Components of Hook-up Systems.

These are some materials that may be used for construction of surface safety valve network or hook-up,viz:
1.kerotest needle valve (1/2''x90degree)
2.pressure regulator (1/2x1/4)
3.water drain valve (1/4x1/2)
4.0-25psi pressure guage
5.Regulator valve
6.Nipple 2''x36''
7.Flowline pipe 6''
8.0-5000psi pressure guage
9.Bracket 2''x4''
10.u-valve
11.kerotest needle valve 45x90 (degree)x1/2
12.sigma valve (1/2''x1/4'').
13.Tee joint.1/4''
14. P-pilot 1/2''x1/4''
15. weldolet. 2''x1/2''
16.Dust protector 1/4''
17.Fuse plug
18.Stainless steel connector,1/2''
19.U-valve indicator
20.Pressure relief valve
21.Instrument line1/4''
22.Elbow1/4''
23.Instrument connector 1/2''
24.Flowline flange 6''x14''x36
25.Sigma valve control 1/4''x1/2''
26.Instrument air.
27.Coupling 1/2''x6''
28.Bull plug1/2''x2''

Field Observation of Well Characteristics

This observation is made based on series of activities that were performed in various fields.It will be  interesting to understand that well calibration could be affected by what is called surges. Surges occurs due to the kinetic velocity or energy level of the fluid.The crude oil reservoir is drilled several dept away from the surface and the velocity of crude or oil/gas seem to be affected by this factor.The surging or turbulence effect in the overal calibration process can also lead to a fault, thereby tripped the contromatic system.Sometimes surging in some of the wells are continous while in others, it may be  intermittent and also has lots of effect in the overal operation. The particles that associates with the fluid have some corrosive effect in the mechanical instrumentation materials and the instrument sensors.It is therefore expected that adequate monitoring or routine maintenance be adopted, because it will enhance and provide the necessary information on the condition of the contromatic and the well upkeep. 

The Safety Gate valves components.

1.Hard hand wheels assy.                   24.Spring

2.Bearing cap                                     25.Pin used only on valves under 10,000 psi wp                                                                               

                                                                         

                                                           26.Body

3.Grease fitting                                   27.Name plate

4.O-Ring                                             28.Seal ring 

5.Bearig race                                       29.Bonnect

6.Thrust bearing.                                 30.Check valves,(10,000 psi wp and above) 

7.O-Ring.                                             31.Grease fitting.

8.Stem adapter                                     32.Gaskets

9,Packing gland                                   33.Body bushing 

10.Stem Ring                                       34.Guide

11.Nut                                                  Note: w.p= working pressure,where pressure= force per unit                                                                                       area(N/mm)

12.Stem packing                                                       

13.Stud

14.Stem

15.Gate

16.Retainer plate

17.Seat ring

18.Seal ring

19.Dog

The safety of offshore/onshore field operation/ calibration of wells.

In active participation on offshore and onshore operations, the following safety processes are essential.
1.Ensure that you know the number of items to take along in each operation.
2.Do not forget your communication radio and each operating field activity or platform frequency.
3.while carrying out well calibration on a surging well,make sure you ascertain the surging differential of low and high pressure lines.

4.All items must/should be arrange at a postion/location where it will be easily accessible for             operation.

5.Do not rush or hasten over your plans on the job,but should carefully handle your tooling.
6.Inform your field Supervisor when you are ready for the operation.
7.Radio the production platform on your arrival at the site and after the day's job.
8.Always record your shut-in time and opening of well for production interval.
9.Always pass through the front side of the helicopter to avoid being injured by the fan on the side.
10. Do not step on the rubber stand of the helicopter, a wooden plank is provided for stepping.
11.While in the helicopter remember to put your life jacket and ear muffle and off your phone
     or handset.
12.Do not arrange your working loads on the helideck.
13.Take suitable rope to hold your head-hat in position if it does not have such an attachment.
14.Do not jump steps either up or down. 

How a well calibration is streamlined.

 In most well calibration there are parameters that is expected to be presented to the oil field manager,to enable him have some insight of the well.
A. The name of the field where the activity was peformed must be mentioned and the well number.
The parameters obtained shall be thus:
1.Upstream pressure u/p =2750psi
    Downstream pressure d/s=390psi
    observation: found flowline valve faulty.
Maintenance:re-connected fault.
Re- calibrated p-pilot
                             H= 500psi
                              Lo=130psi
Shut-in-interval = 08.30 - 11.30Hrs
well no. ok. no.4. etc

2.   u/s=3000(psi)   
       d/s=530(psi)
 observation=malfunctioned p-pilot and instrument guage;
 maintenance=replaced p-pilot.
Recalibrated p-pilot needle
                     H=800(psi)
                      L=350(psi)
Shut-in- interval 14.00 - 15.00Hrs. etc 

MODE OF OPERATION

The safety valves system is designed to accomodate stainless steel tubing connections interwoven to form a closed loop. The instrument air from the regulator to the supply inlet of the sigma valve keeps the u-valve permanently open and maintain a pressure in the pilot.The pilot has a calibrated range of low and high and to obtain each parameter for calibration,the flowline pressure has to be determined. Note that the high pressure range is obtained in the wellhead through the crown valve,whereas the low pressure of the well is obtained through the wing valve of the flowline.These classification as low and high  are sometimes refer as downstream and upstream pressure,depending on the operators.Therefore the pilot is calibrated at 75% of the flowline pressures both for low and high, however any variation arising from flow causes a bleed off pressure from the sigma valve.The u-valve is actuated by this variation which the p-pilot transduced.This automatically close the gate of the u-valve actuator,thereby shutting off the flowline.The plug is also for safety purpose,and its action occurs when there is risk of fire in the well.As the temperature of gas and pressure increases. the lead in the fusible plug will met and creates a vent for pressure escape; and automatically the u-valve will be actuated thereby close or shut-in the flow.

Wellhead protective devices.1

3.Sigma Valve:The sigma valve basic function is to bleed off instrument gas or block it depending on  the prevailing circumstance or situation.The signal is tranduced by the sensor (p-pilot),which has a supply inlet and two way outlet to the sigma valve and the u-valve which consist of gasket,plunger,and spring.
4.Fusing Plug:The fusing plug is a mechanical elbow filled with lead and acts as fire safety device because the melting point of lead is less than the ignition temperature of oil/gas.

The wellhead protective sensors.

It consist of valve basic components essentially for the smooth sourcing of the hydro-carbon to the surface reservoir which are as follows:
1.Regulator
2.The fusible plug
3.The p-pilot
4.U-valve

U-Valve:
For the well to flow sucessfully without the presence of the operator at the site there must be a means of ascertaining that the devices in the process network are adequately kept.So the U-Valve function as a security man over the behaviour of well flow processes.when the flow of the flowline is within the calibrated range,the gate of the valve remain open and hydrocarbon passes through it smoothly without any eruption.In an abnormal increase above the set -point or calibrated range of the pressure;the gate is forced to closed,thereby making the entire operation automatically safe.
The P-Pilot: the p-pilot is designed to sense or percieve the pressure abnormalility or change in pressure in the flow lines.The signal is transduced to the u-valve actuator,note that the p-pilot consistof the following components: piston,plunger,torgle valve,spring(low and high tension) and adjustable screw.
Sigma Valve:The basic function of this device is to bleed-off instrument gas or block it based on the percieveable condition.The signal is percieved or transduced by the sensor (p-pilot). It is a three-way
valve with a supply inlet and two outlets to the p-pilot and u-valve,whch consist of gasket, plunger and springway.
Fusible plug:The fusible plug is a mechanical elbow filled with lead and acts as a fire safety device.

Wellhead Maintenance Advantages.

The wellhead also enhance well maintenance advantages and means of servicing all the downhole devices installed in the well such as hydraulic parkers,subsurface safety,production of dual reservoir,opening of sliding sleeves and surface safety valves calibration.It also enable means of pump down techniques and maintenance services through wireline. The well head valves are  produced from high grade alloy casted to resist high pressurs above 0-9,998 to 0-24,750 (psi). allowable minimum and utmost working pressure.

AN BRIEF OVERVIEW OF OIL WELL PROCESSES.

The oil/gas industry is one of the most sophiscated operation where various anciliaries are employed to achieve their goals, and almost all areas of professional fields are involved in order to accomplish what is desirable.Its excellent gearing can not be overemphasied and on the sucessful completion of a drilling rig work , an installation of the well safety devices such as hydraulic packers,surface control subsurface valves (scssv)and the surface safety valves (ssv) are installed for process protection.It is activated when the necessary storage has been provided,then the necessary process network will be enabled to produce and flow through the piping network .However before it may begin to flow a christmas tree has to be install on the well annulus which will be used to control the flow of hydro carbon to the surface reserviour.The making of crude oil requires series of steps.The well-head is therefore installed and as an assembly of valves for controlling the flow on the processes hence creates an enabling system to direct the flow of oil to the surface seperators where oil,gas and water is seperated.So each of the fluid will flow according to their energy level.

Barton-Meter Disassembling.

1.To remove chart plate,push the two chart clips and and carefully remove the plate,
    watch ends to see how they are position.
2.Clock winding is carried out with a key,and is done in the clockwise direction.
3.The chart pen has a clip and it is removable.
4.The barton-meter calibration is usually carried out in the worksop.

Barton Meter Assemblying

1.Mount chart plate to position and clipped.
2.Check pen if it is ok,where otherwise stated,replace pen.
3.Replace chart and position it to zero point(psi),clipped it,
    and ensure that its ends conform to the groove.
4.Replace pen position by displacing it downward of the linkage.
5.Lift up the cover linkage to close and lock knob by turning it clockwise.
6.The instrument line linkage swage lock size is 3/8''.
7.Turn handle anticlockwise to open.
8. Lift the upper linkage to remove pen from  chart.
9.At the centre of the chart,push chart clip and lift it up to remove the chart.

         

Barton meter -Overview.

Differential has double pen arm and linkages at 90 degree centigrade,connected to the barton tube chart and graduated in time/lbs/inch or psi.
The static has only one pen arm.These analysis is being presented in this article as a part of the test carried out after the manfacturing and design of the product.The composition of the barton meter,types of internal components are specified herein.Be it also known that the system of how the calibration of a barton meter is conducted will also be presented.

The barton meter- brief overview.

The device barton-meter is an instrument device, that is used in process line to monitor the flow of fluid along the process network,it is calibrated in low and high pressures and it enables the interpretation of the variance,displacement of the pressure differential and the fluid temperature.In the event of hydrotest some special variable can also be easily interpreted when mounted on the discharge.there two types of barton meter,viz, i) Differential ii) Static. It consist of several components such as the following:
1. A chart plate with clip and other accessories.
2.It has pen link.
3.Linkage
4.Cover
5.A Clock
6.A Chart-pen

confirmation and evaluation.

The materials that are specified in the design and production of the pump are highly recommended and adequate care must be taken in its selection,stainless steel materials will be of utmost advantage.
Many organization in which the pump were used in performing a hydrotest can always attest on its effectiveness, and adequate care must be taken to avoid hydrotesting errors.The design of  the pump is used for hydrotesting of vessels, scrubbers,pipelines and boilers systems.It has been applied in several companies both in manufacturing industries and production company and their requirements were achieved.The pressuring process does not seem to experience any constrain in the sequence of the test,and the range of its performance is within norminal standard, 0 - 5000(psi).if the specified pressure output is converted it will be about,  lb/in2,=1bar=14.6 psi, hence,5000/14.6=342.67lbs/in2.

Design Definition.

 The task may involved additional field requirements and other devices, which can only be easily obtained in the operating field. It therefore imply that a site visit will justify the exact size of device that can be used for such work. Identification of material specifiction is also essential,and a site report because incomplete site requirement could make the task difficult,and poorly performed.viz:
1.Flowline dimension
2,Flange size
3.Size of vessel
4.The pump size and orientation.
5.Mounting.
6.Instrument valve etc.
7.Design drawing
The oil and gas industry whose activity involved almost all facet of engineering  process,, experience
differences in maintenance update and some other application.

Material analysis-1

Discritiontion of materials    Qty                 Materials Specification
1.Twin pressure guage
2.Diaphragm pump
3.Twin pressure regulator
4.Equal Tee
5.Nipple
6.Kerotest needle valve
7.connector3/8''x1/4''x1/2''
8.Bushing 1x1/2'
9.Nipple 1/2''x6'',3/8''x 3/8'',
10.Equal Tee,1/4''x1/4''
11.Tubing connector,1/4x1/8''.
12.Pressure relief valve,1/4''
13.Pressure gauge 1/4''
14, Base plate 2'x4',2'x8'
15.Base stand dxh) etc.,U-clamp,pant.

MATERIALS ANALYSIS.

The materials required for performing hydrotest activities at  the worksite may involved the following:
1.Barton-meter
2.Pressure chart.
3. completeTool-box.
4.Tipe wrench
5.Diaphragm pneumatic water pump.
6.Water reservior
7.Pressure regulator,i/p=60psi, o/p=300psi.
8.Stainless steel tubing materials
9.Kerotest needle valve
10.Pressure relief valve
11. Pressure indicator
12.Twin air regulator
13. Paint

DPR-Reference.

4)All compressed-air recievers shall be drained of liquid daily where the internal surface of the reciever can not be examined and in any event not often less than once every 26months. The reciever shall be tested hydraulically to the recommended test pressures.
5) Gas seperators shall be tested whenever the opportunity occurs and at interval not exceeding five years. They shall be tested to the recommended test pressures which shall not be less than half times the design working pressure.
6)Relieve valves shall be inspected at least once every six months,or at shorter interval as shall be necessary to maintain them in a satisfactory condition to ensure that they operates effectively as soon as the safe working pressure is exceeded.They shall be set to operate at pressure not exceeding ten percent (10%) above the working pressure and shall pass full design quality at the setting.All safety valve shall be stamped or tagged at their set pumping pressure,where appropriate bursting discs may be used in lieu of safety valves.

DPR- Reference- 1

1. Every pressure vessel shall be fitted with a tested presure guage,graduated in pounds per square inch or the metric equivalent and guage pressure shall be checked for accuracy at interval not exceeding six months.
2. All new pipeworks shall be tested in accordance with ASME working pressure befor being put in service. Pipe works shall also be similarly tested when alteration or repairs have been carried out.
3. All pressure vessels and their fitting in use in the oil field installations shall meet the America society of engineers code and as far as their routine inspection and testing are concerned. These shall comply with the requirement of factories acts. A record of such inspection and testing shall be maintained to the satisfaction of Chief petroleum Engineer.In particular,The following matters shall be carried out and recorded (Factory Acts cap.66)

THE ESSENTIAL NEEDS OF THE SURVEY.

There are series of experiments and surveys that are conducted in the fields and the flowstations in which their results are essential for the safety of the production facilities,vessels,coolers and others.The vessels where the crude oil is collected and stored are inspected when their last test date has expired. These survey results are obtained to determine the condition of the storage tanks and the design factors.Every vessels and materials have some specification of the original equipment manufacturer (OEM ),which enable the end user to apply the proper systems of maintenance in the facility.
The original equipment manufacturer (OEM) design specifications may consist of the following.
1) The allowable stress factor.
2) Manufacturer date and year of equipment design.
3) Factor of safety
4) Design materials
5) Manufacturer date of test and the interval/lag.
These are the few factors that are usually inspected in each storage vessels,coolers, and others .  Each item specification shall be defined according their category and specification.

THE STATEMENT OF PROBLEMS.

In every engineering environment, series of technical activities are involved,and in such circumstance absolute care must be taken to avoid unsafe operations for any co-activity, meaning that effective supervision is essential for the sucessful performance of  the task. Other problems might be the following:
1.To determine the possible ways of  the hdrotesting vessels or other anciliaries.
2.To confirm the proficiency of the contractor carryingout the tasks.
3.To carry out surveys of the environment or vicinity where the task will be conducted or position.
4.To determine or differentiate lags in the existing facility.
5.To produce effects and make recommendation of areas of interest.

METHOD OF INSTALLATION OF PNEUMATIC PUMP.

The pneumatic pump is sometimes called the instrument pump because it uses air to fuction, they are of various types.it enhance effective safety measures and simple in design and application.It is also attached a water reservior in its suction, to enhace effective leverage during the transportation phenomena.The essence of pneumatic pump is for easier installation in the facility since usage of air and water is their major operational requirement.The oil company operating in the Nation are technically proven, and the need for a case study on the installation is vital to avoid any technical drawdown,or flaw during such operation.

RECOMMENDATIONS

 The following suggestions are presented for production well:
i) The environment for installation of tree should be carefully checked, to enhance adequate     positioning for maintenance of the wells.
ii) The installation of pits should also be protected aginst falls and accident.
iii) It will be wise to install some pump within the well vicinity for evacaution of water etc.

FINDINGS IN SEQUENCE OF OIL PRODUCTION SURVEY.

i) The two major wellhead facilities are the Cameron and Gray Tree which is mounted on the surface of the well annulus, for conduction of oil/gas production to the surface reservoir.They consist of interrelated valves for control/conducting of the hydro-carbon to the surface reservoir.
ii) The companies hook-up systems are not of the same design and construction.
iii)The hydrotesting of vessels are performed by some specialist companies.

A simple Design of Hydrotesting pump for vessels and comparative study of oil and gas wellhead monitoring process.

The design of a hydro-testing pump for vessels and comparative study of oil/Gas wellhead monitoring process is performed for updates of corrosion effects in vessels and nature of operational field monitoring devices.Though it was conducted as a research project to create better opportunity for effective outcome however, it is conductd as a part of some of the recommendations made by the Directorate of petroleum resources,(DPR).
 Prior to this discussion it will be reasonable to creates few interval and make some simple definitions of terms of reference.
i) Hydro-test means a system of using water to inject into a vessel with the application of  a hydro- test pump designed above the test/calibrated range of  the vessel.
ii) In the process of such activity,the client/DPR/insurance/Specialist representatives are usually involved at the site.
iii)It is performed in conformation of some recommendations to determine the structural granular conditions of the vessel /corrosion allowable factor.etc
iv) On sucessful conclusion of the test a certificate will be issued by DPR.