Choke Manifold Manual [PDF]

Zitiervorschau

No. SKC19W-045 Rev.A1

Wellhead equipment

Manual

Choke/Kill Manifold

www.shenkai.com

《Operation instructions for throttling kill manifold》Rev. A1

Special Notes This manual is applicable to the throttle and kill manifold products of SHANGHAI company.

®

® 、

® 、

are registered trademarks of SHENKAI Company. Any use of other names related to the trade marks herein by any third party for its own purpose will infringe interest of the trade mark owner. Copyright © 2020SHENKAI Company, All rights reserved. Without the express written permission, it is forbidden to copy, transmit or use this manual or part of it. Any violation of the above will be disciplined. All rights, including patent rights, utility model or appearance design patent rights, are reserved. Our Wellhead and Tree Equipment with API 6A andAPI 16C standard requirements, having obtaining the monogram use permit awarded by American Petroleum Institute (API).

SHANGHAI SHENKAI PETROLEUM EQUIPMENT CO., LTD. hereby declares that contents of this manual are verified and compliant with the said hardware and software. Mistakes, however, are unavoidable, so complete consistence can’t be guaranteed. Contents of this manual are subject to periodic review and will be modified in the next version. Your opinions on improvement are welcome. Copyright © 2020 SHENKAI Company. The information in this manual is subject to change without notice. SHANGHAI SHENKAI PETROLEUM EQUIPMENT CO., LTD. After-sale Service Department

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《Operation instructions for throttling kill manifold》Rev. A1

Content 1. Foreword ..................................................................................................3 2. Introduce ..................................................................................................7 3. Structural Features ...................................................................................9 4. Installation and debugging ..................................................................... 11 5. Method of use ........................................................................................17 6. MAINTENANCE AND REPAIR ...............................................................21 7. STORAGE STANDARD .........................................................................23 8. SAFETY PRECAUTIONS ......................................................................26 9. The appended drawings .........................................................................27

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《Operation instructions for throttling kill manifold》Rev. A1

1. Foreword 1.1. General Information This manual is intended for use by field engineering, installation, operation, and repair personnel. Every effort has been made to ensure the accuracy of the information contained herein. however, SHENKAI makes no representation or warranty with respect to the accuracy, completeness or usefulness of the information contained herein. SHENKAI will not be held liable for errors in this material, or for consequences arising from misuse of this material.

1.1.1 Notes, Cautions, and Warnings The manual includes precautions that should be followed to ensure personnel safety and prevent products and connected devices from being damaged.For these precautions, symbols are used for alarm purpose and the following descriptions will be given depending on severity.Please pay close attention to these advisories.： 注意：

Note: Arouse your attention to important information on products and to specific parts of products or files.

Caution：

Caution： The caution symbol indicates that potential damage to equipment or injury to personnel exists. Follow instructions

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《Operation instructions for throttling kill manifold》Rev. A1

explicitly. Extreme care should be taken when performing operations or procedures preceded by this caution symbol.

Warning：

Warning： The warning symbol indicates a definite risk of equipment damage or danger to personnel. Failure to observe and follow proper procedures could result in serious or fatal injury to personnel, significantproperty loss, or significant equipment damage. 1.1.2 Warning Illustrations (figures) provide a typical and graphical representation of equipment, its components or screen snapshots for use in identifying parts, establishing nomenclature or calling out notes and procedures. Illustrations may or may not be drawn to scale. Illustrations may be different from the real products or parts.

1.1.3 Weights and Dimensions Some weights and dimensions of the equipment and components within the manual are typical and subject to change.

1.2. Safety requirements 1.2.1. Qualified personnel Only qualified personnel are allowed to install and operate the equipment. Qualified personnel refer to those who, with experience in field well-control, can install, test run and operate equipment according to established safety practices and standards. 4

《Operation instructions for throttling kill manifold》Rev. A1

1.2.2. Replacement Components Replacement Components must be design and manufactured by SHENKAI. Failure to do so could result in equipment damage or injury to personnel and SHENKAI will not be responsible. Conduct timely replacement on quick-wear metal parts and non-metallic parts which may cause any influence on the product safety and performance in the test, especially the ram seals.

1.2.3. Routine Maintenance Equipment must be maintained on a routine basis.

Note： Failure to conduct routine maintenance could result in equipment damage or injury to personnel. 1.2.4. Correct operation The equipment and its components can only be used for description of product catalog or technical specification and can only be connected to facilities or components recognized or recommended by SHENKAI Company. The equipment can function correctly and safely only when transported, stored, assembled, installed correctly and run and maintained as recommended.

1.3. Customer Service Address: No.1769 PuXing Road, Shanghai, China Tel.+86(21)64290467 Postcode：201114 Fax：+86(21)64290467 Web site：www.shenkai.com

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《Operation instructions for throttling kill manifold》Rev. A1 ng The Inner Ri 内 环 线

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《Operation instructions for throttling kill manifold》Rev. A1

2. Introduce The throttle and kill manifold is composed of plate valve, throttle valve, whole body and connecting flange.In order to facilitate installation and use, the following instructions are made: when drilling, the throttle manifold and the kill manifold are connected to the two sides of the bop respectively. The flat plate valve on the switch manifold and the adjusting throttle valve opening size can realize the throttling cycle and the blowout, and can adjust the pressure difference between the bit pressure and the sleeve pressure. It is a matching tool for balanced or underbalanced drilling. If the well blowout or kick in the drilling process, bleed and reduce the pressure by opening the chokemanifold in the side way or the gate valve in the middle. Mud with high pressure from the well pump can control the blowout and kick, when it goes into the casingthrough the kill manifold. The choke manifold and the kill manifold are the necessary equipment for drilling.

2.1. Main technical parameters  Working Pressure：

10000psi

 Main bore size：

4-1/16”

 Choke Outlet size：

3-1/16”

 Outlet size：

-

 Temperature Class：

PU（-29℃-121℃）

 Material Class：

EE-1.5（REF）

 Product Specification：

PSL3 （REF）

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《Operation instructions for throttling kill manifold》Rev. A1

2.2. Method to Express the Type of the Choke and Kill Manifold:

Number of company products Rated working pressure code：（Table 2-1） The way to Control choke valve：Y—Hydraulic；S—Pneumatic： （No throttle omitted） Manifold Code：JG—Choke Manifold；YG—Kill Manifold； LG—Vertical Manifold

2.2.1.Rated Working Pressure There are five grades of rated working pressure, as shown in table 2-1。

Table2-1 Rated working pressure&Static strength test pressure Pressure Code

Rated working pressure

Static strength test pressure

MPa

psi

MPa

psi

14

13.8

2,000

4,000

21

20.7

3,000

35

34.5

5,000

70

69.0

10,000

105

103.5

15,000

140

138.0

20,000

27.6 41.4 51.7 103.4 155.2 207

6,000 7,500 15,000 22,500 30,000

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《Operation instructions for throttling kill manifold》Rev. A1

3. Structural Features The choke manifold (See figure3-1) contains one way main bleed line, left and right two ways choke line, buffer pipe, etc. Middle way bleed line contains two gate valves, the bleed was connected to the mud pit; side way choke line contains three gate valves and a choke valve, each side can be used singly;one side of buffer pipe was connected to the drilling fluid separatorwhile the other side was connected to the mud pit. When drilling the well, we can control the pressure of well bottom by adjusting the left and right 2 waysmanual or hydraulic choke valve, which is controlled by the remote control console, opening the gate valve above the entrance five-way can make the pressure gauge show the true pressure of casing and make the gauge of remote control console in the working state. The configuration of hydraulic choke valve control box is decided by the working pressure of manifold, thestructural form of choke valve and the number of control choke valve. There are mono-hydraulic and di-hydraulic two kinds of box. The control box panel can display the pressure of rising pipe, the pressure ofcasing and the orifice size of bean, if the customer needs the pump impulse counter and the controlbox used to control two hydraulic choke valves or hydraulic orifice choke valve, please tell us when you order ourproducts. Kill manifold (See

figure ) contains main bleed line and killline. After opening the gate

valve of main bleed, the bleed will be connected to the mud pit; killline contains check valve and the gate valve, which allow the well fluid flow from mud pump to the casing only. Lifting skid makes it possible to adjust the height of choke and kill manifold when the height of BOP was changed. The configuration and form of choke and kill manifold can be designed to meet the different requirement,it can be either vertical or horizontal.

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《Operation instructions for throttling kill manifold》Rev. A1

LxWxH=3908x3787x241.5mm Weight：9870Kg

Figure 3-1 Choke Manifold（10000psi） 10

《Operation instructions for throttling kill manifold》Rev. A1

4. Installation and debugging 4.1. Precautions before installation 4.1.1.Check valve on manifold to ensure handwheel operation is successful and valve is fully open and closed. 4.1.2.Before installing the manifold, please familiarize yourself with the technical data attached to the equipment and understand the manifold specifications, procedures, distribution of high and low pressure working areas, hoisting and precautions for use.Check on site manifold or completion data to ensure compliance with the following requirements： Rated working pressure： 10000psi Main bore size：

4-1/16”

Secondary hole size：

3-1/16”

Kill sizes available：

-

Every time the manifold enters the well site, it is necessary to check whether there are any defects caused by impact or corrosion during the transfer of the manifold products. If the defects are located in important parts (such as valve body, connecting pipe, connecting flange, non-coupling, etc.), welding is not allowed.If it is in a non-important part, it can be repaired according to the requirements of repair welding, and according to the relevant inspection requirements for ultrasonic or magnetic particle inspection.

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《Operation instructions for throttling kill manifold》Rev. A1

4.2. Pre-installation test A hydrostatic test must be carried out before each use of the high-pressure manifold.For the manifold with two working pressure zones, the whole manifold is first hydrostatic tested at the rated working pressure of the low pressure zone.After the low pressure test is qualified, close the last high pressure gate valve connected with the low pressure area in the manifold and conduct hydrostatic test on the high pressure area according to the rated working pressure of the high pressure area.The allowable pressure drop per test is 5% of the test pressure or 3.4 mpa (a smaller value).Pressure test personnel shall be trained by the competent authorities and hold the qualification certificate of high-pressure manifold test before they can take up their posts。

Warning： When the device is under pressure test, please stay away from the subject device.

Warning： Seat seal pressure test shall not exceed the rated operating pressure of the valve.

Note：

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《Operation instructions for throttling kill manifold》Rev. A1

During the overall static pressure strength test of the manifold, test flanges shall be installed at all exits, and all flat plate valves shall be in a half-on/off state, which can be performed according to table 2-1.If the valve is closed (instead of the pressure flange) for pressure test, the test pressure is the rated working pressure of the valve.

4.3. Installation of throttle kill manifold 4.3.1.Hoist throttle and kill manifold in place according to drilling site layout.When hoisting, according to the relevant hoisting procedures do not wire rope string sleeve in the connection pipe or valve, to be lifted gently, pry seat and the ground should be put flat。

Note： Pay attention to avoid collision with valve handwheel when lifting

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《Operation instructions for throttling kill manifold》Rev. A1

4.3.2.When the lifting type pry seat is adjusted, loosen the lock handle first, then lift the upper workbench to the appropriate height, re-insert the pin and then lock the upper workbench.The adjustment spacing of the 90 degree crossing positioning holes is 50mm.(for lift manifold only). 4.3.3.Install the internal blowout line to connect the throttle manifold inlet with the bop's drilling four-way connection, the blowout line of the kill manifold with the blowout preventer's drilling four-way connection, and the kill line of the kill manifold with the mud pump. 4.3.4.If gasket is used in connection of throttling, killing manifold and well control system pipelines, please clean the gasket groove and add butter, fit the correct gasket ring and tighten the double-end screw.Please pay attention to the specification printed on the valve and connecting flange of each part, do not install unqualified gasket ring.For non-union joints, threaded flange joints, welded joints shall be connected in accordance with the relevant regulations. All joints shall be hydrostatic tested at rated working pressure before use.Bolt fastening shall follow the following requirements. 4.3.4.1.

The order in which the stud bolts are tightened on the flange connection is very important. The bolts must be cross-tightened in the direction of the cross to ensure that the connection is evenly applied. It is recommended that the bolts be tightened in the numerical order indicated in the diagram below.Refer to appendix D in API 6A for torque sizes.This sequence applies to flange connections with more than 8 bolts. 14

《Operation instructions for throttling kill manifold》Rev. A1

Wrong installation order

Correct installation sequence

4.3.5.Before the use of the manifold should check whether each valve has been lubricated, and turn the valve to check whether the switch is flexible, according to the relevant regulations, each valve should be listed number, and indicate the status of the switch. 4.3.6.No scars shall be left on the working surface during installation or disassembly of manifold。 4.3.7.Installation and debugging of hydraulic control box. Field equipment installation, debugging and installation personnel should first read the instructions of the hydraulic control box attached with the equipment, and then correctly connect the hydraulic control pipeline as required to install the jacking pressure sensor, the drilling-pressure sensor and the pressure gauges of each part.After completion of connection of the whole well control system, check the working reliability of the hydraulic throttle valve under rated working 15

《Operation instructions for throttling kill manifold》Rev. A1

pressure.Adjust the throttle valve to be fully closed in accordance with the 0 scale of the open indicator.Check whether the control box manual pressure pump can provide hydraulic pressure to the system.Open the hydraulic control control box and check whether the reading of the accumulator pressure gauge is up to the pressure specified in the specification.

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《Operation instructions for throttling kill manifold》Rev. A1

5. Method of use 5.1. Operating personnel should be familiar with the methods of operation and maintenance of all the valves which constitute the manifold. 5.2. In order to prevent the false operation, please make sure the nominal working pressure on the label and the actual fluid direction of every valve. Don’t move the manifold and does any repairing or maintenance work to it when it is in working state. 5.3. The max working temperature of the manifold should not be above 121℃ and min temperature should not be under -29℃, or the rubber sealing will be damaged. If the environment temperature is under 0℃, the drilling fluid and the mixture of oil and gas in the valve cavity will be frozen when the manifold isn’t in working state, then valves can’t be opened. It will damage the valve if open the valve forcedly. Please flush the manifold with hot water first, then open the valves after the ice melt. 5.4. Operating personnel should be familiar with the structure and principle of hydraulic choke valve of the control box .When drilling the well, the energy storer in the control box should keep the nominal working pressure of the action of hydraulic choke valve fluid cylinder piston, then can provide high pressure fluid tothe manifold control system in time when the drilling table gas source is interrupted.

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《Operation instructions for throttling kill manifold》Rev. A1

5.5. When people are drilling the well, main bleed in the middle is closed

while the gate valve in two sidesis open, adjust the choke valve in two sides to control the pressure of well bottom. 5.6. If the well blowout or kick, please open the gate valve between the choke manifold and drilling fluid splitter first to let the drilling fluid go into the splitter. During the circulation working process, should observe the pressure gauge on the top of drilling fluid splitter at any time. When the indication of the gaugego up to 0.7MPa,should open the main bleed in the middle quickly, close the gate valve connected to thedrilling fluid splitter when necessarily and kill the pass through which the drilling fluid go into the splitter.

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《Operation instructions for throttling kill manifold》Rev. A1

5.7. If the well blowout strongly, open both the main bleed and the bleed in the side of confluence line tobleed at the same time. Using choke kill manifold can accomplish soft closure, it is a method of closing the well that open the choke valve when overflow closure, then close the BOP and try to close the choke valve at last, becauseit can assure to keep the well safe that the wellhead casing pressure of closing well won’t higher than thenominal wellhead casing pressure, if the pressure is too high, can choke to bleed. Pay attention to the indication of manifold casing pressure gauge at any time when doing the operation of soft closure, it is necessary to point out that don’t use the tapered head choke valve to do the soft closure, because it will crush the hard alloy head, it usually use cylinder choke valve or cage choke valve or orifice choke valve. 5.8. When using flow drilling, we should prevent block of choke line and check the hard alloy head whetherit is be crushed or not, because all the drilling fluid and debris flow through the manifold. 5.9. The bleed of kill manifold is usually closed; the kill line is also at closure with the effect of check valve. When needing to kill the well, the drilling technology personnel on the site should command to openor close it in time.

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《Operation instructions for throttling kill manifold》Rev. A1

5.10. Clean the drilling fluid in the cavity and pipe after using the manifold; flush the surface with fresh water, then flow the water break dry with high pressure gas.

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《Operation instructions for throttling kill manifold》Rev. A1

6. MAINTENANCE AND REPAIR 6.1. Items for Inspection in Normal Use 1. Regularly check the indication of the pressure gauge in the pipeline and make records well. 2. Regularly check the tightness and integrity of the connection between the flange and the bolts, and whether there is gas leakage at the connections for each flange。 3. Regularly check whether there is gas leakage of the valves. And check in phase the performance to open and close each set of wellhead valves according to relevant operation rules. Grease the oil cup on the valve bearing base to ensure the flexible rotation of the bearing. 4. The valve can be maintained according to the following monthly and quarterly maintenance items (or according to the requirements of the relevant valve manual for regular maintenance), such as the surface paint off should be repainted。 5. The exposed threads on the manifold should be coated with anti-rust oil and fitted with corresponding thread protection sleeve to prevent rust or damage。

6.2. Monthly Regular Maintenance Items 1. Including inspection items in normal use. 2. Add butter to the oil cup in the bearing block of the valve to ensure flexible rotation of the bearing. 21

《Operation instructions for throttling kill manifold》Rev. A1

Note：

After running 10 operating cycles, the inner cavity is lubricated. One cycle is equivalent to one opening and one closing of the valve.The maintenance cycle can be adjusted according to the fluid used and the well condition.If the pressure on both ends is balanced before the valve is opened, the maintenance period can be extended;If the valve is removed from the line, lubrication is also required before reloading。

3. Clean up the oil in the throttling kill manifold.

6.3. Quarterly Regular Maintenance Items 1. Including the items of monthly regular maintenance. 2. Inject anti-leakage grease into the valve through the check valve on the valve cap to lubricate the valve plate and valve seat.

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《Operation instructions for throttling kill manifold》Rev. A1

7. STORAGE STANDARD 7.1. Short-term storage that is less than 6 months 1. Clean the auxiliaries and lubricate the parts. 2. Store the sealed parts in accordance to the requirement as specified in 7.3. 3. Apply the internal components with machine grease. 4. Raise the equipment up with cushion and place it in the dry room to avoid stagnant water.

7.2. Long-term storage that is longer than 6 months 1. Clean all the components and dry them. 2. Apply all parts with heavy grease. 3. Protect all external seal surfaces with covers. 4. Raise the equipment up with cushion and place it in the dry room to avoid stagnant water. 5. Clean all the components and apply light grease on them before reassembly.

7.3. The Storage and Inspection of the Rubber Parts 1. Our company adopts special material for the rubber parts to ensure its long life span. The long life of the rubber can be guaranteed if the following items are obeyed. 1) Avoid direct light, in particular ultraviolet radiation of the sunlight which 23

《Operation instructions for throttling kill manifold》Rev. A1

will cause harm to the rubber. 2) Ozone from environment will react with rubber which will make rubber be deteriorated. So rubber parts should be stored far away from electrical equipment which will produce ozone. 3) In ozone or oxygen environment, the heat will cure the rubber parts. In warm and humid climate, especially in tropical zone, mould fungus will erode the organic matter of rubber. There will also be some changes of the rubber if it is exposed in the environment with low temperature. The rubber will become brittle and breakable at the temperature of -40℉ /-40℃, while it will recover its original performances when the temperature reaches the ambient temperature or 18℃(65℉/18℃). 4) The service life of rubber parts varies with the size, composition and function. The big rubber parts have longer life than the small ones. Natural and synthetic rubber parts will expand or contract due to the effect of hydrocarbon in the oil field. 5) In summary, users should decide whether the rubber parts can be continued to use or not according to specific conditions. If there is any question about that, the user should change the rubber parts. 2. The Storage of Rubber Parts： 1) The rubber parts should be stored in the following conditions. 2) The rubber parts should be placed in the dark place. It’s best to be kept indoors and away from such direct light sources such as sunlight, windows or artificial light source. 24

《Operation instructions for throttling kill manifold》Rev. A1

3) The rubber parts should be kept in the environment with very low temperature, about 18℃ and away from any heat sources, and it should also be kept away from any electrical equipment and high pressure equipment which will produce electric corona. 4) The rubber parts should be stored in accordance with its natural shapes instead of being hung up. 5) The storage place should be kept as dry as possible. Grease and other liquid should be stored in other places. 6) When stored for a long time, the rubber should be stored in sealed container or be protected with protective coverings into which temperature and light cannot penetrate. 7) The using of the rubber parts should comply with the principle of

“first in,

first out”. 3. The Inspection of Rubber Parts： 1. The rubber parts should be checked whether there are cracks or not, whether the surfaces have become brittle or not, or whether there is other deterioration or aging by means of bending, stretching or compressing prior to use. 2. Check whether there is hardening, chalk or peeling of the surface of the rubber parts. 3. The rubber parts should be replaced if there is any of the above phenomenon. 25

《Operation instructions for throttling kill manifold》Rev. A1

8. SAFETY PRECAUTIONS

All the parts of Shanghai Shenkai Petroleum Equipment Co.,Ltd. are produced, manufactured and tested in strict accordance with the design requirements. It is recommended to only use the original parts to avoid of potential danger and ensure the reliability for use. During operation, all kinds of obvious boards and instructions must be used to remind the operators and other concerning people of the danger which may cause injury. The internal structure of the product should not be changed without permission. Please contact with engineers of Shanghai Shenkai Petroleum Equipment Co.,Ltd. if there are any particular requirements. In order to avoid of injury, there should be no any chemical substances or potential damages to cause any interference. In order to ensure a safe workplace, the following items must be followed: 1. Any factors causing hazardous effects above or beside the work area or near the ground should be eliminated in time; 2. Any combustibles or leaked flammable materials near the workplace should be got rid of in time; Any situation that is possible to cause serious damages to the workplace should be got rid of or corrected in time.

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《Operation instructions for throttling kill manifold》Rev. A1

9. The appended drawings

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《Operation instructions for throttling kill manifold》Rev. A1

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《Operation instructions for throttling kill manifold》Rev. A1

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《Operation instructions for throttling kill manifold》Rev. A1

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《Operation instructions for throttling kill manifold》Rev. A1

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