secured flexiline.
6) Close in the bleed point.
7) Record the A annulus pressures at the start of the test.
8) Record the test Start pressure in the WIMS Checklist.
9) Measure the pressure build-up in the tubing and the Tree Cavity over 4 hours as described
in the note below. Use the Well Failure Model Leak Rate Equation to determine if the leak
rate is acceptable.
Note: Where a well is plugged or suspended, first carry out the Tree Valve Leak-off
test using any pressure that has built up above the plug. Then bleed off the
pressure above the plug, close in the bleed and carry out and extended (4
hour) inflow test on the plug recording the results at hour average over the
test period (i.e. one eighth of the observed rise over the 4 hour test period).
Simply cycle and maintain the tree valves where no pressure is initially seen
above the plug.
10) Record the test Finish pressure in the WIMS Checklist.
11) Record the A Annulus pressure at the end of the test.
12) Bleed off any built-up pressure through the chosen bleed point.
Note: WIMS Master Data for the well will be adapted to include allowable leak rates
for any plugs fitted. So check WIMS to confirm the calculated allowable leak
rate!
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7. Valves must not be greased before testing. Valve maintenance will be carried out
after the initial test, not before (irrespective of whether the test results is a pass or
fail), this to allow the condition as found to be analysed in terms of failure rates for
both as found and as left conditions.7
2.1.6.5 Testing
2.1.6.5.1 WIT Task Adjust Stuffing Box Seals
WELL TYPE 5 WIT
TASK CODE SPSA
TASK DECRIPTION Adjust Stuffing Box Seals
This task is specific to rod-pumps
1) Monitor the external leakage from the stuffing box with the pump running.
2) If the Leak rate exceeds those specified in the Well Failure Model, stop the pump and adjust
the stuffing box, this to give optimum sealing capability without binding.
3) Restart the pump and re-check leakage.
4) Continue steps 2 to 3 until the observed leak rate is within limits or no further improvement
is achieved.
5) Record the result as Pass or Fail in the WIMS Checklist.
6) Inspect the vitraulic joint and report any condition degradation in the Free Text box in the
WIMS Checklist.
7) Inspect the polished rod and report any condition degradation in the Free Text box in the
WIMS Checklist.
7 If the number of tests performed and recorded in WIMS equals 1 the condition as found can be concluded to have
been within limits. The data obtained in this manner will allow analysis of valve performance with a view to establishing
the appropriate long-term reliability based maintenance frequency.
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2.1.6.5.6 WIT Task Function/ Leak-off test Kill Wing Valve Inner (or only)
WELL TYPE 5 WIT
TASK CODE KWVIW
TASK DESCRIPTION Function / Leak-off test Kill Wing Valve Inner (or only)
Note: This test applies to all types of pumped wells
1) This test shall be carried out with the pump running!
2) Close KWV.
3) Bleed KWV downstream cavity.
4) Close in the bleed point and install Test Manifold.
5) Record the test Start pressure in the WIMS Checklist.
6) Measure the pressure build-up above the KWV over 10 minutes using a gauge known to be
accurate.
7) Record the test Finish pressure in the WIMS Checklist.
8) If the test result is within the Allowable Leak Rate for the tested valves size then record the
result as Pass with Start and Finish pressures in the WIMS WIT Checklist; record the
number 1 in the Number of Tests done field.
9) If the test results in a Fail on the first attempt, grease and cycle the valve and re-test it until
a Pass test result is achieved or no improvement in results is seen.
a. Flush the Valve Cavity after two failed tests using flushing liquid.
The pump must be isolated for greasing and/ or flushing!
10) Record the final test (last test carried out) result in the WIMS WIT Checklist including Start
and Finish pressure and number of tests done.
2.1.6.5.7 WIT Task Function/ leak-off test Flow Wing Valve (Inner or only)
WELL TYPE 5 WIT
TASK CODE FWVIW
TASK DESCRIPTION Function / leak-off test Flow Wing Valve
1) Shut down and electrically isolate the pump
2) Function and maintain the valve in line with the relevant Maintenance Guide.
a. Enter Pass in the WIMS Checklist where the valve functions correctly.
b. Enter Fail in the WIMS Checklinst where the valve fails to function and where this
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2.1.6.5.8 WIT Task Function/ Leak-off test the Upper Master Valve UMV
WELL TYPE 5 WIT
TASK CODE UMVW
TASK DECRIPTION Function/ Leak-off test Upper Master Valve
Warning: Do NOT function any Master Valve on a rod-type pumped well
A: Task Description for non-rod type wells
1) Function and maintain the valve in line with the relevant Maintenance Guide.
a. Enter Pass in the WIMS Checklist where the valve functions correctly.
b. Enter Fail in the WIMS Checklinst where the valve fails to function and where this
condition cannot be rectified by the test crew
2.1.6.5.9 WIT Task Function/ Leak-off test the Upper Master Valve LMV
WELL TYPE 5 WIT
TASK CODE LMVW
TASK DECRIPTION Function/ Leak-off test Upper Master Valve
Warning: Do NOT function any Master Valve on a rod-type pumped well
A: Task Description for non-rod type wells
1) Function and maintain the valve in line with the relevant Maintenance Guide.
a. Enter Pass in the WIMS Checklist where the valve functions correctly.
b. Enter Fail in the WIMS Checklinst where the valve fails to function and where this
condition cannot be rectified by the test crew
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2.1.7 Well Types 6 and 7 (Water Injection/ Disposal wells with/ without tubing)
The Testing Frequency as per SP-2017, Well Failure Model
2.1.7.1 Safety Precautions
8 If the number of tests performed and recorded in WIMS equals 1 the condition as found can be concluded to have
been within limits. The data obtained in this manner will allow analysis of valve performance with a view to establishing
the appropriate long-term reliability based maintenance frequency.
2.1.7.4 Testing
2.1.7.4.1 WIT Task Carry out External Leak Test
WELL TYPES 6 AND 7 WIT
TASK CODE ELCW /CAPW
TASK DESCRIPTION Carry out external leak check
1) Check all gaskets, flanged, bolted connections and packings for leakage and rectify as
required.
2) Measure and record all annulus pressures and the closed in tubing pressure (CITHP).
Note: Pressure within bolted or flanged connections must be bled off prior to attempting
to pull up any minor weeps
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2.1.7.4.5 WIT Task Function/ Leak-off test Kill Wing Valve Inner (or only)
WELL TYPES 6 AND 7 WIT
TASK CODE KWVIW
TASK DESCRIPTION Function / Leak-off test Kill Wing Valve Inner (or only)
1) This test shall be carried out whilst the well is injecting.
2) Close KWV.
3) Bleed KWV downstream cavity.
4) Close in the bleed point and install Test Manifold.
5) Record the test Start pressure in the WIMS Checklist.
6) Measure the pressure build-up above the KWV over 10 minutes using a gauge known to be
accurate.
7) Record the test Finish pressure in the WIMS Checklist.
8) If the test result is within the Allowable Leak Rate for the tested valves size then record the
result as Pass with Start and Finish pressures in the WIMS WIT Checklist; record the
number 1 in the Number of Tests done field.
9) If the test results in a Fail on the first attempt, grease and cycle the valve and re-test it until
a Pass test result is achieved or no improvement in results is seen.
a. Flush the Valve Cavity after two failed tests using flushing liquid.
The well must be closed in prior to greasing or flushing of valves!
10) Record the final test (last test carried out) result in the WIMS WIT Checklist including Start
and Finish pressure and number of tests done.
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2.1.7.4.7 WIT Task Function/ Leak-off test the Upper Master Valve UMV
WELL TYPES 6 AND 7 WIT
TASK CODE UMVW
TASK DECRIPTION Function/ Leak-off test Upper Master Valve
1) Close UMV
2) Open SV or KWV (dependent on where the measurement will be taken)
3) Bleed off pressure above the UMV through a fixed flexible bleed line into a portable waste
drum.
4) Once flow has stabilized, start measuring the outflow into a graduated container.
5) Measure the quantity of fluid collected during the 10 minute test and calculate the average
flow per minute.
6) If the test result is within the allowable leak rate for the tested valves size, record the test as
a Pass with the average flow rate in the WIMS WIT Checklist; record the number 1 in the
Number of Tests done field.
7) If the test results in a Fail on the first attempt, grease and cycle the valve and re-test it until
a Pass test result is achieved or no improvement in results is seen.
a. Flush the valve Cavity after two failed tests using flushing liquid.
8) Record the final test (last test carried out) result in the WIMS WIT Checklist including the
average flow rate and number of tests done.
9) Close in the bleed point.
2.1.7.4.8 WIT Task Function/ Leak-off test the Lower Master Valve LMV
WELL TYPES 6 AND 7 WIT
TASK CODE LMVW
TASK DECRIPTION Function/ Leak-off test Lower Master Valve (if fitted)
1) Open UMV.
2) Close LMV.
3) Open SV or KWV (dependent on where the measurement will be taken)
4) Bleed off pressure above the LMV through a fixed flexible bleed line into a portable waste
drum.
5) Once flow has stabilized, start measuring the outflow into a graduated container.
6) Measure the quantity of fluid collected during the 10 minute test and calculate the average
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2.2.1 Well Type 1 (High Pressure Wells or high GLR or H2S Wells)
The testing frequencies are as per SP-2017, Well Failure Model
2.2.1.1 Safety Precautions
1) Perform tool box talks as per PDOs Toolbox Talk Prompt Card.
2.2.1.1.1 Permit to Work
Ensure that PR-1172, Permit to Work Procedure is followed.
2.2.1.1.2 H2S
Well Type 1, High Risk Wells, comprises H2S wells. This Chapter highlights the particularities
relating to H2S wells and provides links to Reference Documents.
1) Comply with all items outlined in SP-1219, Drilling Specification Hydrogen Sulphide.
2) A calibrated pressure gauge fitted to the tree cap with bleed facility (in line with H2S
controls) maybe bled off to the outside fence downwind of the work area.
P would exist across the valve than under test conditions; so a Pass under test
conditions demonstrates integrity. A fail under these conditions will also have
occurred before the valve has equalised; therefore this method is deemed to be a
valid test method.
5. Where no pressure exists for testing, the annuli have to be topped up with the fluid
stipulated in WIMS.
6. The pressure to be applied to the annuli shall be as per Table 2-3Error! Reference source
not found..
Table 2-3, Test Pressures for Annuli Tests
Note: Where the observed annulus pressure is above MAASP, a full annulus
investigation will be instigated by the WIMS.
a. Where the above applies, the test shall be suspended until an annulus
investigation has been completed.
b. Ensure that the tubing, annulus and the wellhead void pressures are captured
before leaving the worksite; this data is required as background information to
base the annulus investigation upon.
7. The Pressure Measurement Method shall be Pressure Build-up within an enclosed volume
for valve tests and Bleed-off from an enclosed volume for annulus tests.
Note: Where pressure cannot be maintained in the annulus, cycling and maintaining only
(greasing or lubricating) of the annulus valve(s) shall be deemed a test Pass.
8. Hook up Chicksan lines to the annuli valves.
9. Record the CITHP and all annular pressures as found in the WIMS Checklist.
10. The tests and the work to be carried out are defined, for each individual well type, in
the Well Failure Model, in the worksheet titled Well Integrity Testing/ Maintenance
Matrix (ensure work is carried out based on the approved version of the Well Failure
Model).
11. Tests must be carried out in the order stated below as the valve status is assumed
as left from the previous test
12. Valves must not be greased before testing. Valve maintenance will be carried out
after the initial test, not before (irrespective of whether the test results is a pass or
fail), this to allow the condition as found to be analysed in terms of failure rates for
both as found and as left conditions. 9
9 If the number of tests performed and recorded in WIMS equals 1 the condition as found can be concluded to have
been within limits. The data obtained in this manner will allow analysis of valve performance with a view to establishing
the appropriate long-term maintenance frequency.
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2.2.1.4 Testing
2.2.1.4.1 SIT Task Check no external leaks
WELL TYPE 1 SIT
TASK CODE ELCS
TASK DESCRIPTION Check no external leaks
1) Check all gaskets, flanged, bolted connections and packings for leakage and rectify as
required.
2) Measure and record all annulus pressures and the closed in tubing pressure (CITHP).
Note: Pressure within bolted or flanged connections must be bled off prior to attempting to
pull up any minor weeps
2.2.1.5 Testing
2.2.1.5.1 SIT Task Pressure Containment Test A annulusulus
WELL TYPE 1 SIT
TASK CODE APT
TASK DESCRIPTION Pressure Containment Test A Annulus
Note: Whilst carrying out all steps of the test below, monitor the adjacent annuli for pressure
communication effects and report any observations in the Free text area in the WIMS
SIT Checklist. Abort any test if communication between annuli and/ or the tubing may
result in any annulus MAASP being breached.
1) Bleed off any pressure in all annuli to as low as practical above zero in order to remove any
gas caps that may have formed.
Note: If it is not possible to bleed down the annulus, abort the test and initiate an
annulus investigation.
2) Lubricate all annuli to surface using the fluid stipulated in WIMS, recording volumes
pumped in the WIMS SIT Checklist.
Note: Where it is not possible to fill the annulus, ensure that 110% of the annular
volume has been added prior to aborting the test on that particular annulus.
3) Pressure up the A annulus to the test pressure stated in Table 2-3 above.
Note: Where it is not possible to achieve the required test pressure, record this fact in
the Free text area in the WIMS SIT Checklist, recommending further
investigation and continue with the test below.
4) Allow the pressure to stabilise for 10 mins
5) Record and enter the Start pressure in the WIMS SIT Checklist.
6) Monitor the pressure for 30 minutes.
7) Record the Test Finish pressure in the WIMS SIT Checklist.
8) Record the test result as Pass or Fail in the WIMS SIT Checklist.
Notes: 1. The Allowable Leak Rate must be calculated using the formula provided in
the Well Failure Model Subsurface Leak Rates in the Allowable leak rates
sheet.
2. The annular volume must be calculated in m3 based on the Packer Depth.
3. Where the Top of Cement is unknown, use the casing shoe depth in the
calculation as the resulting Allowable Leak Rate will be more conservative.
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2.2.1.5.13 SIT Task Leak off test Tree to tubing head/ Adaptor Flange Connection if
fitted
WELL TYPE 1SIT
TASK CODE TTCS
TASK DECRIPTION Leak off test Tree to tubing head/ Adaptor Flange Connection if
fitted
1) Identify the Cavity testing port as per the relevant Wellhead Maintenance Guide.
2) Install the Universal Bleeder Tool and Testing Manifold complete with a recording gauge on
the test port.
3) Stab the Cavity testing port and record the pressure found as Start pressure in the WIMS
SIT Checklist.
4) Bleed off the void pressure to zero.
5) Close in the Bleeder port and monitor the build-up for 10 minutes.
6) Record the final pressure as Finish pressure in the WIMS SIT Checklist.
Notes: 1. Where pressure is found in the void, which cannot be bled off, recommend an
Annulus Investigation.
2. Where Tubing and Adaptor Flange and void Start and Finish pressures are
zero, the test is recorded as Pass in the WIMS SIT Checklist.
2.2.1.5.14 SIT Task Leak off test Adaptor Flange to Tubing Head Connection if fitted
WELL TYPE 1SIT
TASK CODE ATC
TASK DECRIPTION Leak off test Adaptor Flange to Tubing Head Connection if fitted
1) Identify the Cavity testing port as per the relevant Wellhead Maintenance Guide.
2) Install the Universal Bleeder Tool and Testing Manifold complete with a recording gauge on
the test port.
3) Stab the Cavity testing port and record the pressure found as Start pressure in the WIMS
SIT Checklist.
4) Bleed off the void pressure to zero.
5) Close in the Bleeder port and monitor the build-up for 10 minutes.
6) Record the final pressure as Finish pressure in the WIMS SIT Checklist.
Notes: 1. Where pressure is found in the void, which cannot be bled off, recommend an
Annulus Investigation.
2. Where Adaptor Flange and Tubing and void Start and Finish pressures are
zero, the test is recorded as Pass in the WIMS SIT Checklist.
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2.2.1.5.15 SIT Task Leak off test Surface Casing Wellhead Connection Void
WELL TYPE 1SIT
TASK CODE SCWC
TASK DECRIPTION Leak off test Surface Casing Wellhead Connection Void
1) Identify the Cavity testing port as per the relevant Wellhead Maintenance Guide.
2) Install the Universal Bleeder Tool and Testing Manifold complete with a recording gauge on
the test port.
3) Stab the Cavity testing port and record the pressure found as Start pressure in the WIMS
SIT Checklist.
4) Bleed off the void pressure to zero.
5) Close in the Bleeder port and monitor the build-up for 10 minutes.
6) Record the final pressure as Finish pressure in the WIMS SIT Checklist.
Notes: 1. Where pressure is found in the void, which cannot be bled off, recommend an
Annulus Investigation.
2. Where Casing and void Start and Finish pressures are zero, the test is
recorded as Pass in the WIMS SIT Checklist.
2.2.2 Well Type 2 (Free Flowing Low Pressure Oil Wells, < 20,000 kPa)
The testing frequencies are as per SP-2017, Well Failure Model
2.2.2.1 Safety Precautions
2) Perform tool box talks as per PDOs Toolbox Talk Prompt Card.
2.2.2.1.1 Permit to Work
Ensure that PR-1172, Permit to Work Procedure is followed.
2.2.2.1.2 H2S
Well Type 1, High Risk Wells, comprises H2S wells. This Chapter highlights the particularities
relating to H2S wells and provides links to Reference Documents.
3) Comply with all items outlined in SP-1219, Drilling Specification Hydrogen Sulphide.
4) A calibrated pressure gauge fitted to the tree cap with bleed facility (in line with H2S
controls) maybe bled off to the outside fence downwind of the work area.
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occurred before the valve has equalised; therefore this method is deemed to be a
valid test method.
17. Where no pressure exists for testing, the annuli have to be topped up with the fluid
stipulated in WIMS.
18. The pressure to be applied to the annuli shall be as per Table 2-3 above.
Note: Where the observed annulus pressure is above MAASP, a full annulus
investigation will be instigated by the WIMS.
c. Where the above applies, the test shall be suspended until an annulus
investigation has been completed.
d. Ensure that the tubing, annulus and the wellhead void pressures are captured
before leaving the worksite; this data is required as background information to
base the annulus investigation upon.
19. The Pressure Measurement Method shall be Pressure Build-up within an enclosed volume
for valve tests and Bleed-off from an enclosed volume for annulus tests.
Note: Where pressure cannot be maintained in the annulus, cycling and maintaining only
(greasing or lubricating) of the annulus valve(s) shall be deemed a test Pass.
20. Hook up Chicksan lines to the annuli valves.
21. Record the CITHP and all annular pressures as found in the WIMS Checklist.
22. The tests and the work to be carried out are defined, for each individual well type, in
the Well Failure Model, in the worksheet titled Well Integrity Testing/ Maintenance
Matrix (ensure work is carried out based on the approved version of the Well Failure
Model).
23. Tests must be carried out in the order stated below as the valve status is assumed
as left from the previous test
24. Valves must not be greased before testing. Valve maintenance will be carried out
after the initial test, not before (irrespective of whether the test results is a pass or
fail), this to allow the condition as found to be analysed in terms of failure rates for
both as found and as left conditions. 10
2.2.2.4 Testing
2.2.2.4.1 SIT Task Check no external leaks
WELL TYPE 2 SIT
TASK CODE ELCS
TASK DESCRIPTION Check no external leaks
3) Check all gaskets, flanged, bolted connections and packings for leakage and rectify as
required.
4) Measure and record all annulus pressures and the closed in tubing pressure (CITHP).
Note: Pressure within bolted or flanged connections must be bled off prior to attempting to
pull up any minor weeps
10 If the number of tests performed and recorded in WIMS equals 1 the condition as found can be concluded to have
been within limits. The data obtained in this manner will allow analysis of valve performance with a view to establishing
the appropriate long-term maintenance frequency.
2.2.2.5 Testing
2.2.2.5.1 SIT Task Pressure Containment Test A annulusulus
WELL TYPE 2 SIT
TASK CODE APT
TASK DESCRIPTION Pressure Containment Test A Annulus
Note: Whilst carrying out all steps of the test below, monitor the adjacent annuli for pressure
communication effects and report any observations in the Free text area in the WIMS
SIT Checklist. Abort any test if communication between annuli and/ or the tubing may
result in any annulus MAASP being breached.
9) Bleed off any pressure in all annuli to as low as practical above zero in order to remove any
gas caps that may have formed.
Note: If it is not possible to bleed down the annulus, abort the test and initiate an
annulus investigation.
10) Lubricate all annuli to surface using the fluid stipulated in WIMS, recording volumes
pumped in the WIMS SIT Checklist.
Note: Where it is not possible to fill the annulus, ensure that 110% of the annular
volume has been added prior to aborting the test on that particular annulus.
11) Pressure up the A annulus to the test pressure stated in Table 2-3 above.
Note: Where it is not possible to achieve the required test pressure, record this fact in
the Free text area in the WIMS SIT Checklist, recommending further
investigation and continue with the test below.
12) Allow the pressure to stabilise for 10 mins
13) Record and enter the Start pressure in the WIMS SIT Checklist.
14) Monitor the pressure for 30 minutes.
15) Record the Test Finish pressure in the WIMS SIT Checklist.
16) Record the test result as Pass or Fail in the WIMS SIT Checklist.
Notes: 1. The Allowable Leak Rate must be calculated using the formula provided in
the Well Failure Model Subsurface Leak Rates in the Allowable leak rates
sheet.
2. The annular volume must be calculated in m3 based on the Packer Depth.
3. Where the Top of Cement is unknown, use the casing shoe depth in the
calculation as the resulting Allowable Leak Rate will be more conservative.
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The controlled version of this CMF Document resides online in Livelink. Printed copies are UNCONTROLLED.
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2.2.2.5.13 SIT Task Leak off test Tree to tubing head/ Adaptor Flange Connection if
fitted
WELL TYPE 2 SIT
TASK CODE TTCS
TASK DECRIPTION Leak off test Tree to tubing head/ Adaptor Flange Connection if
fitted
1) Identify the Cavity testing port as per the relevant Wellhead Maintenance Guide.
2) Install the Universal Bleeder Tool and Testing Manifold complete with a recording gauge on
the test port.
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2.2.2.5.14 SIT Task Leak off test Adaptor Flange to Tubing Head Connection if fitted
WELL TYPE 2 SIT
TASK CODE ATC
TASK DECRIPTION Leak off test Adaptor Flange to Tubing Head Connection if fitted
1) Identify the Cavity testing port as per the relevant Wellhead Maintenance Guide.
2) Install the Universal Bleeder Tool and Testing Manifold complete with a recording gauge on
the test port.
3) Stab the Cavity testing port and record the pressure found as Start pressure in the WIMS
SIT Checklist.
4) Bleed off the void pressure to zero.
5) Close in the Bleeder port and monitor the build-up for 10 minutes.
6) Record the final pressure as Finish pressure in the WIMS SIT Checklist.
Notes: 1. Where pressure is found in the void, which cannot be bled off, recommend an
Annulus Investigation.
2. Where Adaptor Flange and Tubing and void Start and Finish pressures are
zero, the test is recorded as Pass in the WIMS SIT Checklist.
2.2.2.5.15 SIT Task Leak off test Surface Casing Wellhead Connection Void
WELL TYPE 2 SIT
TASK CODE SCWC
TASK DECRIPTION Leak off test Surface Casing Wellhead Connection Void
1) Identify the Cavity testing port as per the relevant Wellhead Maintenance Guide.
2) Install the Universal Bleeder Tool and Testing Manifold complete with a recording gauge on
the test port.
3) Stab the Cavity testing port and record the pressure found as Start pressure in the WIMS
SIT Checklist.
4) Bleed off the void pressure to zero.
5) Close in the Bleeder port and monitor the build-up for 10 minutes.
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2.2.3.1.2 H2S
Well Type 1, High Risk Wells, comprises H2S wells. This Chapter highlights the particularities
relating to H2S wells and provides links to Reference Documents.
1) Comply with all items outlined in SP-1219, Drilling Specification Hydrogen Sulphide.
2) A calibrated pressure gauge fitted to the tree cap with bleed facility (in line with H2S
controls) maybe bled off to the outside fence downwind of the work area.
occurred before the valve has equalised; therefore this method is deemed to be a
valid test method.
5. Where no pressure exists for testing, the annuli have to be topped up with the fluid
stipulated in WIMS.
6. The pressure to be applied to the annuli shall be as per Table 2-3.
Note: Where the observed annulus pressure is above MAASP, a full annulus
investigation will be instigated by the WIMS.
e. Where the above applies, the test shall be suspended until an annulus
investigation has been completed.
f. Ensure that the tubing, annulus and the wellhead void pressures are captured
before leaving the worksite; this data is required as background information to
base the annulus investigation upon.
7. The Pressure Measurement Method shall be Pressure Build-up within an enclosed volume
for valve tests and Bleed-off from an enclosed volume for annulus tests.
Note: Where pressure cannot be maintained in the annulus, cycling and maintaining only
(greasing or lubricating) of the annulus valve(s) shall be deemed a test Pass.
8. Hook up Chicksan lines to the annuli valves.
9. Record the CITHP and all annular pressures as found in the WIMS Checklist.
10. The tests and the work to be carried out are defined, for each individual well type, in
the Well Failure Model, in the worksheet titled Well Integrity Testing/ Maintenance
Matrix (ensure work is carried out based on the approved version of the Well Failure
Model).
11. Tests must be carried out in the order stated below as the valve status is assumed
as left from the previous test
12. Valves must not be greased before testing. Valve maintenance will be carried out
after the initial test, not before (irrespective of whether the test results is a pass or
fail), this to allow the condition as found to be analysed in terms of failure rates for
both as found and as left conditions. 11
2.2.3.4 Testing
2.2.3.4.1 SIT Task Check no external leaks
WELL TYPE 3 SIT
TASK CODE ELCS
TASK DESCRIPTION Check no external leaks
1) Check all gaskets, flanged, bolted connections and packings for leakage and rectify as
required.
2) Measure and record all annulus pressures and the closed in tubing pressure (CITHP).
Note: Pressure within bolted or flanged connections must be bled off prior to attempting to
pull up any minor weeps
11 If the number of tests performed and recorded in WIMS equals 1 the condition as found can be concluded to have
been within limits. The data obtained in this manner will allow analysis of valve performance with a view to establishing
the appropriate long-term maintenance frequency.
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2.2.3.5 Testing
2.2.3.5.1 SIT Task Pressure Containment Test A Annulus
WELL TYPE 3 SIT
TASK CODE APT
TASK DESCRIPTION Pressure Containment Test A Annulus
Note: Whilst carrying out all steps of the test below, monitor the adjacent annuli for pressure
communication effects and report any observations in the Free text area in the WIMS
SIT Checklist. Abort any test if communication between annuli and/or the tubing may
result in any annulus MAASP being breached.
B annulus (and others) must be topped up in advance but bled to just above zero in
order to not collapse the casing when de-pressurised and monitored for pressure build
up in advance.
1) Close the well on FWV and leave the gas lift supply open to allow pressure to build up in the
A Annulus and tubing.
Note: If the well was isolated prior to the test, the possibility of using gas to carry out test must be
confirmed in advance..
2) Allow the pressure to stabilise.
3) Isolate the gas lift supply flow line at location and bleed contents of line between location
valve and side outlet valves.
Note: This is to prevent a spurious pressure build up from the supply side that caould result
in a false fail test result.
4) Bleed off pressure in the A annulus to as near zero as possible ensuring D.P. at start of test
is above 1.2 times allowable leak rate.
Note: Fast bleed required first in order to close and seal the gas lift valve check vales
5) Once annulus pressure is at zero or minimum stated, close in bleed and enter the Start
pressure in the WIMS SIT Checklist.
6) Allow annulus to stabilise for 15 mins
7) Record start pressure in WIMS checklist and monitor pressure pressure in A Annulus for 30
minutes.
8) Record the Test Finish pressure in the WIMS SIT Checklist.
9) Record the test result as Pass or Fail in the WIMS SIT Checklist.
Notes: 1. The Allowable Leak Rate must be calculated using the formula provided in the Well
Failure Model Subsurface Leak Rates in the Allowable leak rates sheet.
2. The annular volume must be calculated in m3 based on the Packer Depth.
Possible cases:
1. A Annulus bled to zero / minimum ok and pressure build up over 30 minutes is below
allowable leak rate Pass (No additional investigation required)
2. Unable bleed A Annulus to zero / minimum means annulus is being pressurised from
reservoir - Fail (Additional investigation is required to assess what component is leaking
and / repair)
3. A Annulus pressure build up after 30 minutes is above allowable leak rate Fail
(Additional investigation is required to assess what component is leaking and / repair)
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2.2.3.5.13 SIT Task Leak off test Tree to tubing head/ Adaptor Flange Connection if
fitted
WELL TYPE 3 SIT
TASK CODE TTCS
TASK DECRIPTION Leak off test Tree to tubing head/ Adaptor Flange Connection if
fitted
1) Identify the Cavity testing port as per the relevant Wellhead Maintenance Guide.
2) Install the Universal Bleeder Tool and Testing Manifold complete with a recording gauge on
the test port.
3) Stab the Cavity testing port and record the pressure found as Start pressure in the WIMS
SIT Checklist.
4) Bleed off the void pressure to zero.
5) Close in the Bleeder port and monitor the build-up for 10 minutes.
6) Record the final pressure as Finish pressure in the WIMS SIT Checklist.
Notes: 1. Where pressure is found in the void, which cannot be bled off, recommend an
Annulus Investigation.
2. Where Tubing and Adaptor Flange and void Start and Finish pressures are
zero, the test is recorded as Pass in the WIMS SIT Checklist.
2.2.3.5.14 SIT Task Leak off test Adaptor Flange to Tubing Head Connection if fitted
WELL TYPE 3 SIT
TASK CODE ATC
TASK DECRIPTION Leak off test Adaptor Flange to Tubing Head Connection if fitted
1) Identify the Cavity testing port as per the relevant Wellhead Maintenance Guide.
2) Install the Universal Bleeder Tool and Testing Manifold complete with a recording gauge on
the test port.
3) Stab the Cavity testing port and record the pressure found as Start pressure in the WIMS
SIT Checklist.
4) Bleed off the void pressure to zero.
5) Close in the Bleeder port and monitor the build-up for 10 minutes.
6) Record the final pressure as Finish pressure in the WIMS SIT Checklist.
Notes: 1. Where pressure is found in the void, which cannot be bled off, recommend an
Annulus Investigation.
2. Where Adaptor Flange and Tubing and void Start and Finish pressures are
zero, the test is recorded as Pass in the WIMS SIT Checklist.
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2.2.3.5.15 SIT Task Leak off test Surface Casing Wellhead Connection Void
WELL TYPE 3 SIT
TASK CODE SCWC
TASK DECRIPTION Leak off test Surface Casing Wellhead Connection Void
1) Identify the Cavity testing port as per the relevant Wellhead Maintenance Guide.
2) Install the Universal Bleeder Tool and Testing Manifold complete with a recording gauge on
the test port.
3) Stab the Cavity testing port and record the pressure found as Start pressure in the WIMS
SIT Checklist.
4) Bleed off the void pressure to zero.
5) Close in the Bleeder port and monitor the build-up for 10 minutes.
6) Record the final pressure as Finish pressure in the WIMS SIT Checklist.
Notes: 1. Where pressure is found in the void, which cannot be bled off, recommend an
Annulus Investigation.
2. Where Casing and void Start and Finish pressures are zero, the test is
recorded as Pass in the WIMS SIT Checklist.
2.2.4.1.2 H2S
Well Type 1, High Risk Wells, comprises H2S wells. This Chapter highlights the particularities
relating to H2S wells and provides links to Reference Documents.
1) Comply with all items outlined in SP-1219, Drilling Specification Hydrogen Sulphide.
2) A calibrated pressure gauge fitted to the tree cap with bleed facility (in line with H2S
controls) maybe bled off to the outside fence downwind of the work area.
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Note: The reasoning behind this rule is that the purpose of leak testing valves is to assess
their likely performance in the worst case scenario. In a failure situation, a greater
P would exist across the valve than under test conditions; so a Pass under test
conditions demonstrates integrity. A fail under these conditions will also have
occurred before the valve has equalised; therefore this method is deemed to be a
valid test method.
5) Where no pressure exists for testing, the annuli have to be topped up with the fluid
stipulated in WIMS.
6) The pressure to be applied to the annuli shall be as per Table 2-3 above.
Note: Where the observed annulus pressure is above MAASP, a full annulus
investigation will be instigated by the WIMS.
g. Where the above applies, the test shall be suspended until an annulus
investigation has been completed.
h. Ensure that the tubing, annulus and the wellhead void pressures are captured
before leaving the worksite; this data is required as background information to
base the annulus investigation upon.
7) The Pressure Measurement Method shall be Pressure Build-up within an enclosed volume
for valve tests and Bleed-off from an enclosed volume for annulus tests.
Note: Where pressure cannot be maintained in the annulus, cycling and maintaining only
(greasing or lubricating) of the annulus valve(s) shall be deemed a test Pass.
8) Hook up Chicksan lines to the annuli valves.
9) Record the CITHP and all annular pressures as found in the WIMS Checklist.
10) The tests and the work to be carried out are defined, for each individual well type, in
the Well Failure Model, in the worksheet titled Well Integrity Testing/ Maintenance
Matrix (ensure work is carried out based on the approved version of the Well Failure
Model).
11) Tests must be carried out in the order stated below as the valve status is assumed
as left from the previous test
12) Valves must not be greased before testing. Valve maintenance will be carried out
after the initial test, not before (irrespective of whether the test results is a pass or
fail), this to allow the condition as found to be analysed in terms of failure rates for
both as found and as left conditions. 12
2.2.4.4 Testing
2.2.4.4.1 SIT Task Check no external leaks
WELL TYPE 4 SIT
TASK CODE ELCS
TASK DESCRIPTION Check no external leaks
Safety Note: Prior to commence SIT on Steam Injector wells steam injection must
be closed-in three days prior to start to allow Christmas tree to
cool down. Special precautions must be taken to prevent scorch
12 If the number of tests performed and recorded in WIMS equals 1 the condition as found can be concluded to have
been within limits. The data obtained in this manner will allow analysis of valve performance with a view to establishing
the appropriate long-term maintenance frequency.
2.2.4.5 Testing
2.2.4.5.1 SIT Task Check no external leaks
WELL TYPE 4 SIT
TASK CODE CBTS
TASK DESCRIPTION ChecK Tighten all Bolts and Nuts
1) All casing bowl flange bolts need to be retightened on wellhead cooling in order to
prevent a steam leak upon restart of steam injection.
Note: Pressure within bolted or flanged connections must be bled off prior to attempting
to pull up any minor weeps
2.2.4.6 Testing
2.2.4.6.1 SIT Task Pressure Containment Test A annulusulus
WELL TYPE 4 SIT
TASK CODE BPT
TASK DESCRIPTION Pressure Containment Test B Annulus
Note:
1. Whilst carrying out all steps of the test below, monitor the adjacent annuli for
pressure communication effects and report any observations in the Free text
area in the WIMS SIT Checklist. Abort any test if communication between annuli
and/ or the tubing may result in any annulus MAASP being breached..
2. Ensure correct testing fluids are used as stipulated in WIMS (Inhibited fresh
water or diesel ???)
1) Bleed off any pressure in all annuli to as low as practical above zero in order to remove
any gas caps that may have formed.
Note: If it is not possible to bleed down the annulus, abort the test and initiate an
annulus investigation.
2) Lubricate all annuli to surface using the fluid stipulated in WIMS, recording volumes
pumped in the WIMS SIT Checklist.
Note: Where it is not possible to fill the annulus, ensure that 110% of the annular
volume has been added prior to aborting the test on that particular annulus.
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2.2.4.6.2 SIT Task Leak off test DSAF to Tubing spool ring gasket void (if fitted) or
Christmas tree to tubing spool.
WELL TYPE 4 SIT
TASK CODE TRGVS
TASK DECRIPTION Leak off test DSAF to Tubing spool ring gasket void (if fitted) or
Christmas tree to tubing spool.
1) Identify the Cavity testing port as per the relevant Wellhead Maintenance Guide.
2) Install the Universal Bleeder Tool and Testing Manifold complete with a recording gauge on
the test port.
3) Stab the Cavity testing port and record the pressure found as Start pressure in the WIMS
SIT Checklist.
4) Bleed off the void pressure to zero.
5) Close in the Bleeder port and monitor the build-up for 10 minutes.
6) Record the final pressure as Finish pressure in the WIMS SIT Checklist.
7) Bleed off test pressures and leave bleed point open.
Notes: 1. Where pressure is found in the void, which cannot be bled off, recommend an
Annulus Investigation.
2. Where Casing and void Start and Finish pressures are zero, the test is
recorded as Pass in the WIMS SIT Checklist.
3. Test bleed points are left open after tests to allow fluid to boil off.
Notes: 1. Annulus Valve testing shall be carried out using the test pressure applied to
the annuli or in conjunction with the annulus pressure containment test where
possible.
2. Test the outer valve(s) first, then inner or only.
1) Function-test all Annulus valves in accordance with the relevant Wellhead Maintenance
Guide.
2) Close the respective Annulus valve to be tested.
3) Bleed down the downstream side of the valve to be tested to as near zero as possible
maintain some positive pressure on the gauge.
4) Record the test Start pressure in the WIMS Checklist.
5) Measure the pressure build-up downstream of the valve to be tested over 10 minutes
using the installed pressure gauge.
6) Record the test Finish pressure in the WIMS SIT Checklist.
7) If the test result is within the Allowable Leak Rate for the tested valves size then record
the result as Pass with Start and Finish pressures in the WIMS SIT Checklist; record
the number 1 in the Number of Tests done field.
8) If the test results in a Fail on the first attempt, grease and cycle the valve and re-test it
until a Pass test result is achieved or no improvement in results is seen.
9) Record the final test (last test carried out) result in the WIMS SIT Checklist including
Start and Finish pressure and number of tests done.
Note: Repeat this Procedure for all annulus valves fitted as per the instruction in Note 2
above.
2.2.4.6.4 SIT Task Leak off test Surface Casing Wellhead Connection Void
WELL TYPE 4SIT
TASK CODE SCWC
TASK DECRIPTION Leak off test Surface Casing Wellhead Connection Void (if fitted)
1) Identify the Cavity testing port as per the relevant Wellhead Maintenance Guide.
2) Install the Universal Bleeder Tool and Testing Manifold complete with a recording gauge
on the test port.
3) Stab the Cavity testing port and record the pressure found as Start pressure in the WIMS
SIT Checklist.
4) Bleed off the void pressure to zero.
5) Close in the Bleeder port and monitor the build-up for 10 minutes.
6) Record the final pressure as Finish pressure in the WIMS SIT Checklist.
7) Bleed off test pressures and leave bleed point open.
Notes: 1. Where pressure is found in the void, which cannot be bled off, recommend an
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Annulus Investigation.
2. Where Casing and void Start and Finish pressures are zero, the test is
recorded as Pass in the WIMS SIT Checklist.
3. Test bleed points are left open after tests to allow fluid to boil off.
2.2.5.1.2 H2S
Well Type 1, High Risk Wells, comprises H2S wells. This Chapter highlights the particularities
relating to H2S wells and provides links to Reference Documents.
1) Comply with all items outlined in SP-1219, Drilling Specification Hydrogen Sulphide.
2) A calibrated pressure gauge fitted to the tree cap with bleed facility (in line with H2S
controls) maybe bled off to the outside fence downwind of the work area.
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occurred before the valve has equalised; therefore this method is deemed to be a
valid test method.
5) Where no pressure exists for testing, the annuli have to be topped up with the fluid
stipulated in WIMS.
6) The pressure to be applied to the annuli shall be as per Table 2-3 above.
Note: Where the observed annulus pressure is above MAASP, a full annulus
investigation will be instigated by the WIMS.
i. Where the above applies, the test shall be suspended until an annulus
investigation has been completed.
j. Ensure that the tubing, annulus and the wellhead void pressures are captured
before leaving the worksite; this data is required as background information to
base the annulus investigation upon.
7) The Pressure Measurement Method shall be Pressure Build-up within an enclosed volume
for valve tests and Bleed-off from an enclosed volume for annulus tests.
Note: Where pressure cannot be maintained in the annulus, cycling and maintaining only
(greasing or lubricating) of the annulus valve(s) shall be deemed a test Pass.
8) Hook up Chicksan lines to the annuli valves.
9) Record the CITHP and all annular pressures as found in the WIMS Checklist.
10) The tests and the work to be carried out are defined, for each individual well type, in
the Well Failure Model, in the worksheet titled Well Integrity Testing/ Maintenance
Matrix (ensure work is carried out based on the approved version of the Well Failure
Model).
11) Tests must be carried out in the order stated below as the valve status is assumed
as left from the previous test
12) Valves must not be greased before testing. Valve maintenance will be carried out
after the initial test, not before (irrespective of whether the test results is a pass or
fail), this to allow the condition as found to be analysed in terms of failure rates for
both as found and as left conditions. 13
2.2.5.4 Testing
2.2.5.4.1 SIT Task Check no external leaks
WELL TYPE 5 SIT
TASK CODE ELCS
TASK DESCRIPTION Check no external leaks
1) Check all gaskets, flanged, bolted connections and packings for leakage and rectify as
required.
2) Measure and record all annulus pressures and the closed in tubing pressure (CITHP).
Note: Pressure within bolted or flanged connections must be bled off prior to attempting to
pull up any minor weeps
13 If the number of tests performed and recorded in WIMS equals 1 the condition as found can be concluded to have
been within limits. The data obtained in this manner will allow analysis of valve performance with a view to establishing
the appropriate long-term maintenance frequency.
2.2.5.5 Testing
2.2.5.5.1 SIT Task Pressure Containment Test A annulusulus
WELL TYPE 5 SIT
TASK CODE APT
TASK DESCRIPTION Pressure Containment Test A Annulus
Note: Whilst carrying out all steps of the test below, monitor the adjacent annuli for pressure
communication effects and report any observations in the Free text area in the WIMS
SIT Checklist. Abort any test if communication between annuli and/ or the tubing may
result in any annulus MAASP being breached.
1) Bleed off any pressure in all annuli to as low as practical above zero in order to remove any
gas caps that may have formed.
Note: If it is not possible to bleed down the annulus, abort the test and initiate an
annulus investigation.
2) Lubricate all annuli to surface using the fluid stipulated in WIMS, recording volumes
pumped in the WIMS SIT Checklist.
Note: Where it is not possible to fill the annulus, ensure that 110% of the annular
volume has been added prior to aborting the test on that particular annulus.
3) Pressure up the A annulus to the test pressure stated in Table 2-3 above.
Note: Where it is not possible to achieve the required test pressure, record this fact in
the Free text area in the WIMS SIT Checklist, recommending further
investigation and continue with the test below.
4) Allow the pressure to stabilise for 10 mins
5) Record and enter the Start pressure in the WIMS SIT Checklist.
6) Monitor the pressure for 30 minutes.
7) Record the Test Finish pressure in the WIMS SIT Checklist.
8) Record the test result as Pass or Fail in the WIMS SIT Checklist.
Notes: 1. The Allowable Leak Rate must be calculated using the formula provided in
the Well Failure Model Subsurface Leak Rates in the Allowable leak rates
sheet.
2. The annular volume must be calculated in m3 based on the Packer Depth.
3. Where the Top of Cement is unknown, use the casing shoe depth in the
calculation as the resulting Allowable Leak Rate will be more conservative.
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2.2.5.5.13 SIT Task Leak off test Tree to tubing head/ Adaptor Flange Connection if
fitted
WELL TYPE 5 SIT
TASK CODE TTCS
TASK DECRIPTION Leak off test Tree to tubing head/ Adaptor Flange Connection if
fitted
1) Identify the Cavity testing port as per the relevant Wellhead Maintenance Guide.
2) Install the Universal Bleeder Tool and Testing Manifold complete with a recording gauge on
the test port.
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2.2.5.5.14 SIT Task Leak off test Adaptor Flange to Tubing Head Connection if fitted
WELL TYPE 5 SIT
TASK CODE ATC
TASK DECRIPTION Leak off test Adaptor Flange to Tubing Head Connection if fitted
1) Identify the Cavity testing port as per the relevant Wellhead Maintenance Guide.
2) Install the Universal Bleeder Tool and Testing Manifold complete with a recording gauge on
the test port.
3) Stab the Cavity testing port and record the pressure found as Start pressure in the WIMS
SIT Checklist.
4) Bleed off the void pressure to zero.
5) Close in the Bleeder port and monitor the build-up for 10 minutes.
6) Record the final pressure as Finish pressure in the WIMS SIT Checklist.
Notes: 1. Where pressure is found in the void, which cannot be bled off, recommend an
Annulus Investigation.
2. Where Adaptor Flange and Tubing and void Start and Finish pressures are
zero, the test is recorded as Pass in the WIMS SIT Checklist.
2.2.5.5.15 SIT Task Leak off test Surface Casing Wellhead Connection Void
WELL TYPE 5 SIT
TASK CODE SCWC
TASK DECRIPTION Leak off test Surface Casing Wellhead Connection Void
1) Identify the Cavity testing port as per the relevant Wellhead Maintenance Guide.
2) Install the Universal Bleeder Tool and Testing Manifold complete with a recording gauge on
the test port.
3) Stab the Cavity testing port and record the pressure found as Start pressure in the WIMS
SIT Checklist.
4) Bleed off the void pressure to zero.
5) Close in the Bleeder port and monitor the build-up for 10 minutes.
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2.2.6 Well Types 6 and 7 (Water Injection/ Disposal wells with/ without tubing)
The testing frequencies are as per SP-2017, Well Failure Model
2.2.6.1 Safety Precautions
1) Perform tool box talks as per PDOs Toolbox Talk Prompt Card.
2.2.6.1.1 Permit to Work
Ensure that PR-1172, Permit to Work Procedure is followed.
2.2.6.1.2 H2S
Well Type 1, High Risk Wells, comprises H2S wells. This Chapter highlights the particularities
relating to H2S wells and provides links to Reference Documents.
1) Comply with all items outlined in SP-1219, Drilling Specification Hydrogen Sulphide.
2) A calibrated pressure gauge fitted to the tree cap with bleed facility (in line with H2S
controls) maybe bled off to the outside fence downwind of the work area.
5) Where no pressure exists for testing, the annuli have to be topped up with the fluid
stipulated in WIMS.
6) The pressure to be applied to the annuli shall be as per Table 2-3 above.
Note: Where the observed annulus pressure is above MAASP, a full annulus
investigation will be instigated by the WIMS.
k. Where the above applies, the test shall be suspended until an annulus
investigation has been completed.
l. Ensure that the tubing, annulus and the wellhead void pressures are captured
before leaving the worksite; this data is required as background information to
base the annulus investigation upon.
7) The Pressure Measurement Method shall be Pressure Build-up within an enclosed volume
for valve tests and Bleed-off from an enclosed volume for annulus tests.
Note: Where pressure cannot be maintained in the annulus, cycling and maintaining only
(greasing or lubricating) of the annulus valve(s) shall be deemed a test Pass.
8) Hook up Chicksan lines to the annuli valves.
9) Record the CITHP and all annular pressures as found in the WIMS Checklist.
10) The tests and the work to be carried out are defined, for each individual well type, in
the Well Failure Model, in the worksheet titled Well Integrity Testing/ Maintenance
Matrix (ensure work is carried out based on the approved version of the Well Failure
Model).
11) Tests must be carried out in the order stated below as the valve status is assumed
as left from the previous test
12) Valves must not be greased before testing. Valve maintenance will be carried out
after the initial test, not before (irrespective of whether the test results is a pass or
fail), this to allow the condition as found to be analysed in terms of failure rates for
both as found and as left conditions. 14
2.2.6.4 Testing
2.2.6.4.1 SIT Task Check no external leaks
WELL TYPES 6 AND 7 WIT
TASK CODE ELCS
TASK DESCRIPTION Check no external leaks
1) Check all gaskets, flanged, bolted connections and packings for leakage and rectify as
required.
2) Measure and record all annulus pressures and the closed in tubing pressure (CITHP).
Note: Pressure within bolted or flanged connections must be bled off prior to attempting to
pull up any minor weeps
14 If the number of tests performed and recorded in WIMS equals 1 the condition as found can be concluded to have
been within limits. The data obtained in this manner will allow analysis of valve performance with a view to establishing
the appropriate long-term maintenance frequency.
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2.2.6.5 Testing
2.2.6.5.1 SIT Task Pressure Containment Test A annulusulus
WELL TYPES 6 AND 7 SIT
TASK CODE APT
TASK DESCRIPTION Pressure Containment Test A Annulus
Note: Whilst carrying out all steps of the test below, monitor the adjacent annuli for pressure
communication effects and report any observations in the Free text area in the WIMS
SIT Checklist. Abort any test if communication between annuli and/ or the tubing may
result in any annulus MAASP being breached.
1) Bleed off any pressure in all annuli to as low as practical above zero in order to remove any
gas caps that may have formed.
Note: If it is not possible to bleed down the annulus, abort the test and initiate an
annulus investigation.
2) Lubricate all annuli to surface using the fluid stipulated in WIMS, recording volumes
pumped in the WIMS SIT Checklist.
Note: Where it is not possible to fill the annulus, ensure that 110% of the annular
volume has been added prior to aborting the test on that particular annulus.
3) Pressure up the A annulus to the test pressure stated in Table 2-3 above.
Note: Where it is not possible to achieve the required test pressure, record this fact in
the Free text area in the WIMS SIT Checklist, recommending further
investigation and continue with the test below.
4) Allow the pressure to stabilise for 10 mins
5) Record and enter the Start pressure in the WIMS SIT Checklist.
6) Monitor the pressure for 30 minutes.
7) Record the Test Finish pressure in the WIMS SIT Checklist.
8) Record the test result as Pass or Fail in the WIMS SIT Checklist.
Notes: 1. The Allowable Leak Rate must be calculated using the formula provided in
the Well Failure Model Subsurface Leak Rates in the Allowable leak rates
sheet.
2. The annular volume must be calculated in m3 based on the Packer Depth.
3. Where the Top of Cement is unknown, use the casing shoe depth in the
calculation as the resulting Allowable Leak Rate will be more conservative.
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2.2.6.5.13 SIT Task Leak off test Tree to tubing head/ Adaptor Flange Connection if
fitted
WELL TYPES 6 AND 7 SIT
TASK CODE TTCS
TASK DECRIPTION Leak off test Tree to tubing head/ Adaptor Flange Connection if
fitted
1) Identify the Cavity testing port as per the relevant Wellhead Maintenance Guide.
2) Install the Universal Bleeder Tool and Testing Manifold complete with a recording gauge on
the test port.
3) Stab the Cavity testing port and record the pressure found as Start pressure in the WIMS
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2.2.6.5.14 SIT Task Leak off test Adaptor Flange to Tubing Head Connection if fitted
WELL TYPES 6 AND 7 SIT
TASK CODE ATC
TASK DECRIPTION Leak off test Adaptor Flange to Tubing Head Connection if fitted
1) Identify the Cavity testing port as per the relevant Wellhead Maintenance Guide.
2) Install the Universal Bleeder Tool and Testing Manifold complete with a recording gauge on
the test port.
3) Stab the Cavity testing port and record the pressure found as Start pressure in the WIMS
SIT Checklist.
4) Bleed off the void pressure to zero.
5) Close in the Bleeder port and monitor the build-up for 10 minutes.
6) Record the final pressure as Finish pressure in the WIMS SIT Checklist.
Notes: 1. Where pressure is found in the void, which cannot be bled off, recommend an
Annulus Investigation.
2. Where Adaptor Flange and Tubing and void Start and Finish pressures are
zero, the test is recorded as Pass in the WIMS SIT Checklist.
2.2.6.5.15 SIT Task Leak off test Surface Casing Wellhead Connection Void
WELL TYPES 6 AND 7 SIT
TASK CODE SCWC
TASK DECRIPTION Leak off test Surface Casing Wellhead Connection Void
1) Identify the Cavity testing port as per the relevant Wellhead Maintenance Guide.
2) Install the Universal Bleeder Tool and Testing Manifold complete with a recording gauge on
the test port.
3) Stab the Cavity testing port and record the pressure found as Start pressure in the WIMS
SIT Checklist.
4) Bleed off the void pressure to zero.
5) Close in the Bleeder port and monitor the build-up for 10 minutes.
6) Record the final pressure as Finish pressure in the WIMS SIT Checklist.
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2.3.1 Well Type 1 (High Pressure Wells or high GLR or H2S Wells)
2.3.1.1 SIT Maintenance Task Carry out Visual Inspection
WELL TYPE 1SIT MAINTENANCE
TASK CODE VIS
TASK DECRIPTION Carry out Visual Inspection
1) Visually inspect all wellhead components and report any anomalies or unacceptable
degradation through free text format area of the SIT Checklist suggesting possible remedies
required.
2) Visually inspect wind socks and other related well site safety equipment; report anomalies
and replace equipment as required.
Note: As this section is open to interpretation and has no clear pass or fail criteria it is
important to describe the problem noted clearly to allow the Well Integrity
Engineer to make the decision whether to request follow-up repair or not.
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2.3.2 Well Type 2 (Free Flowing Low Pressure Oil Wells, < 20,000 kPa)
2.3.2.1 SIT Maintenance Task Carry out Visual Inspection
WELL TYPE 2 SIT MAINTENANCE
TASK CODE VIS
TASK DECRIPTION Carry out Visual Inspection
1) Visually inspect all wellhead components and report any anomalies or unacceptable
degradation through free text format area of the SIT Checklist suggesting possible remedies
required.
2) Visually inspect wind socks and other related well site safety equipment; report anomalies
and replace equipment as required.
Note: As this section is open to interpretation and has no clear pass or fail criteria it is
important to describe the problem noted clearly to allow the Well Integrity
Engineer to make the decision whether to request follow-up repair or not.
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2.3.6 Well Types 6 and 7 (Water Injection/ Disposal wells with/ without tubing)
2.3.6.1 SIT Maintenance Task Carry out Visual Inspection
WELL TYPES 6 AND 7 SIT MAINTENANCE
TASK CODE VIS
TASK DECRIPTION Carry out Visual Inspection
1) Visually inspect all wellhead components and report any anomalies or unacceptable
degradation through free text format area of the SIT Checklist suggesting possible remedies
required.
2) Visually inspect wind socks and other related well site safety equipment; report anomalies
and replace equipment as required.
Note: As this section is open to interpretation and has no clear pass or fail criteria it is
important to describe the problem noted clearly to allow the Well Integrity
Engineer to make the decision whether to request follow-up repair or not.
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3) Carry out routine gate valve maintenance on all gate valves, involving the injection of
grease into the valve body cavity, greasing the stem bearings and injection of sealing
compound, as specified in manufactures' maintenance procedures
Whilst lubricating the body cavities and stem bearings of all wellhead valves, ensure that
the master and swab valves are locked open to prevent fouling of the pump rods. Also,
one of the 'A' annulus valves may be the exit point for a stainless steel PTS line, this
should not be closed either
4) Observe the operation of the pump and note any unusual noise or vibration.
5) Record the amperage drawn by the pump motor.
6) Switch off and lock the power switch near the pump motor ensuring that the pump is
stopped with the counterweights at their lowest position.
7) Isolate and lock off at the control panel the electrical supply. This must be done by the
Competent Electrical Person who will sign the Isolation Certificate to that effect.
8) Record the following information for the beam pump unit:
Pump : Manufacturer's name and serial number
Gearbox : Manufacturer's name and serial number
V-belt type
V-belt pulley size
Counterweight position
Stroke length
1) Apply the mechanical lock, if fitted, or secure the counterweight to the pump base with
chains or wire rope
2) Close the BOP rams around the polished rod.
3) Check the oil level in the gearbox and check the gearbox for evidence of oil leaks. Collect a
sample of oil from the gearbox in a container and label it with the well number, date and
point of collection.
4) Clean the breather on the gearbox, if fitted.
5) Check the alignment of the horse head.
6) Check the tension, alignment and condition of the V-belts and, if necessary, adjust the
tension or alignment by moving the jacking bolts on the motor.
7) Check the condition and tightness of the brake rod/cable and adjust it if necessary,
according to the instructions in the manufacturer's service manual.
8) Grease all the bearings.
9) Check the tightness of all the hold-down bolts.
10) Apply lubricant to the wire rope of the carrier bar sling.
11) Check the alignment of the polished rod with a spirit level and adjust it as necessary by
moving the jacking bolts on the horse head or frame.
12) Check the condition of polished rod stuffing box and replace if necessary with New packing.
13) Inspect the Victraulic joint, if fitted.
14) Open the rams on the polished rod BOP and disengage the mechanical lock or remove the
restraining chains from the counterweight.
15) De-isolate the electrical supply at the control panel. This has to be done by the Competent
Electrical Person who will sign to this effect on the Isolation Certificate.
16) Remove the lock from the power switch near the pump motor and switch on the pump.
Monitor the operation of the pump to check there is no abnormal noise or vibration.
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17) Adjust the polished rod stuffing box packing to give optimum sealing without leaking or
binding
18) Return all valves, especially valves closed for isolation purposes, to their original status, as
found upon commencement of the maintenance
19) Report any changes to the status of the wellhead and any safety hazards encountered on
the Well Location Custodianship Transfer Form and inform the Well Services Supervisor.
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sand or oil fill - the Asset Team shall be informed if cellar requires clearing of sand
or oil. The Contractor shall carry out this if instructed by the Company in
accordance with the contract.
10) All flange studs and nuts shall be checked to see that they are in place, properly made-up
and fully engaged with the studs. Lose studs shall only be made-up after it has been
confirmed that the ring joint is fully de-pressurised.
11) All bull plugs, needle valves and pressure gauges shall be checked for correct make-up and
tightened if necessary before opening any upstream wellhead gate valves.
12) If installed, the condition and fixtures of the working platform shall be checked for integrity.
13) The tubing and annulus pressures shall be measured and recorded. If either the 'B' or 'C'
annulus pressures are greater than 500 kPa they shall be bled down below 500 kPa,
providing this can be achieved within a few minutes. This shall be done initially via the flow
line then by a line to the downwind side the well site to the point when liquids are produced,
only.
If the annulus pressures cannot be easily bled down this shall be reported with a
recommendation for the provision of additional equipment, e.g. tanks, etc., or the need for
further investigation of the problem leading to the possibility of a workover in the severest
cases.
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The following equipment checks must therefore be completed before commencing change-out
of the Christmas Tree:
A. Crane Driver:
Check that the crane driver has a valid license authorizing him to operate the size and type of
crane to be used, and that he is competent to do so.
Discuss the method of signaling to be used. Assign a single person to give signals to the crane
driver, and check that the crane driver understands the signaling.
Prior to moving the crane onto the wellhead area discuss the positioning of the crane with the
driver, and brief him on the danger of hitting the Christmas Tree. He must never reverse directly
towards the Christmas Tree.
Brief the crane driver to limit the lifting height of the Christmas Tree to the required minimum
over the wellhead.
The Christmas Tree will therefore be lowered to one side of the wellhead to the approximate
height required, and then swung round over the wellhead. This is a precautionary measure to
limit impact in the event of a lifting equipment failure.
B. Crane:
Check the certification of the crane to ensure it is valid, and rated for the load to be lifted at the
required radius. Check that the crane appears to be in good condition and fit for purpose. The
crane driver will carry out a functional check of the crane before starting operations.
The Well Services Supervisor must be aware of the location of a back-up crane in the area, to
be made available for emergency use in the event of a crane breakdown, as the Christmas Tree
must not be left off the well for a prolonged period.
A. CF-13 Ring Joint, SRL Seal, Flange Ring Joints, Studs & Nuts:
As a new CF-13 ring joint will be fitted to the wellhead for the replacement Christmas Tree, two
of these will be available on site.
As a new SRL seal will be fitted to the tubing for the replacement Christmas Tree, two of these
will be available on site.
Five ring joints type BX- 169 are to be available on site for the 5-1/8" 10,000 psi Christmas Tree
flanged outlets. (3 may be required leaving 2 spare)
Twenty four (24) spare stud bolts size 9-1/4" x 1-1/8" 8 TPI, and forty eight (48) spare nuts size
1-1/8" 8 TPI will be available on site, should it be necessary to replace those on the flanged
outlets. Flogging wrenches for the 1-1/8" nuts and for the Fastlock hub nuts are also required,
and must be checked for fit prior to commencing operations.
B. Hook-up of High Pressure Pump, Choke & Vent Line (See Drawing Appendix 1)
An high pressure pump is required on site for pressure testing the Monolock and HE-3- type
tubing barrier isolation plugs, for equalizing pressure prior to removing the prongs from these
plugs, and for pressure testing the replacement Christmas Tree body, using inhibited water. The
pump will be hooked up by rigid steel hoses (Chiksans) to the KWV (kill wing valve), as outlined
in hookup drawing Appendix 1. Also required in the hookup is a manual choke and vent line to
pit or other safe area, to enable controlled bleed down of the tubing pressure for inflow testing
the lower Monolock plug.
The line from the pump truck to the KWV, choke and vent shall be wired down and pressure
tested to 60,000 kPa for 15 minutes as per standard hook-up and pressure testing procedures.
The vent line to pit shall be restrained by use of a concrete saddle block, placed over the top of
the vent line at the end, after which the vent line will be wired to the block to prevent pressure
whipping.
A water tanker will be required on site with +/- 10 m3 inhibited water (with oxygen scavenger) for
pressure testing, and filling the tubing above the Monolock plugs.
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D. Installation, Inflow Testing & Pressure Testing of Monolock Plug Tubing Isolation
Barriers
Isolation from the formation will be achieved by setting a Monolock type Bridge plug in the 4-
1/2" tubing at a depth of +/- 250m (55 m if TRSCSSSV installed). The Monolock plug is
designed to withstand differential pressure of up to 10,000 psi (69,000 kPa) from either
direction, and is retained in position by slips rather than keys. The sealing element is located
above the slips, preventing any debris accumulation around the slip area. The Monolock plug
will be inflow tested against full reservoir pressure by depressurizing the tubing above it to
0 kPa, and monitoring the pressure for 4 hours. It will then be pressure tested from above to
CITHP + 2,000 kPa (or 35,000 kPa, whichever is greater) for 1 hour using inhibited water with
oxygen scavenger.
A second Monolock type Bridge plug will be set at 50 m (25m if TRSCSSSV installed), and
pressure tested from above to CITHP + 2,000 kPa (or 35,000 kPa, whichever is greater) for 1
hour using inhibited water with oxygen scavenger. This pressure test should be done through
the tree cap, using a small volume pump fed from a calibrated reservoir tank. This will enable
measurement of the exact volume pumped in relation to the theoretical volume required,
thereby making it easier to observe if the plug leaks.
Run and set the lower and upper Monolock plugs as follows:
1) Rig up WL Lubricator to tree cap, with Monolock drift inserted, and pressure test lubricator
to CITHP + 2,000 kPa (or 35,000 kPa, whichever is greater) against Swab valve for 15
minutes. If the Swab valve is leaking use of a secondary Swab valve will be required.
2) RIH full bore Monolock drift in 5-1/2" tubing to 350 m. POOH.
3) Make-up WL lubricator with Monolock body to tree cap, and pressure test lubricator to
CITHP + 2,000 kPa (or 35,000 kPa, whichever is greater) against closed Swab valve for 15
minutes
4) RIH Monolock body with DPU & Running Tool and set in 5-1/2" tubing at +/- 250m (55m if
TRSCSSSV installed). Stand by for 1 hour whilst the DPU activates. POOH DPU & Running
Tool.
5) RIH Monolock prong and set in Monolock body. POOH running tool.
6) Inflow test Monolock, plug by bleeding down tubing slowly to zero pressure in a controlled
manner, through the manual choke and vent line. When zero pressure has been achieved
and conditions are stable, monitor and record the pressure for a period of four hours.
Should a pressure fluctuation occur during this period re-establish a stable zero pressure
condition and repeat the four hour monitoring and recording period, until an acceptable test
is achieved. The Monolock inflow test must be accepted by the Well Services Supervisor, in
which case a copy of the inflow test chart must be sent to him by fax.
7) RIH Monolock body with DPU & Running Tool and set in 5-1/2" tubing at +/- 50m (25m if
TRSCSSSV installed). POOH DPU & Running Tool.
8) RIH Monolock prong and set in Monolock body. POOH running tool and rig down WL
lubricator.
9) Using the high pressure pump and inhibited fresh water fill the tubing above the upper
Monolock plug by pumping +/- 2.5 m3 (+/- 0.25 m3 if plug set at 25m) through the KWV,
whilst venting through the Swab valve until all the air is displaced. (Tubing volume +/- 1 m3
per 100 m of 5-1/2" 26 lbs/ft tubing)
10) Pressure test the upper Monolock plug to CITHP + 2,000 kPa (or 35,000 kPa, whichever is
greater) for 1 hour, and monitor / record the pressure on a chart recorder. This pressure test
should be done through the tree cap, using a small volume pump fed from a calibrated
reservoir tank. This will enable measurement of the exact volume pumped in relation to the
theoretical volume required, thereby making it easier to observe any plug leakage.
The Monolock pressure test must be accepted by the Well Services Supervisor, in which
case a copy of the pressure test chart must be sent to him by fax.
If the pressure test is acceptable, Christmas Tree replacement may commence.
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8) Break the flange on the downstream side of the Flow wing valve and restrain the flow
line to prevent it fouling the tree during removal.
9) Position the crane, fit slings to the Christmas Tree and take up the slack in the lifting
cable.
10) Break the flange at the base of the Christmas Tree and remove the tree from the
wellhead. Stand well clear of the Christmas Tree while it is being lifted off the wellhead.
11) Fit a new ring gasket in the groove on the top of the tubing spool then pick up the
replacement Christmas Tree and lower it into position. Make up the flange at the base
of the Christmas Tree.
12) Close the Flow wing valve and kill valve and open the master valve(s).
13) Fill the Christmas Tree with water and connect the air-operated pump to the swab cap
needle valve. Pressure-test the bottom flange connection and Christmas Tree assembly
to rated working pressure for 30 minutes. Record the test on a chart recorder.
14) Disconnect the pressure testing equipment and make up the flow line flange.
15) Pressure test the flow line.
16) Rig up the BPV lubricator and retrieve the two way check valve. Rig down the BPV
lubricator.
17) Equalize the pressure across the isolation plug and retrieve same.
18) Re-install the swab cap. Leave the Christmas Tree with the master valve(s) open and
the swab, kill and Flow wing valves closed.
19) Inflow Testing Christmas Tree Valves: Now that full wellhead pressure is available the
pressure integrity of the LMGV, UMGV, FWV, KWV and Swab valve must be tested. To
test these valves refer to Chapter 2.1.2 above Ensure that all tests are chart recorded.
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11) Close the Flow wing valve and kill valve and open the master valve(s).
12) Fill the Christmas Tree with water and connect the air-operated pump to the swab cap
needle valve. Pressure test the bottom flange connection and Christmas Tree assembly to
rated working pressure for 30 minutes. Record the test on a chart recorder.
13) Disconnect the pressure testing equipment and make up the flow line flange.
14) Pressure test the flow line.
15) Rig up the BPV lubricator and retrieve the two way check valve. Rig down the BPV
lubricator and re-install the swab cap. Leave the Christmas Tree with the master valve(s)
open and the swab, kill and Flow wing valves closed.
Note: In case of solid block Christmas Tree, the P-seals of Christmas Tree bottom
flange needs to be de-energised before lifting the tree off the wellhead. The
same seals need to be energised and pressure tested to 30 minutes on the
new Christmas Tree. Haskel pump or a hand pump may be used for testing.
Note: For Medium Risk wells refer to SP-1217, Well Control Barrier Specification,
Chapter 2.3.1 .
25) Body test Christmas Tree to 60,000 kPa for 30 minutes as per Cameron procedure and
chart record the test. Standard precautions for pressure testing and safeguarding the area
to be observed.
26) Make-up FWV flange to flow line. Fill the system with inhibited fresh water, vent off air and
pressure test connection using the HT-400 pump, pumping through the Christmas Tree
against the closed HIPPS valve.
A. Bearing Inspection
1) Remove bonnet cap (with valve open or shut).
2) Pull off front race and needle bearing.
3) Inspect for corrosion or damage to race.
4) Inspect for freedom of movement of needle rollers. If front bearing is satisfactory refit and
replace the BONNET CAP.
5) If the front race and needle bearing is defective and inner race and bearing is suspect the
following procedure should be followed: - Remove pin and stem adapter and replace back
bearing.
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3) If after a reasonable length of time pressure is still evident, do not continue but inform the
Wellhead Maintenance Foreman.
4) Remove hand wheel, bearing cap, stem to adapter pin, bearings, adapter and packing
gland. (Do not stand in front of valve).
5) Inject grease through injection point until stem packing comes out. (alternately packing
puller may be used)
6) Clear out grease from housing completely and replace a new J-packing half way inside the
housing.
C. Refit Assembly
1) With new J-packing inserted, screw in the gland packing and nip tight.
2) Fit inner race and bearing.
3) Fit stem adapter and drive in location pin.
4) Fit outer race and bearing.
5) Inspect and fit new O-ring if required.
6) Fit bonnet cap and nip tight.
7) Back off valve slightly too un-back seat and nip tight bonnet cap again.
8) Re-grease at all grease points.
9) Refit injection grease cap.
10) Check that the number of turns to fully open the valve is as specified for that type of valve.
A. Minor Repairs
Minor repairs such as replacement of grease fitting and stem bearing on WG model 2200 may
be carried out while the valve is in service under pressure by back-seating the valve and
depressurizing using a stinger tool.
B. Back-seating procedure
Close the valve fully. Back off the bearing cap three turns using a pipe wrench. If the valve is
under pressure the internal pressure should automatically backseat the valve. If not, grab the
hand wheel and pull outward on the stem. This would be approximately 1/8 of movement.
Install Stinger tool on grease fitting and bleed off trapped pressure. Do not attempt to carry out
any repair on valve if the back seating do not seal. (indicated by continued bleed off)
Caution: Trapped pressure may be hazardous depending upon the actual service the
valve has seen.
On 2,000 psi. through 10,000 psi. valves, the body grease fitting are line pipe.
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4) Disassemble the actuator for inspection and accessing the defective parts.
5) Clean thoroughly and replace the defective part/seals.
6) Assemble the actuator.
7) Function test the actuator.
Note : Extreme care should be taken while working on actuators as springs are energised
with control line pressure applied. Only trained personnel may be allowed to work
on actuators. For disassembly refer to manufacturers procedure.
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2.5.3.2.2 FLS Gate Valve Bonnet Grease Fitting & Buried Check Valve Replacement
Two isolation barriers are required and must be in place and tested before removing and
replacing the FLS valve grease fitting or buried check valve in the valve bonnet. Back-seating
the valve and pressure testing the back seat provides one barrier. The other barrier may be
provided by either an inflow tested TRSCSSSV, insertion of a bridge plug at +/- 10 m and inflow
or pressure testing it, or closure of an up-stream tree valve(s), e.g. LMGV when removing
UMGV grease fitting. Where fitted, the buried check valve on newer style trees provides a
barrier if it is pressure tested.
A. Changing out a Grease Fitting on a LMGV with a buried Check Valve, on a well with a
TRSCSSSV
1) Close and inflow test TRSCSSSV. Leave Christmas Tree depressurised
2) Back-seat the valve as follows:
3) Close LMGV fully.
4) Unscrew the four Allan Screws on the bearing cap then unscrew the bearing cap four
complete turns.
5) Turn the hand-wheel clockwise (the closing direction) until the gate firmly contacts the
bottom of the cavity and the stem moves outward, contacting the internal backseat
shoulder.
6) Bump the hand-wheel in the closing direction
7) Pressure Test Effectiveness of Backseat as follows:
8) Fill the Christmas Tree with inhibited water and pressurise to 3,000 kPa. Maintain pressure
9) Remove cap from the grease fitting
10) Trip the ball in the grease fitting check valve by inserting a 1/8" diameter by 3/4" long pin
(bleeder tool) into the run of the fitting.
11) Replace the cap slowly until the ball in the fitting is unseated and the pressure/water
trapped by the back-seating process is released.
12) If pressure/water escapes quickly then stops, the backseat is effective. Depressurise tree
and change out the grease fitting.
Note: If water continues to escape & the pressure drops, the backseat is ineffective.
Backseat the valve again as above and repeat test.
B. Changing out a Grease Fitting on a LMGV without a buried Check Valve, on a well
without a TRSCSSSV
1) Set Bridge plug at +/- 10 m and inflow test to 0 kPa for 30 minutes.
2) Fill tubing with inhibited water and pressurise to 3,000 kPa. Maintain pressure.
3) Remove cap from the grease fitting
4) Trip the ball in the grease fitting check valve by inserting a 1/8" diameter by 3/4" long pin
(bleeder tool) into the run of the fitting.
5) Replace the cap slowly until the ball in the fitting is unseated and any trapped pressure is
released.
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6) If pressure escapes quickly then stops, the buried check valve is effective.
7) Depressurise Christmas Tree to 0 kPa.
8) Change out grease fitting
9) Equalise pressure and remove Bridge plug.
C. Changing out buried Check Valve in LMGV Bonnet on a well without a TRSCSSSV
1) Set Bridge Plug at +/- 10 m and inflow test to 0 kPa for 30 minutes. Leave Christmas Tree
depressurised
2) Backseat LMGV and pressure test effectiveness of backseat by pressurising Christmas
Tree with inhibited water, & stinging grease fitting, as outlined above
3) Remove grease fitting
4) Sting buried check valve with bleeder tool to re-test for trapped pressure
5) Depressurise and change out buried check valve
6) Replace the grease fitting and un-backseat the LMGV
12) Using a punch, drive in the stem and ensure that the pin does not protrude over the OD of
the adapter shoulder.
13) Replace the stem adapter O ring if necessary
14) Inspect the bearing cap to ensure that an extra race, held by grease tension is not retained
inside. Clean and install the cap.
15) Rotate the stem adapter counter clockwise to ensure that the gate is off the bottom of the
body. This will confirm that the stem back seating shoulder is not contacting the bonnet
shoulder. Inject grease through the bearing cap grease fittings until excess grease passes
through the bleed port.
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Note: If the seats are stuck, insert a screwdriver in the groove on the OD of the seats and
pry out the seats.
9) Remove the retainer plate from the bottom of the body cavity.
10) Flush the body cavity thoroughly with a suitable solvent and wipe clean with a rag.
11) Inspect the cavity parts for damage.
12) Ensure that the retainer plate is not bent, twisted, or distorted.
Important: Solid material should not be built up on the retainer plate surfaces.
13) Ensure that the seal rings are not damaged
14) Ensure that the seats are not cut or damaged
15) Ensure that the gate is not cut or damaged.
16) Replace any damaged parts.
17) Ensure that the body cavity is free of all foreign matter such as solid particles, grit, trash,
etc.
18) Clean the body cavity with a suitable cleaning solvent.
19) Apply a thin coat of clean grease to the body cavity, gate, retainer plate, seats, and seat
seal rings.
20) Install the U-shaped retainer plate in the bottom of the body cavity. The flat centre part of
the retainer plate goes against the cavity bottom, and the semi-circular cut-outs must be
aligned with the seat pockets.
21) Install the seal rings into the face groove(s) located in the seats.
Note: The FL valve uses one seal ring per seat; the FLS uses two per seat.
22) Install the seats into the seat pockets.
Note: The grooved seat face with its seal ring(s) goes against the body seat pocket seal
face. Do not apply more than a very thin film of grease to the back face of the seat
and seal ring(s) or the seal face on the body seat pocket.
23) Install the gate into the cavity between the seats.
24) Push the gate all the way to the bottom of the cavity and pack the remaining space with
grease.
25) Remove the seal ring from the bonnet groove.
26) Clean the grooves and/or seating area of the body and bonnet.
27) Apply a very thin film of clean grease to the bonnet seal ring and groove
28) Install the new seal ring in the bonnet groove.
29) Install the bonnet over the body studs.
30) On valves 10,000 psi WP and above, rotate the bonnet until the grease fitting is 90 from
the gate bore.
31) Thread the stem into the gate by turning the hand wheel counter clockwise,
32) Pull the bonnet down over the studs.
33) Hand tighten the bonnet nuts.
34) Ensure that the gate is not on the bottom of the cavity.
35) Evenly tighten the bonnet nuts to a torque of 1,275 ft-lb
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The raised bonnet face on valves 10,000 psi and above will fully contact the body face when the
bonnet nuts are tight
2.6 Procedure for acid soaking to clean Tubing hanger BPV thread
profile
2.6.1 Safety Precautions while attempting acid soak.
1) Ensure a wellhead platform or scaffold is available placed in position for acid handling if the
Christmas tree height is above 1.5 meters.
2) Ensure appropriate PPE are worn by the personnel handling acid (Neoprene gloves,
Rubber apron, plastic gobbles, acid vapour mask, Helmet and Safety Boots)
3) Emergency eye wash station or running water facility available on location.
4) Acid (28% HCL) in plastic container to be transported in wooden box with appropriate
warning sign posted on the box and plastic contained identified as containing acid.
5) Always position yourself upwind while handling acid.
6) Ensure the acid is pumped using a HD plastic hand pump and hose and the end of the hose
is secured to wellhead to prevent hose falling off and spilling acid.
7) Ensure extreme care while handling acid as it can cause severe burning in contact with
skin.
8) Ensure SHOC card is available and displayed.
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REF HAZARD
H-04 Explosives
H-08.05a Equipment with moving / rotating parts (ex drill floor equipment)
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REF HAZARD
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5 Appendices
5.1 Appendix 1, Forms and Reports
The following forms are used in relation to this Procedure:
Step-Out Request Form
Well Location Custodianship Transfer Form
The PDO Site Supervisor will ensure that a Pre-Stimulation Audit Checklist is completed
jointly with the Contractor Stimulation Supervisor, and any shortfalls rectified, before the
stimulation operations commence.
Term/Abbreviation Definition
SIT Subsurface Integrity Test
SV Swab Valve
TRSCSSSV Tubing Retrievable Surface Controlled Subsurface Safety
Valve
UMGV Upper Master Gate Valve
UMV Upper Master Valve
WFM Well Failure Model
WIFP Well Integrity Focal Point
WLICoP CP-118, Well Life Cycle Integrity Code of Practice
WIMS Well Integrity Management System
WIT Wellhead Integrity Test
WR-SCSSSV Wireline Retrievable Surface Controlled Subsurface
Safety Valve
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A. Manual Valve
Stroke the valve 2 3 times to check for correct operation. Refer to table for number of turns for
each size of valve.
Note: Manuals valves must be backed off turn after fully opening or closing to allow the
valve to function properly.
B. Actuated Valve
Function the actuated valve 2 3 times to check for correct operation, and confirm full stroke
via rising stem or visual indicator. Operation should be smooth over full travel of valve in both
directions. Time taken to fully close should be recorded.
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A. Stem Bearings
Stem bearings can be greased while the valve is in the open or closed position, or under
pressure. The grease fitting can be found on the bearing cap of the manual valve bonnet.
Connect the manual grease pump to the bearing cap grease fitting. Pump until clean grease
extrudes from the vent port opposite.
Note : Where possible the valve cavity will be de-pressurised, however, grease may be
injected while the valve is under pressure.
Grease may be injected into manual valves in either the open or closed position, but preferably
in the closed position. Actuated valves must be in the open position while injecting grease. A
suitable valve should be installed inline, preferably close to the grease fitting if access allows.
This will enable the pump to be removed in the event that the check valve does not re-seat.
Valves that are seldom used or do not have fluids flowing past them may not require the full
quantity of grease. To avoid blockages of instrumentation, etc with grease, carefully observe the
pump pressure on these valves, and stop injecting as soon as a noticeable rise in pressure
above the initial injection pressure occurs. If excess grease is a known problem, limit the grease
injection to between 10% and 25% of the recommended capacity, irrespective of the pressure
indications.
1) Close the manual valve and back-off the stem turn.
2) Identify the valve grease fitting, and carefully remove the cap.
Warning: Use a back-up spanner to prevent the grease fitting from backing out of
the bonnet. Trapped pressure may exist under the protective cap of the
grease fitting. Back-off the cap carefully and monitor for pressure. If
pressure exists, then re-tighten the cap and record details.
3) If the well is still pressurised, record the upstream and downstream pressures. This will
determine the pump pressure required to overcome the pressure within the cavity.
4) Connect the grease pump to the fitting and begin to pump the grease until the cavity is
filled. At no time should the total amount of grease pumped exceed the recommended
capacity of the valve.
Warning: At no time should pump pressure exceed the maximum working pressure
of the valve.
5) When the required amount of grease has been injected, the pump air supply should be
isolated, and the injection hose should be vented via the bleeder fitting, prior to removing
from the grease fitting.
Warning: If pressure does not vent off quickly, then the grease fitting internal check
valve has not seated. Attempt to reseat by pumping more grease, but if
unsuccessful, then close the inline valve and remove the pump.
Appropriate physical barriers should be placed around the valve to
protect it from impacts until remedial measures are carried out.
6) Replace the grease fitting cap.
7) Return the valve to its normal operating position, ensuring correct operation and full travel.
8) Repeat steps 2 7 with the remaining valves.
A. Manual Valve
Stroke the valve 2 3 times to check for correct operation. Refer to table for number of turns for
each size of valve.
2 1/16 3 1/8
12 1/3 turns 18 1/8 turns
Note: Manuals valves must be backed off turn after fully opening or closing to
allow the valve to function properly.
B. Actuated Valve
Function the actuated valve 2 3 times to check for correct operation, and confirm full stroke
via rising stem or visual indicator. Operation should be smooth over full travel of valve in both
directions. Time taken to fully close should be recorded.
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A. Stem Bearings
Stem bearings can be greased while the valve is in the open or closed position, or under
pressure. The grease fitting can be found on the bearing cap of the manual valve bonnet.
Connect the manual grease pump to the bearing cap grease fitting. Pump until clean grease
extrudes from the vent port opposite.
Warning: If pressure does not vent off quickly, then the grease fitting internal check
valve has not seated. Attempt to reseat by pumping more grease, but if
unsuccessful, then close the inline valve and remove the pump.
Appropriate physical barriers should be placed around the valve to
protect it from impacts until remedial measures are carried out.
6) Replace the grease fitting cap.
7) Return the valve to its normal operating position, ensuring correct operation and full travel.
8) Repeat steps 2 7 with the remaining valves.
5.4.2 FMC
5.4.2.1 Annulus Valve Maintenance
Routine maintenance entails greasing the valve stem bearings and filling the valve with sealant
or grease as applicable, each time the valve is routinely leak tested. It is recommended that this
is carried out while the respective annulus has been bled down.
These procedures should be used in conjunction with the OEM operation and maintenance
procedures, as well as the following GUIDEXPRO procedures.
Well preparation for Christmas Tree Work
Operation and maintenance of Christmas Trees
A. Manual Valve
Stroke the valve 2 3 times to check for correct operation. Refer to table for number of turns for
each size of valve.
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A. Stem Bearings
Stem bearings can be greased while the valve is in the open or closed position, or under
pressure. The grease fitting can be found on the bearing cap of the manual valve bonnet.
1) Connect the manual grease pump to the bearing cap grease fitting.
2) Pump grease into the bearing cavity, rotating the hand wheel back and forth about a turn
to distribute the grease.
3) Disconnect the grease pump
4) Return the valve to its normal operating position.
Warning: If pressure does not vent off quickly, then the grease fitting internal check
valve has not seated. Attempt to reseat by pumping more grease, but if
unsuccessful, then close the inline valve and remove the pump.
Appropriate physical barriers should be placed around the valve to
protect it from impacts until remedial measures are carried out.
6) Replace the grease fitting cap.
7) Return the valve to its normal operating position, ensuring correct operation and full travel.
8) Repeat steps 2 7 with the remaining valves.
A. Manual Valve
Stroke the valve 2 3 times to check for correct operation. Refer to table for number of turns for
each size of valve.
2 1/16 18 turns
Note: Manuals valves must be backed off 1 full turn after fully opening or closing to
allow the valve to function properly.
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A. Stem Bearings
Stem bearings can be greased while the valve is in the open or closed position, or under
pressure. The grease fitting can be found on the bearing cap of the manual valve bonnet.
Connect the manual grease pump to the bearing cap grease fitting. Pump approximately 15
strokes or until pressure builds up.
Warning: If pressure does not vent off quickly, then the grease fitting internal check
valve has not seated. Attempt to reseat by pumping more grease, but if
unsuccessful, then close the inline valve and remove the pump.
Appropriate physical barriers should be placed around the valve to
protect it from impacts until remedial measures are carried out.
6) Replace the grease fitting cap.
7) Return the valve to its normal operating position, ensuring correct operation and full travel.
8) Repeat steps 2 7 with the remaining valves.
A. Manual Valve
Stroke the valve 2 3 times to check for correct operation. Refer to table for number of turns for
each size of valve.
Note: Manuals valves must be backed off turn after fully opening or closing to allow
the valve to function properly.
B. Actuated Valve
Function the actuated valve 2 3 times to check for correct operation, and confirm full stroke
via rising stem or visual indicator. Operation should be smooth over full travel of valve in both
directions. Time taken to fully close should be recorded.
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A. Stem Bearings
Stem bearings can be greased while the valve is in the open or closed position, or under
pressure.
Connect the manual grease pump to the bearing cap grease fitting. Pump until clean grease
extrudes from either the outer dust seal or the relief port.
Warning: If pressure does not vent off quickly, then the grease fitting internal check
valve has not seated. Attempt to reseat by pumping more grease, but if
unsuccessful, then close the inline valve and remove the pump.
Appropriate physical barriers should be placed around the valve to
protect it from impacts until remedial measures are carried out.
6) Replace the sealant injection fitting cap.
7) Repeat steps 2 7 with the opposite seat.
8) Return the valve to its normal operating position, ensuring correct operation and full travel.
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