SONAT_WUBS-PRS-OPS-026 (Rev.0.

0) - Page 1

System Visual Inspection

Client Sonatrach Onshore Operation X Gas X

Region Algeria Offshore Operation Oil X
Contract No 03/[Link]/2001 Underbalanced Drilling X H2O
Document No SONAT_WUBS-PRS-OPS-026 Production Testing H2S
Rev No & Date Well Services CO2

Purpose This chapter outlines the policies and procedures that ensure safe working practices during
the visual inspection of the Underbalanced Drilling Equipment once rigged down.

Scope These policies and procedures apply to all Company employees.

In this document
Topic See Page
General Guidelines 2
Hazards & General Procedures 3

General This document defines the procedures for:

Guidelines
• Visually inspecting system components for signs of erosion, corrosion or abnormal
defects
• Ensuring that the visual inspection can be completed in a safe manner

PDF created with FinePrint pdfFactory Pro trial version [Link]

 SONAT_WUBS-PRS-OPS-026 (Rev.0.0) - Page 2

System Visual Inspection

General Guidelines
Visual Inspection On completion of the rig down process or even during some periods of down time, certain
Philosophy components of the surface package should be thoroughly inspected for any signs of
erosion, corrosion or any unusual damage / defects.

It is critical for any well control or surface separation systems, to be in good working order
at all times.

All equipment will be inspected and tested prior to being deployed for any well-site
operation, however the specific nature under which the systems are exposed to, means
that the integrity of certain components can be quickly jeopardized and should be
monitored, repaired or even replaced if this becomes the case.

Well-bore fluids, drilling fluids, gases and cuttings can all affect various system
components in different ways. High velocity gas with cuttings or the presence of H2S, C02
in samples are specifically critical signs that the system could be under threat from
prolonged periods of exposure with out regular checks.

Regional environment exposure and overall equipment layout design can also be factors
for external wear and damage to equipment components that should also be continually
inspected.

Operational Operational planning for thorough visual inspection should be considered when:
Considerations
• Well bore returns contain H2S and C02 traces in samples, obviously the higher the
levels the more consideration should be taken into the selection of equipment
components deployed.
• The use of membrane N2 with small percentages of 02 levels present should be
monitored, especially if water traces are observed in well returns.
• High velocity gas with or without fluids or cuttings can be especially destructive to
the systems internals, even though specially designed equipment is deployed with
erosion considerations taken into account.
• High gas pressures across chokes can cause extreme temperature drops and
eventually hydrate formation which can seriously effect some components if the
manufactured materials have not been considered.
• Chemical make up of drilling or well bore fluids could have serious effects on
internal rubber components or even steel components in the event a chemical
reaction occurs.
• Sizing the pipelines and fluid / cuttings storage, is essential to prevent
unnecessary over exposure and eventual damage to the equipment during
operations.
• Exposure to environment, sunlight, temperatures can be a hazard to some
components overall condition and performance.
• Protecting hoses and cables from being damaged from vehicles, personnel or
other equipment movement.

PDF created with FinePrint pdfFactory Pro trial version [Link]

 SONAT_WUBS-PRS-OPS-026 (Rev.0.0) - Page 3

System Visual Inspection

Hazards & General Procedure

Purpose This section describes the common hazards that could arise whilst visual inspecting the
system, together with a general procedure to cover the more critical areas that require
checking.

Types of hazards You may encounter, and should look out for these types of hazards during a visual
inspection process:

• Flow line section not disconnected or isolated correctly

• Vessel or storage tanks not purged or thoroughly ventilated
• Vessel or storage tanks not thoroughly emptied
• Electrical components not locked out or disconnected from power source
• System section not correctly purged with N2 or ventilated prior to opening
• Overall system not disconnected from the well flow path, or adequately isolated
using a minimum of two valves
• Improper access to components because of their location or position during
inspection
• System not flushed or cleaned thoroughly enough
• Pressure trapped within some system components or hoses

Preventative Hazard preventative measures to be consider or taken during the visual inspection
Measures process:

• Ensure that all Weatherford personnel are aware of the inspection process if the
equipment is still rigged up
• Ensure that a flow line has been disconnected or at least two valves are closed
isolating the inspection area from any fluid storage or pressurized area of the
system
• Flush and purge vessel and all storage tanks prior to opening
• Leave hatches open to ventilate prior to inspection if timing allows
• All electrical components should be unplugged from power source prior to
inspection, ensuring that plugs are locked out or tagged stating that an inspection
is in process
• Inspection of RCH elements should be carried out while they are out of the RCH
unit, a back up element and bearing assembly shall be deployed as not waste any
rig time
• Overall package should be isolated at the RCH using the manual isolation valve
and the hydraulic isolation valve (the ESD valve is not to be used as an isolating
valve for inspection periods)
• Easy access to components is critical for an efficient inspection, where possible
use pipe racks to inspect flow lines etc, remove choke components, float kits etc.
and thoroughly inspect in the workshop, use bright EX lights in side of tanks or
vessel, use walkway or safety harness’ to inspect RCH if it is still nippled down
• Thoroughly flush system and wash down walls of vessel and tanks with pressure
washer prior to inspection
• Ensure all components and hoses however small, have been thoroughly bled off

PDF created with FinePrint pdfFactory Pro trial version [Link]

 SONAT_WUBS-PRS-OPS-026 (Rev.0.0) - Page 4

System Visual Inspection

Post Rig Down The Supervisors will have overall responsibility during visual inspection. However all UBD
Visual personnel on location will actively be involved with the visual inspection during the rig down,
Inspection ensuring that any signs of wear, erosion or damage etc. is documented, tagged as
Procedure DAMAGED and brought to the attention of the Supervisor.
Step Visually Inspect (instrumentation & electrical)
1 All hose connections for any signs of thread or seal damage
2 All hose condition for signs of blistering or splits
All gauges to ensure they are re-zeroed after bleed off, ensure glass is in good
3
condition and threads are not damaged
All needle valve and ball valve threads for damage, handles are present and that
4
the valves are not blocked with Teflon tape etc.
5 Pressure pilot threads are not damaged
6 All system lights are working, replace bulbs where necessary
7 All electrical cables for signs of stretching or other damage
8 All electrical plugs for signs that the cables are loose of actual plugs are broken
9 All electrical connections to pumps and switchgear are still sealed and secure
10 All pumps and switchgear are securely mounted no brackets are broken or loose
All stainless instrument lines are secure and in good condition, with no abnormal
11
bends or signs of crushing
All level controllers are removed and clean, floats are in good condition and
12
connected securely
All cables are cleaned prior to rolling onto their cable drums
13 CAUTION: Never hang heavy cables on single hooks, excessive bending will break the cable
internally
All DAQ system components sensors and meters etc. are thoroughly cleaned and
14
bench tested / re-calibrated whilst being inspected for any signs of damage

Step Visually Inspect (flow lines and main units)

All main flow line pipe and elbows from the RCH to the separator inlets should be
cleaned and put on pipe racks for close internal inspection for well bore returns
1 erosion. Check threads, sealing faces and condition of seals (replace as needed)
NOTE: Thickness checks along flow lines in the critical area between the RCH and separator
will also indicate any erosion that cannot be physically seen
All chokes and seats should be removed from the UBD manifold and internal
2 inspection carried out to ensure there is no erosion around the choke cavity and
seat threads
Rear choke valves should be removed and internal choke path areas should be
3
inspected for signs of erosion
Data header, port threads should be checked for damage from over tightening
4
valves into them
Open hatches on vessel after flushing and purging with N2, leave for a period to
5 ventilate. Enter vessel and visually inspect vessel walls especially around the
area of the inlet, ensure no lines out are blocked with debris or cuttings
Ensure all sight glasses are clean and not cracked, ensure the valves operate
6
and the handles are present

PDF created with FinePrint pdfFactory Pro trial version [Link]

 SONAT_WUBS-PRS-OPS-026 (Rev.0.0) - Page 5

System Visual Inspection

Flush and rack all downstream pipe work checking the threads, sealing faces and
7
the condition of any seals (replace as needed)
Flush and check all hose connections for signs of damage, ensure they are free
8 from sand and connect either end to protect them
CAUTION: Especially important that no sand or debris becomes trapped in the compression
system hoses, as major damage to the NPU, compressors and booster could occur
Check the condition of the pump skids ensuring the drip trays have been cleaned
9
out and all cables securely rolled up
Open hatches on tanks after flushing and purging with N2, leave for a period to
ventilate. Enter tanks and visually inspect the walls to check the condition of the
10
internal coating especially around the area of the inlets, ensure no lines out are
blocked with debris or cuttings
Check that all sight glasses are clean and that all the valves operate, plus all the
11
handles are present
12 Check the condition of the vacuum vents
Check the compressor skids ensuring that any drip trays have been cleaned out,
13
all valves operate correctly and their handles are present
Check the booster skid ensuring that any drip trays have been cleaned out, all
14
valves operate correctly and their handles are present
All compression equipment, generators and export pumps will have regular engine services.
Note Visual inspection only covers each units overall condition
Check the generator units ensuring any drip trays have been cleaned out, all
16
cables have been cleaned and securely stored off the floor
Ensure no loose equipment is left in the NPU unit, clean out, close and secure
17
doors
Check flare stack, head for signs of damage due to extreme heat, check condition
18 of the ignition system cable connection
NOTE: Ignition cable is designed to be armored to prevent heat exposure damaging it, however
physical stretching signs or internal cable damage cannot be easily detected
Ensure that the diesel fuel lines are fully drained, do not flush with water. Ensure
19
thread connections are not damaged
Ensure that the diesel fuel tank is fully emptied prior to moving and that there are
20
no signs of any leaks. It is not necessary to inspect the tank internally
Check the ESD remote stations for any signs of damage, clean and check
21
threaded connections
Check ESD valve and internals for signs of debris, cuttings etc., Inspect gate
22
faces for signs of scouring.
23 Inspect all flange sealing faces and ring grooves for signs of any damage

Step Action (rotating control head)

Inspect both the removed bearing assemblies, clean and check for and signs of
1
damage
Remove sealing elements, scrap as necessary, do not re-use semi worn
2
elements
Whilst on crane or adequately supported off the floor, inspect the main 13 5/8”
3
sealing face and ring groove for any signs of damage, clean and lubricate

PDF created with FinePrint pdfFactory Pro trial version [Link]

 SONAT_WUBS-PRS-OPS-026 (Rev.0.0) - Page 6

System Visual Inspection

Inspect sensor port threads for signs of damage, and also 7 1/16” outlet flange
4
face
Check all hydraulic fittings, ensure they are secure and cover to protect prior to
5
packing

Ensure that the RCH control container, is clean and tidy, all loose items are
6
secured. Inspect control unit for signs of any hydraulic fluid leaks.

For further inspection and maintenance instructions refer to the RPM 3000
Note
Equipment Manual SONAT_WUBS-EQP-OM-001

Visual Inspection The visual inspection process completed during rig down is undertaken by the Weatherford
Reporting UBD crew, prior to packing away items or securing for transit. An overall report is not
required to be completed for all, however any items found to be damaged, defective,
eroded or corroded will be brought to the attention of the Wellsite Supervisor and
Supervisors.

Individual reports as found in the Supervisors Reporting Pack, such as Equipment Failure
Report SONAT_WUBS-RT-DOC-001, Instrument Failure Report SONAT_WUBS-RT-
DOC-006, etc. are required to be completed, recorded and sent to the Project Manager
and the Dubai Operations facility for review and action.

Damaged or non-reusable items must be tagged and clearly marked “DAMAGED”, these
items must not be re-instated for use until they have been repaired and maintained. Any
items that are non-repairable must be replaced with new components prior to continuing
further operations.

To be signed if document SONAT_WUBS-PRS-OPS-026 has been reviewed and accepted by all parties
concerned.

Weatherford SONAT ENAFOR

PDF created with FinePrint pdfFactory Pro trial version [Link]