Conoco Phillips Specification - Surface Christmas Trees, Christmas Tree Valves and Wellheads

8/18/2019 Conoco Phillips Specification - Surface Christmas Trees, Christmas Tree Valves and Wellheads

1/15

Document / Revision No. Owner Approved

5026 / 02 Director-Mechanical-Integrity 10.10.2006

Title

Surface Christmas Trees, Christmas Tree Valves

and Wellheads

Page no.

1

Total

15

Surface Christmas Trees, Christmas Tree

Valves and Wellheads

Document no.: 5026

Process correspondence:

Anskaffelse, Boring/WS, HMS - risikostyring, Prosjekt, Vedlikehold

NORSOK Standard Reference:

N/A


2/15



Title

Addi tional Requi rements To Norsok Standard

Page no.

2

Total

15

Additional Requirements To Norsok Standard

NORSOK Standard Cross References:

Not Applicable

For information please contact the fol lowing:

Knut Terje Bauge – [email protected], Phone no. (+47) 52 02 13 24

Geir W. Hjelmeland – [email protected], Phone no. (+47) 52 02 17 27


3/15



Title

Introduction

Page no.

3

Total

15

1 Introduction

1.1 Purpose

These technical requirements are developed by ConocoPhillips Norway and definerequirements for surface christmas tree and wellhead systems. The specification is based on

API 6A and states deviations and additions to this standard.

1.2 Scope

The wellhead/ X-mas tree equipment covered by this standard is comprised by the following

sub-systems:

• Surface wellhead

• Tubing hanger

• Tubing bonnet

• Christmas tree

• Valves for christmas tree and Annulus Wing Valves (AWV) mounted on wellhead

1.3 Target group and responsibility

1.3.1 Target group

Purchasing, drilling, project, suppliers and maintenance.

1.3.2 Responsibility

Director Mechanical Integrity is the owner of this document and is responsible for updating or

withdrawal of the document as dictated by organisational or operational changes.

1.4 Handling of Non-Conformances

Deviations shall be reported to the position responsible for this document.

1.5 Abbreviations

AFV Automatic Flow Valve API American Petroleum Institute

FAT Factory Acceptance Test

HMV Hydraulic Master Valve

MMV Manual Master Valve

PSL Product Specification Level

PR Performance Requirement Level

SIT System Integration Test

SMDR Supplier Master Document Register


4/15



Title

Introduction

Page no.

4

Total

15

1.6 References

Standards and specifications

Equipment shall be designed, manufactured and tested in accordance with latest edition of

relevant parts of PSA, API 6A and relevant Norsok standards, Company Additional Technical

requirements and latest revisions of relevant industry standards.

Order of precedence will be PSA regulations, Company Additional Technical Requirements,

Norsok standards and industry standards if nothing else is stated.

These specifications and standards include, but are not limited to:

Company Addit ional Technical Requirements

Norsok specifications

Industry Standards

PSA Petroleum Safety Authority

2169 ConocoPhillips Engineering Numbering System (COPENS)

4293 Surface Preparation and Protective Coating

4314 Documentation For Operation (DFO)

4584 Electrical, Instrumentation & Telecomms. Installation

4676 Field Instrumentation

4985 Lifting Equipment Requirements

M-001 Material Selection

M-501 Surface Preparation and Protective Coatings

M-601 Welding and Inspection of Piping

M-710 Qualification of Non-Metallic Sealing Materials and Manufacturers

R-CR-002 Lifting Equipment

Z-006 Preservation

Z-010 Electrical Instrumentation and Telecommunication Installations

I-001 Field Instrumentation

API 6A Specification for Wellhead and Christmas Tree Equipment

API 6FA Fire Tests for Valves

API 6FB Fire Test for End Connections

API 6FC Fire test for valves with automatic back seats

DnV Cert.

Note 2.7-1

NACE MR-01-75 Standard material requirements sulphide stress

cracking resistant metallic materials

NS 5820 Suppliers Documentation for Equipment


5/15



Title

Technical Requirements

Page no.

5

Total

15

2 Technical Requirements

2.1 General

The Wellhead and Christmas tree equipment shall provide a safety barrier between the reservoirformation and the environment. The chrismas tree, as a complete unit, is defined as one safety

barrier. The system shall provide fail-safe features such that any single failures will not result in

an unsafe system condition.

All X-mas tree valves shall be 10K. Also the AWV for the A-annulus shall be 10K.

Other AWVs for B- and C-annulus can be 5K.

All ESD valves are therefore 10K, but there are no closing/opening time requirements for

maximum design pressure.

2.2 Product Specification Level / Performance Requirement Level

Wellhead and Christmas Tree Equipment shall be designed, manufactured and tested in

accordance with latest revision of API 6A.

Unless otherwise noted, Product Specification Level 3G (PSL 3G) and Performance

Requirement Level 2 (PR2) shall apply.

2.3 Conf igurat ion

The configuration of the X-mas trees and wellhead shall reflect maintainability, flexibility and

accessibility, including both vent and drain on all gate valves. In addition the number of leak

paths in the X-mas tree/wellhead system shall be at a minimum.

2.4 Fire safe design

All the valves on X-mas tree and Wellhead shall be of fire resistant design. The fire safe design

shall be reflected in the interfaces with the Wellhead - annulus valves, Wellhead - tubing bonnet,

and Christmas tree connector. All critical sealing areas are included in this requirement.

API 6FA is applicable for valves, API 6FB for end connections, and API 6FC for valves with

automatic backseat.

2.5 Wellhead equipment

Third party design verification for wellhead equipment orders should include consideration of theeffects of actual field conditions on the ultimate load bearing capacity.

Design verification documents shall be supplied.

All annulus outlet ports shall include provision for installation of Valve Removal (VR) plugs.

The wellhead shall be equipped with test ports for integrity testing of all system seals from the

exterior of the wellhead.


6/15



Title


Page no.

6

Total

15

2.6 Valves

All valves shall be bi-directional.

Valves should include provision for injection of sealing compound in the stem packing area for

temporary stopping of leaks.

2.6.1 Manual valves

Valves that can develop a “pressure lock” condition shall not be used.

All manual valves shall be equipped with hand wheel. Hand-wheels shall be permanently

marked “Open / Closed” with an arrow to indicate direction of rotation, and it shall be clockwise

to close the valve.

Hand wheel-operated valves shall have max. 200 N single hand force and max. 750 mm

diameter of hand wheel. (i.e. max. torque 150 Nm).

NB! If the hand wheel diameter is not 750mm, the max torque will not be 150 Nm.

The torque requirement shall be verified at 5000PSI cavity pressure and differential pressure

when it is closed and opened. No safety factor is required to the torque requirements.

2.6.2 Actuators

Norsok Z-010, I-001 and COPNO doc. 4584 and 4676 are valid for actuators, except that safety

factor required in Norsok I-001 sec 4.15.1 is not applicable.

• Actuator shall be of a compact design and form an integrated part of the valve bonnet.

• Actuators shall be of fail safe close design.

• Stem protectors to be installed.

• It shall be possible to replace the actuators complete hydraulic packing system usingcommon hand tools without interference with the gate drift. The space required for this

operation shall be as little as possible.

• Supplied cleanliness on hydraulic oil will be min. NAS 1638 class 6.

For verification of actuator closing time see section 2.13.2 Closing time for actuated valves on

page 10.

The actuator will be operated with a hydraulic supply pressure between 2200 PSI and 3200 PSI.The opening time requirement shall be accomplished with max. 2000 PSI hydraulic supply pres-

sure.

The design pressure for the hydraulic part of the actuator should be minimum 5000 psi.

Ac tuator c losing time: Max 30 seconds with 5000 PSI in body/ bore

(50% of design pressure)

Ac tuator open ing t ime: Max 30 sec.


7/15



Title


Page no.

7

Total

15

Position indicator

• The actuators shall have a position indication box with visual continous position indication as

well as remote operation for full open and closed position. Visual position indicators shall be

clearly readable for the operator.

• The switches shall be proximity type for intrinsically safe circuits.

• Testing shall be carried out with IEC-CENELEC- or equivalent standards. Ref. “Regulations

for electrical installations etc. (“FEB” para.808.7.4.)

• The position indicator box shall be of a fire resistant design (20-30 sec) so that the data can

be read after a fire.

• Limit switch housing/ boxing material shall be AISI 316 or GRP, ref. instrument specs

referred to in this TCD 5026.

2.7 Tree Cap

Tree cap shall be 9"-4 Acme Otis tree cap if not specifiede otherwise.

2.8 Grease fittings / Vent, drain test connections

All grease fittings and test/bleed nipples shall be protected from potentially dropped items.

Grease Injection nipples and lubrication ports shall be made in min. 22%Cr Duplex ss

(ref. NORSOK M-001) for carbon steel bodies, or SS 316 for stainless steel (A182 F6NM)

bodies.

If drilled and tapped body connections are made (drain, vent, test connections etc.) they shall be

fitted with forged plugs of anti blow out design with hexagon heads. The plugs shall be made to

ANSI B 16.14 in 22%Cr Duplex material, or SS 316 material.

Fittings produced with Line Pipe (LP) or National Pipe Tapered (NPT) threads shall be produced

to stricter tolerances than API 5B for LP or ASME B1.20.1 for NPT requires.

These tolerances are as follows:

• Female part: +¼ to +1 turn above midpoint, i.e. the hole shall be large.

• Male part: -1 to -¼ turn above midpoint, i.e. the plug shall be small.

COPNO recommend Swagelok due to their tighter quality control and stricter tolerances for

NPT / LP. Any other supplier must meet these standards and an approved quality control system

specifically for the above specification must be in place.

2.9 Lift ing and handeling / l i ft ing points

Vendor shall describe lifting and handling of the equipment and include for designated lifting

points, e.g. lifting ears or eyebolts, if necessary.

Designated lifting points must be designed to allow for the X-mas tree to be lifted not only in the

vertical position.

Designated lifting points on the equipment shall be proof load tested in accordance with DnV

Cert. Note 2.7-1 or equivalent.


8/15



Title


Page no.

8

Total

15

2.10 Materials, welding and NDT

2.10.1Materials

Material selection shall be in accordance with Norsok M-001.

Both stainless (13Cr4Ni material) and low alloy steel X-mas trees, loose valves, and wellheads

shall have Inconel 625 weld overlay in seat pockets, ring grooves and critical seals/sealing

areas.

Flanges shall be forged to shape. Flanges machined out of bar or plate are not accepted.

All ring gaskets for API flange connections shall be made of SS 316, except for water injection

x-mas trees.

Water injection valves on the x-mas tree shall have inconel 625 or 25Cr duplex material for the

ring gaskets.

2.10.2Test sampling

General

Samples for testing shall realistically reflect the properties in the actual component.

Test specimens shall be cut at the 1/4T location from the surface where T is the thickness of the

test samples as heat-treated. Sketches shall be established showing type, size and location of

test samples and extraction of test.

One test specimen per heat and heat treatment lot is required.

Forged components

Test samples shall be from prolongations on the actual components. Sacrificial forgings shall be

used for die forged components. However, special agreements may be made for die forged

components with as forged weight exceeding 50 kg.

Test samples shall be heat treated together with the forgings/castings that they represent.

Castings

Thickness of the test block shall be equal to the thickness of the actual components as

heat-treated up to a maximum thickness of 100 mm. For flanged components the largest flange

thickness apply.

Test block shall be integrally cast or gated onto the castings and shall not be removed from the

castings until after the final quality heat treatment.

2.10.3Charpy V-notch testing

Default test temperature for low alloy steel (typical AISI 4130) Charpy V-notch testing shall be

- 30 °C. The minimum absorbed energy for full size specimens shall be 42 J average and 30 J

single.

Default test temperature for stainless steel (typical ASTM A182 F6NM) Charpy V-notch testing

shall be - 46 °C. The minimum absorbed energy for full size specimens shall be 42 J average

and 30 J single.

If minimum temperatures are lower than above default temperatures, the materials shall be

tested at minimum design temperature (P, U or L), but instead of API acceptance criteria's the

following shall be valid: 42J average and 30 J single.


9/15



Title


Page no.

9

Total

15

2.10.4Hardfacing

Hardfacing of gate and seats shall be by thermal spraying of wolfram carbide in accordance with

EDS NHF2 in Norsok L-001.

Other hardfacings shall be qualified and acceped by Company. Reference is also made to

section 2.10.5.

2.10.5Welding / Weld overlay

General

Welding procedures (WPS) and welding procedures qualifications (WPQR) shall be in

accordance with API 6A and Norsok M-601, Welding and Inspection of Piping.

Welding procedures and qualifications shall be accepted by COPNO welding specialist.

Operators

Welders and NDT operators shall be qualified as stated in Norsok M-601.

Overlay welding

Critical sealing surfaces shall be overlay welded with Inconel 625 (AWS ERNiCrMo3). The fin-

ished-machined weld overlay shall minimum be 3mm thick. Maximum allowable iron content in

finished machined weld overlay shall be 10% (weight).

Repair welding

Weld repair is not acceptable on forged components.

Weld repair on forged components may be allowed, but only based on Company approval of the

weld repair proposal.

For castings, repair welding is allowed for defects that will entail removal of not more than

75% of the thickness, or a length in any direction of not more than 6”.

2.10.6NDT

NDT shall be in accordance with API 6A PSL 3G.

2.11 Elastomeric seals

Elastomeric seals exposed to the hydrocarbon service shall meet the requirements of Norsok

M-710. The vendor shall provide documentation in line with the requirements of Norsok M-710,

substantiating compliance with the said standard. The report shall be subject to COPNO

acceptance prior to any contract.

Wellhead Elastomeric seals shall conform to API 6A appendix F and Norsok M-710.

COPNO reserve the right to witness and retain documentation of conformity.

2.12 Surface / corrosion protection

Surface protection shall be in accordance with Norsok M-501 and 4293 Surface Preparation and

Protective Coating.

Surface protection for low alloy bolts shall be hot dip galvanising (HDG) per ASTM A153.


10/15



Title


Page no.

10

Total

15

2.13 Testing of Wellhead and X-mas Tree Equipment

Testing shall be performed in accordance with API 6A, latest edition.

Annex F shall apply.

All valves shall be operated and the torques shall be recorded for opening and closing the valves

under zero and 50 % of maximum rated pressure and differential pressure.

2.13.1Gas test

Gas testing shall be to API 6A PSL 3G.

2.13.2Closing time for actuated valves

Closing time for actuated valves shall be tested at:

• 50% of maximum design pressure, i.e. 5000 psi

• pressure lessReturnline for hydraulic oil shall be minimum 100’ long, OD ½” wt 0.065” or OD 3/8” wt 0.049”.

Acceptable closing times are:

• Maximum 30 seconds at 50% of maximum design pressure

• Maximum 60 seconds when tested with no pressure in the valve

2.13.3FAT / SIT

A review of data from load and Factory Acceptance Testing (FAT) work must be performed to

verify that the manufacturer’s load rating is acceptable.

As part of the FAT a System Interface Test (SIT) shall be carried out to verify all the interfacesinvolved in the overall system. The FAT procedure shall be in accordance with the functional re-

quirements related to the different equipment. Prior to SIT, agreed procedures shall be in place.

When drifting the christmas tree the drift mandrel shall completely pass through the vertical bore

of the christmas tree and the tubing hanger.

All test plugs or Back Pressure Valves, which will be used in the tubing hanger, shall be tested

in the hanger as part of the final factory acceptance test (FAT).

2.13.4Stack-up test

Stack-up testing and extent of this shall be specified for each order.


11/15



Title


Page no.

11

Total

15

2.14 Marking

Marking shall be in accordance with API 6A section 8 with additions as given below.

2.14.1Extent of marking/tagging

All test-, bleed- and lubrication/grease ports shall be clearly marked.

The X-mas tree and X-mas tree components shall be marked with the following:

• Tag number (if known where to be installed)

• Name of equipment

• Equipment number (If not known minimum space of 10X50mm must be reserved on marking/

tagging plate)

• COPNO Purchase order number

• SAP MMN (material master number)

This information shall be supplied from Company/COPNO if available, and a sketch of the sign

must be submitted to COPNO for approval.

In addition the following shall minimum be marked on wellhead and X-mas tree components.

• Supplier

• Model number

• Serial number

The following components shall minimum have their own identification sign:

• Complete X-mas tree

• X-mas tree block• Loose valves

• Cross

• Tubing bonnet

• Wellhead

• Tree cap

• Limit switches

• Junction boxes

In addition, the annulus outlets shall be marked.

2.14.2Materials

Material for tag plates mounted outdoors shall be in stainless steel AISI 316 and the tag plate

shall have thickness of minimum 1 mm. For mounting of the steel plates to the support brackets

stainless steel bolts and/or screws shall be used. Avoid crevice corrosion on tag plates. Avoid

dissimilar materials particularly fasteners. Dissimilar metals shall be separated by using gaskets

or insulators.

2.14.3Lettering

The letters shall be engraved with the lettering permanently coloured black. The letters shall be

8 mm high for the Tag Number and min. 5 mm high for the Tag description for individual plates.


12/15



Title


Page no.

12

Total

15

2.14.4Mounting

The tag plates shall be mounted on the equipment. All tag plates shall be mounted to facilitate

easy notification by maintenance personnel. Mounting of stainless steel signs shall be done with

stainless steel bolts or screws. Gaskets or insulators shall separate dissimilar metals.

2.15 Preservation

Norsok Z-006 shall be used for preservation of the finished equipment.


13/15



Title

Documentation

Page no.

13

Total

15

3 Documentation

3.1 General

Supplier shall with his offer supply a Supplier Master Document Register (SMDR) with theirsuggestion to what documents to be supplied for the order based on Appendix 1, which states

minimum document requirements.

NS 5820 “Suppliers Documentation for Equipment” will be applicable for Suppliers

documentation.

Final documentation, Technical Data Book/User Manual, shall be supplied in agreed upon hard

copies and in an electronic format.

3.2 Datasheets

Datasheets for christmas tree, Production Wing Valve, Hydraulic Master Valve, Hydraulic

Actuated Annulus Valve and Wellhead Datasheet are attached in appendix 2 to appendix 6.

The datasheets shall be used when requesting new equipment and to be updated by the vendor

and included in bid and final documentation.


14/15



Title

Documentation

Page no.

14

Total

15

APPENDIX 1 Minimum document requirements

Item Description With Bid For acc. Final

doc.

With

goods

Retained

001 Supplier Master Document Reg-

ister (SMDR)

X

002 Engineering, Procurement &

Manufacturing Sch. (EPMS)

X

003 Quality plan / Inspection & Test

Plan

X X

004 Detailed drawings w. part list X X

005 General arrangement drawings X X

006 Data sheets

- valves

- instrument/actuator

- X-mas tree

- Wellhead

X X

007 User manual index X

008 User manual

Minimum including:

- Drawings

- Datasheets

- Design verification

documents

- Installation, Opera-

tion & Maintenance

Manual

- Special Tools list

- Packing & Preserva-

tion Procedure

- Spare Part List

- Lifting & Handeling

Procedure

X X

009 SPIR (Spare Part List) X X


15/15



Title

Documentation

Page no.

15

Total

15

010 Manufacturing Data Book Index X

011 Manufacturing Data Book

Minimum including:

- Material certificates

- NDT certificates

- Pressure test

certificates

- EEX certificates

- Other test certifi-

cates

- Daily log for painting

- Welding log

X X X

012 Certificate of Conformity Index X

013 Certificate of Conformity

Minimum including:

- PO number

- Statement of compli-

ance to API 6A, PSL,

PR level, hydrostat-

ic and function test-

ing, NDT and PO

requirements

- Part no./serial no

- Eq. description

X X

014 Paint Specification X

015 Packing & Preservation Proce-

dure

X

016 Lifting & Handeling Procedure X

017 Test Procedures X

018 Welding Procedures X

Item Description With Bid For acc. Final

doc.

With

goods

Retained

Documents

Conoco Phillips Specification - Surface Christmas Trees, Christmas Tree Valves and Wellheads