Well Test Manual 1

Section 9

Rigging Up and Down

Table of Contents
Introduction……………………………………………………………………… 9 - 2
Objectives………………………………………………………………………… 9 - 2
Rigging Up …………..………………………………………………………… 9 - 3
Surface Test Tree……………………………………………………………… 9 - 13
Pipework.................…………………………………………………………… 9 - 19
Auxiliary Equipment…………………………………………………………… 9 - 21
Pressure Testing ……………………………………………………………… 9 - 22
Rigging Down. ………………………………………………………………… 9 - 23
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Introduction
The section contains information on the processes of Rigging Up and Down

Objectives
After completing this section, you should be able to

• Know some of the objectives for rigging up.

• Know what you have to do for the Surface Test Tree.
• Know about some of the auxiliary equipment rigup.
• Know some of the objectives for rigging down.

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Rigging Up
Firstly you must take part in a Tool Box Talk. During this, each person will be
allocated a job, to help rig up. Potential risks must be assessed and discussed prior
to Rig Up. This will be achieved by Preparing a Risk Assessment and discussing all
associated possible hazards and how to control those risks. All personnel taking
part in rig up operations must attend this Tool Box Talk.
Example of Permit to work and Toolbox Talk.

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Equipment Positioning
As equipment is unloaded, it should be placed in the designated positions. The
unloading must be carried out by trained personnel. The Test Supervisor must at all
times be in communication with Roustabouts, Banksman, who will in turn be in
communication with the Crane Operator. The area must be kept totally clear of all
personnel not taking part in the operation.

Tag Lines

Suspended loads must at all times be in control. Tags lines should be fitted at the
corners of equipment as it is lowered to allow for precise control.
HOW LONG IS A TAG LINE?
It is long enough so that the operator holding the tag line:
• Will be far enough away from the load to be safe.
• Have good control of the load.
• Can keep away from any possible obstructions.
Any alterations to the original layout must be discussed before implementation.
Once equipment is placed in the right positions it must be earthed (ground), to the rig
and to each other. This will prevent the possibility of static discharge (this can be as
much as 50,000 volts).

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HOOK-UP

1. Locate main items of equipment in the designated area taking into

account:-
a) Hook-up as shown on the layout diagram
NOTE: If anything affecting the hazardous areas eg. rig vents or
power points is altered from the layout diagram, then this
should be brought to the attention of the OIM or Company man.
b) Ease of hook up, minimising bends, tidiness of pipe pins etc.
2. During rig up, sampling and inspection points should be orientated
downwards and fitted with double isolation valves.
3. Whilst assisting in the positioning of equipment during hook-up operations,
the handling of loads must be supervised and carried out by properly
trained personnel. Expro personnel should liase with crane operators,
roustabouts and banksmen for the siting of equipment and other heavy
loads, but the actual operations should only be done by those personnel on
board properly authorised to do so.
4. All items of equipment should be fitted with suitably sized earthing straps
(11mm cross section multi-strand) and should be earthed to the rig
structure, on a place where there is no paint, as part of the hook-up
procedure. This will then earth any static electricity (generated by the
friction of flowing fluids) and prevent any discharge with the associated
dangers this would create.
NOTE: If an item of equipment is not earthed and it is subject to a build
up of static electricity, this static can build up to a infinite level before it
discharges (this level will be dependant on what the equipment can
discharge. Obviously if it is in contact with a metal deck it will discharge
at a lower level than if discharging to people or even the atmosphere).

ONSHORE
If no earthing points are available at the well-site then the equipment should be
earthed by driving a spike into the ground, to a depth of 3 feet. The area around
this spike should then be watered regularly.

5. All piping containing hydrocarbons will be securely tied down using 11 mm

diameter wire rope which will be wound around and clamped to all
pipework and anchored by clamps to the deck, or to any permanently
installed pad eyes. Pipe stands should be welded to the deck where
practical to hold pipework securely in the event of a shock loading.

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6. During sand clean up wall thicknesses will be monitored at selected areas

of the pipework, eg. bends, targets etc. to monitor possible areas of
erosion. This will be performed with an ultrasonic thickness gauge.
Process fluid velocities must also be checked using the relevant formula.
This is especially critical immediately downstream of pressure drops.
7. Electrical equipment is to be tied into the power source by a qualified
electrician only. The correct function of such equipment MUST be checked
fully prior to use.
8. Vent hoses and bleed off lines to be run to locations as per the layout
diagram. These will be previously decided 'safe' area.
NOTE: The vent hoses must be suitably tied down.

9. Rig to burner boom access points should have properly secured hand rails
even if of a temporary nature.
10. The test equipment area should be as far as is practical free of all rig
equipment, baskets, containers, etc.
11. When rigging up a steam generator, the steam return line should be laid to
overboard and not returned to the steam generator. This is to prevent the
possible migration of hydrocarbons to the steam generator in the event of a
process coil failure in the heat exchanger.
12. The steam vent line should be hard piped (not necessary when using a
degasser where this is plumbed into the steam return line).
13. To prevent injury from whiplash through burst hoses, air hoses must be
fitted with a means of securing the end fittings. Small bore air hoses must
be fitted with “Safety R Clips” or similar and “Whipchecks” or similar on 2”
or larger hoses.

NOTE: The degasser should be calibrated for the type of gas expected
on a particular test and will produce an alarm or can be used as part of the
Safety Shutdown System (when tied into the ESD loop) to close in the well
in the event of a failure in the heat exchanger process coils.

RIG DOWN
It is important that none of the pressure containing equipment or parts of the
equipment are rigged down, dismantled or removed until the well is officially
declared dead and safe and instructions are received to rig down. Well testing
systems, including ESD and Relief systems can be complex and premature
rigging down without authority can result in hazardous situations.

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Before commencing a rig down, all vessels, lines, etc. should be depressurised
and flushed prior to breaking out. Great care should also be taken when breaking
out equipment after a sour service well test.

NOTE: After a sour service well test, the equipment /flowlines should
be purged with N2 prior to breaking out.

1. Any possible falling objects during back-loading should be

removed.
a) Tools should be put away and not left on equipment.
b) Sand filter davits should be securely tied down.
c) Pipework should retained in the pipe racks using the
proper bars.
d) Valve handles should be pinned or removed.

2. Gauges on equipment should be removed and tappings

plugged to prevent damage during transit.

3. All loose objects should be packed in the well test container in

such a way as to minimise movement during transit.

4. All vessels should be EMPTIED as far as possible. NEVER

attempt to lift a tank etc. when full.

5. Valves on vessel drains should be closed and outlet(s)

plugged, to prevent possible spillage’s during transit.

6. Female (thread) end connections should be fitted with

protectors or have grease tape wound round to prevent
damage during transit.

7. When loading baskets be aware as to the maximum weight of

the basket. DO NOT OVERLOAD basket.

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Surface Test Tree

The Surface Test Tree in its basket should be positioned as close to the rig floor as
Possible.
• It should be removed from its basket and examined to make sure no damage
has occurred in transit.
• It should then be function tested and pressure tested before lifting onto the rig
floor. Count the number of turns on each manual valve.
• The Swivel should be rotated to make sure it is free.
• Mark the swivel clearly across its top connection so you can identify if it has
backed off during setting of the packer.

When pressure testing (Full Body

Test), all valves should be open
and the Check Valve locked open.
End caps fitted with needle valves.
Fill Tree completely with water.
Do low pressure test and then high
pressure Test, charting the results.

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Before shutting the Kill Valve make

sure that the check valve is holding
pressure. Then shut in at the Swab,
Kill and Flow Wing valves. As
before do a low and high pressure
test. Needle valves downstream of
these valves should be open to check
for leaks.

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Close in Upper Master Valve and open

Swab, Kill and Flow Wing valves. If there
is a Lower Master Valve this should then be
tested.

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The Pump and

recorder should then
be moved to check
the downstream side
of each valve.

Flowhead Lifting
1. During the flow head lifting process to rig floor, it is mandatory that everybody stay
alert, avoiding putting themselves underneath or between the flow head and fixed
objects.
• Conduct pre job toolbox talk and review specific task.
• When rigging up the STT on semi-submersible installations or boats,
consideration must be given to the weather, sea.
A sufficient period of calm weather and sea state should be available to complete the
rig up of the STT. If this is not considered there is a potential to cause injury to
personnel and or damage to equipment.

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2. Remove slings from the flow head as soon as they are no longer needed for
stabilisation.
3. Keep the cap on the actuator during the flow head rig up to protect the stem.
Flowhead Lifting To Rig Floor

ACTUATOR STEM ENSURE

SLINGS DO NOT CATCH OR
DAMAGE

TAGLINES

1
THEAD PROTECTORS
TAGLINES

Note: It should be in position (1). Lift Sub toward rig floor.

(A) (B)
LOWER THE FLOW HEAD ONTO
THE RIG FLOOR WITH THE CRANE LIFT BY THE RIG
FLOOR WINCHES
LIFT BY THE RIG
CRANE

(1) DISCONNECT THE SLING AND

CONNECT TO 2 RIG FLOOR WINCHES

PEOPLE TO HELP WITH FLOWHEAD

PLACEMENT

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1. If the STT is fitted with lift lugs, clamp and sling assembly, these should be used to
lift the STT to the rig floor. If the STT does not have lift lugs, clamp and sling
assembly then suitably rated slings will have to be wrapped around the corner block
flanges and below the swivel (ensure that the slings are wrapped around the flange
and do not fall into the gap between the block and nuts, as this will cause extreme
problems in removing the slings after they have been used).
2. Have the rig crane place the STT on the rig floor as far inside the V-door as
possible (this will prevent it from toppling out the V-door when the crane slacks off).
Use taglines to stabilise the lift.
STT is to be placed on the rig floor with the handling sub pointing towards the rotary
table.

(C) (D)

CRANE LOWERING
LIFT BY THE RIG CABLE SLOWLY
CRANE LIFT BY THE RIG FLOOR
WINCHES

REMOVE
CABLE WHEM
FLOW HEAD
IS VERTICAL

ASSISTANT DRILLER
LOCKING ELEVATOR PERSON WATCHING THE X-
PERSON WATCHING THE X- OVER DOES NOT DRAG
OVER DOES NOT DRAG

3. Once the crane has placed the STT on the rig floor, remove the crane hook from
the 2 STT block lift points and transfer these to 2 rig floor winches.
4. If running Subsea Test Tree, make the necessary number of wraps in the Subsea
Test Tree control line around the tubing joint hanging in the rotary table to allow right
hand rotation setting of the packer.
5. Pick up the STT level with the 2 winches and the rig crane. Move the STT towards
the rotary table until the elevators can be latched around the handling sub. Secure
the elevators so that they cannot be released.
6. Slowly have the driller pick up the STT with the block. The 2 rig floor winches
should be kept in tension to prevent the STT from flipping over.

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The rig crane should keep the bottom of the STT assembly from dragging on the rig
floor, but should slowly slack off until the STT is in the vertical position.

7. Once STT is in the vertical position release the rig crane and the 2 rig floor
winches.
8. Remove the bottom STT thread protector and stab the connection. Make-up and
torque the connection (the block may need to be locked in position to prevent it
rotating during make-up).
The STT should be kept as vertical and central as possible during make-up of this
connection to prevent damage to the threads and to prevent binding of the
connection.
9. Make-up pipework or Flexible hoses to the flow and kill wing of the STT.
Hoses should be fitted with saver subs to prevent damage to the hose end fittings. Respect the
Minimum Bend Radius (MBR) of the hoses (normally 12 x ID of line).

Pipework
Handling of pipework should be kept to a minimum, the shortest runs possible and
with as few bends as possible (especially Upstream of the Choke Manifold).
Manual Handling techniques should be used at all times. During these operations
several risks are particularly prone:
• Lifting and lowering of pipework puts severe strain on anyone carrying
pipework.
• When positioning the pipework for connection there is possibility of pinch
points.
• When using a hammer everyone must keep clear and the hammer must be in
good condition.
DO NOT WORK WITH DAMAGED OR BROKEN TOOLS
All pipework must be tied down used the proper 11mm wire rope.

North Sea Code:

Different areas around the world require different connections. In the North Sea,
EXPRO uses 10 foot lengths of wire rope that has swaged fittings on the end and
joined together by shackles.

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Elsewhere in the world the fixings below may be the in use.

Any one of the above two methods is acceptable to join to pieces of wire rope
together. Any other method is not acceptable.
All relief pipework should have if possible pipe Clamps fitted and they should be
welded to the deck. They should be tight enough that no movement of the pipework
is allowed.
Relief lines should be in positions agreed upon as these have been designated as
safe areas.

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Auxiliary Equipment
Electrical Cables
All electrical connections should be carried out by a qualified electrician only. He
must be qualified to work on the rig. All cables should be run in such a way as to
avoid trip hazards if possible and damage caused by other operations.
All equipment must be checked that it is functioning properly before operations
commence.

Air Hoses
All hoses must be connected properly and have “R” clips fitted and whip checks.
Again try to identify passageways and if possible keep them clear of trip hazards. If
any trip hazards exist then they should be identified and marked clearly.

Steam Hoses
Steam Hoses as with air hoses should be secured properly, and must be identified
as being dangerous and high temperature.
Steam return lines when degassers are not fitted must go overboard and not
returned to the Steam Generator. This is to prevent any hydrocarbons returning to
the boiler should a coil in the Well Stream Heater leak.

Working on the Burner Boom

Before going onto the burner boom the following should be in place:
• The rig must be informed of work taking place on the burner boom and a
permit to work issued.
• The standby boat must be present during these operations and the sea state,
must allow rescue craft to be deployed.
• The person/persons going onto the boom, must have a brightly coloured vest
and or safety jacket and harness.
• There must be a standby person who does not go onto the boom. This
person should be in direct contact with the standby boat.
If there is high winds or a possibility of high winds then there should be a risk
assessment carried out. Normally if the wind speed is over 30 knots then no work on
the burner booms can take place.
If any person should be working out with the safety barrier of the boom, he must
attach himself by his fall arrest harness securely to the boom.

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Night activities on the burner boom is not advisable, but should it become necessary,
extra safety cautions must be taken. (See risk assessment and rig mandatory
regulations.) This will include sufficient lighting both on the boom and below the
boom.
NOTE: UNDER NO CIRCUMSTANCES SHOULD THE STANDBY PERSON
LEAVE THE LOCATION WITH PERSONS ON THE BOOM. THEREFORE UNDER
NO CIRCUMSTANCE SHOULD PERSON/S BE ON THE BOOM WITHOUT A
STANDBY PERSON PRESENT.

Pressure Testing after Rigging Up

Once you have completed the rig up of the equipment, it will be necessary that the
equipment is pressure tested to prove its integrity.
The following Steps should be taken:
1. Hold Tool Box Talk, Risk Assessment and fill out Permit to Work.
2. Erect warning barriers around test area.
3. Announce over P.A. system that pressure testing is about to commence.
4. Ensure all non-essential personnel are clear of test area. Have someone
make sure that no persons directly involved with the pressure test enter
the area.
5. All lines to be pressure tested must be tied down.
6. Make sure that the fittings and lines to the pressure test pump are of the
right pressure rating.
7. When pressuring up all personnel to keep clear of the equipment.
Inspection should be carried out only after pressuring up is complete, and
from as far a distance as possible.
8. Pressure up the equipment in stages of 20% increments. Hold the
pressure there for several minutes before increasing the pressure.
9. Do not pressure test equipment to above working pressure.
10. Devices protected by rupture discs should be tested to a maximum of 90%
working pressure.
11. If any leaks are discovered shut down and bleed pressure off
immediately. DO NOT TRY TO FIX LEAKS WITH PRESSURE IN THE
EQUIPMENT.
12. Any relief valves that have activated during Pressure Testing must be
removed and replaced.
13. When finished a thorough check must be made to make sure that no
residual pressure remains in the equipment.

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Rigging Down
Let us first of all say: THE START OF THE NEXT JOB IS AT THE END OF THE
LAST JOB.
What do we mean by that?
When you are finishing a job it is just as important to follow all the procedures and
not just throw everything into baskets and send to shore.
Firstly, the following should be taken into consideration before rigging down:
• All pressure should be bled from the system
• The well is secure. In other words the equipment is isolated from the
tubing/reservoir pressure.
• Authorization has been given to start rigging down the equipment.
• The equipment has been thoroughly emptied and flushed as necessary.
• If it is a sour service well then special precautions must be taken. (Even
flushing with an inhibitor and nitrogen before rigging down).
• Spill kits should be strategically placed around the site before rigging down.
As with rigging up a risk assessment must be carried out before hand and then a tool
box talk. Once this has been carried out then the following should be carried out.+
• All instrumentation should be removed prior to knocking pipework apart.
• All tools should not be damaged or broken
• All drains on vessels should be closed and sealed where necessary.
• All male and female thread ends should have protectors fitted or if none
available should have grease tape wound round to prevent damage.
• Pipework should be secured in pipe racks with bars.
• Any loose objects must be either stored or secured to there equipment.
• Tools should be put back into containers and secured.
• Sand filter davits should be securely tied down
• Make sure that all valve handles are secured to the various equipment.
• When placing equipment in baskets it should be packed with care and secure.
(no loose objects within the baskets). Do not overfill baskets, they have a
weight restriction.
• When packing labs/workshops, it must be done with care. Keep your
equipment tidy.
• Wrap all electrical cables and secure them to the equipment.

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When finished a check should be made of the surrounding area to make sure that:
• It is clear of all debris.
• No oil or other liquid has been left on the deck.
• All equipment has been shipped back to the base.
• Any faults pertaining to the rig have been reported.
• Permits have been handed back.

EXPRO’s Post Test Guidelines

EXPRO's commitment to quality continues after a particular job has finished. This
is in the form of post job procedures that take place once equipment has been
returned to the base from offshore.

All equipment returned to base has routine maintenance carried out on it, as laid
out in the maintenance procedures manuals. The actual maintenance required is
laid out on "job cards" which details the maintenance procedures, any special
maintenance requirements to follow and allows for the work completed to be
signed off by the person carrying out the maintenance. This allows any problems,
and the person who carried out the work, to be traced in order that the actual
steps taken in carrying out the maintenance can be identified to allow flexibility of
response to ensure the problems do not occur again.

DAMAGED EQUIPMENT

If equipment has been returned damaged, photographs are taken of the damage,
and if the costs or re-chargeable to the customer then they are invited to view the
equipment within three days after which time the necessary repairs are carried
out. If the repair costs are not re-chargeable then an insurance claim will be made.

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RETURN OF EQUIPMENT FROM H2S CONTAMINATED WELL TESTS

All equipment returned from a well test involving H2S, involves the need for extra
care in performing even routine maintenance.

Special maintenance procedures have been laid out for equipment that has
returned from well tests on H2S wells which include the following :-

1. All equipment will be quarantined until deemed H2S free. This

quarantine takes the form of a label attached to the actual equipment
and also a note on the job card. This forbids any maintenance to be
carried out on equipment or for that equipment to be brought into a
building until it has been deemed H2S free.

2. The equipment report will be checked to see if equipment has been

flushed offshore prior to backloading.

3. Sniffer checks will then be carried out to ensure the equipment is H2S
free. Once equipment has been deemed H2S free, the quarantine
labels are removed and normal maintenance procedures can be carried
out.

4. Where sniffer checks indicate the presence of H2S the equipment will
be flushed / purged as required until subsequent sniffer checks allow
the equipment to be deemed H2S free.

NOTE: Special attention should be paid to tanks, and the possibility that
sludge may remain in the bottom of the tank that has not been flushed
away. This may require the tank to be filled with water and the sludge
skimmed off. The tank should then be filled with water and left for
several days, to allow the water to absorb any H2S, and then drained
away. This should be repeated as required.

Personal safety of the maintenance staff should be considered at all times

when working on equipment returned from H2S well tests. If in doubt seek
advice.

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