This procedure identifies the assembly and test method for all completion sub assemblies.
All assembly and testing shall be performed by persons, who have, as a minimum, undergone indoctrination and been qualified as Functional Test Operator. Assistant(s) shall have undergone indoctrination of new assembly / disassembly personnel.
Two persons shall always be present during testing.
Prior to commencement, an authorised Company representative shall approve the description of each sub assembly in writing. The workshop supervisor shall check equipment lists against the written approval with sub assembly description. This approval shall be retained by the contractor.
Prior to assembly, the workshop personnel shall obtain approved equipment check list and test procedure from the workshop supervisor. Only properly approved equipment check list may be used.
General Completion Assembly Procedure
The general procedure listed below shall apply to all assembly preparation:
1) The length and composition of sub assemblies are largely dictated by available space and handling considerations. All sub assemblies shall be made up and tested onshore at the Cantractor Base(s) for the completion sub assemblies, TRSCSSV and ASV sub assemblies.
2) Every sub assembly shall have a backup available on site eliminating the need for making up sub assemblies offshore.
3) Every sub assembly, complete with suitable thread protectors, shall be transported to the site with the applicable tubing pup joint connection box up, and the applicable tubing pup joint connection pin down. For handling and make up purposes, the pup joints shall be approximately 2 metres long.
Procedure For Completion Testing and Assembling
1) All pressure tests shall be recorded on a chart recorder which will then be attached to the equipment check list to be retained indefinitely by Company.
Test fluid: Soluble oil / water
Duration of test: 15 minutes at 35 bar and 15 minutes at 345 bar
2) All assemblies shall be tested to 345 bar unless otherwise specified.
3) After the pressure test, each assembly shall be drifted with the appropriate API spec. drift. All drift diameters shall be recorded on the equipment check lists. For assemblies with a No Go nipple, a special drift shall be used. All drifts shall be inserted from both above and below the assembly to ensure that no deformation has taken place during make up.
4) All assemblies shall be made up using the Jam system or equivalent. All make up torque-turn and pressure test charts shall be attached to the equipment check lists. The correct torque values shall be verified by the tubing make up company.
5) The torque values shall be as follows:
7" 29# Vam AG (13%Cr) Grade L-80: 12380-13750 - 15120 ft/lbs.
7" 29# New Vam (9Cr 1Mo) Grade L-80: 8460 - 9400 - 10340 ft/lbs.
5 1/2" 23# Vam AG (13%Cr) Grade L-80: 9700 -10000 - 10300 ft/lbs.
5 1/2" 23# New Vam (9Cr 1Mo) Grade L-80: 7170 - 7960- 8750 ft/lbs.
6) The above values are specified and approved by Company.
Be aware that torque values used by Company can differ from manufacturers recommended. Torque values for tubing shall be as per COMPANY recommendation.
7) For non standard or not often used equipment, the actual functioning of equipment and wireline operating tools shall be performed before equipment leaves the contractors site.
Detalied Procedures for preparation of the different sub assemblies are given below.
Tailpipe X-Over Assembly
1) Inspect interior and exterior of each component. Ensure that all threads are clean and free from damage.
2) Ensure that any / all part numbers correspond to the equipment check list.
3) Drift each component with the correct API drift.
4) Apply thread lubricant to box end and by hand make up the connection.
5) Make up all connections to the specified torque value.
6) Drift assembly from above and below.
7) Apply storage grease and install thread protectors.
8) Complete the equipment check list.
Bottom Landing Nipple / Perforated Joint Assembly
1) Inspect interior and exterior of each component. Ensure that all threads are clean and free from damage.
2) Ensure that any / all part numbers correspond to the equipment check list.
3) Drift each component with the correct API drift.
4) Drift the Landing nipple with a special Camco no go drift ( manufactured to tolerances corresponding to the appropriate lock mandrel ).
5) Apply thread lubricant to box end and by hand make up the connection.
6) Make up all connections to the specified torque value.
7) Drift assembly from above and below.
8) Apply storage grease and install thread protectors.
9) Complete the equipment check list.
Bottom Landing Nipple and Packer Assembly
1) Inspect interior and exterior of each component. Ensure that all threads are clean and free from damage.
2) Ensure that any / all part numbers correspond to the equipment check list.
3) Drift each component with the correct API drift.
4) Apply thread lubricant to box end and by hand make up the connection.
5) Make up all connections to the specified torque value.
6) Install steel test pins in the ratchet retainer.
7) Pressure test assembly to 138 bar as per programme.
8) Drift assembly from above and below.
9) Apply storage grease and install thread protectors.
10) Complete the equipment check list and pressure test chart.
Expansion Joint Assembly
1) Inspect interior and exterior of each component. Ensure that all threads are clean and free from damage.
2) Ensure that any / all part numbers correspond to the equipment check list.
3) Drift each component with the correct API drift.
4) Apply thread lubricant to box end and by hand make up the connection.
5) Make up all connections to the specified torque value.
6) Pressure test assembly to 345 bar as per programme.
7) Drift assembly from above and below.
8) Apply storage grease and install thread protectors.
9) Complete the equipment check list and pressure test chart.
Top Landing Nipple Assembly
1) Inspect interior and exterior of each component. Ensure that all threads are clean and free from damage.
2) Ensure that any / all part numbers correspond to the equipment check list.
3) Drift each component with the correct API drift.
4) Apply thread lubricant to box end and by hand make up the connection.
5) Make up all connections to the specified torque value.
6) Pressure test assembly to 345 bar as per programme.
7) Drift the Landing nipple with a special Camco no go drift ( manufactured to tolerances corresponding to the appropriate lock mandrel ).
8) Drift assembly from above and below.
9) Apply storage grease and install thread protectors.
10) Complete the equipment check list and pressure test chart.
Side Pocket Mandrel Assembly
1) Inspect interior and exterior of each component. Ensure that all threads are clean and free from damage.
2) Ensure that any / all part numbers correspond to the equipment check list.
3) Drift each component with the correct API drift.
4) Install dummy/dummies in the side pocket. Note. Install the lower pup joint and protect the upper threads prior to installing the dummy/dummies.
5) Apply thread lubricant to box end and by hand make up the connection.
6) Make up all connections to the specified torque value.
7) Pressure test assembly to 345 bar as per programme.
8) Drift assembly from above and below.
9) Apply storage grease and install thread protectors.
10) Complete the equipment check list and pressure test chart.
11) The relevant procedures used by Otis for all TRSCSSV and ASV sub assembly make up and testing are detailed in the Contractor Service Manual.
X-Over Assembly
1) Inspect interior and exterior of each component. Ensure that all threads are clean and free from damage.
2) Ensure that any / all part numbers correspond to the equipment check list.
3) Drift each component with the correct API drift.
4) Apply thread lubricant to box end and by hand make up the connection.
5) Make up all connections to the specified torque value.
6) Drift assembly from above and below.
7) Apply storage grease and install thread protectors.
8) Complete the equipment check list.
TRSSV and ASV
1) Ref. to detailed procedures in Contractor manual