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SYSTEM REQUIREMENTS
Please note that whilst every effort has been made to ensure the accuracy of the NORSOK standards neither OLF nor TBL or any of their members will assume liability for any use thereof.
Coiled tubing equipment CONTENTS 1 FOREWORD 2 SCOPE 3 NORMATIVE REFERENCES 4 DEFINITIONS AND ABBREVIATIONS 4.1 Definitions 4.2 Abbreviations 5 FUNCTIONAL REQUIREMENTS 5.1 General 5.2 Product/services 5.3 Equipment/schematic/borderline 5.4 Process/ambient conditions 5.5 Performance and operational requirements 5.6 Maintenance requirements 5.7 Layout requirements 5.8 Interface requirements 5.9 Commissioning requirements ANNEX A COILED TUBING EQUIPMENT REQUIREMENTS ANNEX B WELL CONTROL SYSTEM REQUIREMENTS ANNEX C PRIMARY WELL CONTROL SYSTEM ANNEX D SECONDARY WELL CONTROL EQUIPMENT ANNEX E TERTIARY WELL CONTROL SYSTEM (SAFETY HEAD) ANNEX F COMPUTERISED DATA ACQUISITION SYSTEM (CDA) ANNEX G MINIMUM DOCUMENTATION REQUIRED
2 2 2 2 2 3 3 3 3 3 4 4 4 4 5 5 6 8 10 11 12 13 14
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FOREWORD
NORSOK (The competitive standing of the Norwegian offshore sector) is the industry initiative to add value, reduce cost and lead time and remove unnecessary activities in offshore field developments and operations. The NORSOK standards are developed by the Norwegian petroleum industry as a part of the NORSOK initiative and are jointly issued by OLF (The Norwegian Oil Industry Association) and TBL (The Federation of Norwegian Engineering Industries). NORSOK standards are administered by NTS (Norwegian Technology Standards Institution). The purpose of this industry standard is to replace the individual oil company specifications for use in existing and future petroleum industry developments, subject to the individual company's review and application. The NORSOK standards make extensive references to international standards. Where relevant, the contents of this standard will be used to provide input to the international standardisation process. Subject to implementation into international standards, this NORSOK standard will be withdrawn.
SCOPE
This standard describes functional, performance and operational requirements for the coiled tubing equipment.
NORMATIVE REFERENCES
Design of control systems for drilling well control equipment Recommended practice for blow-out prevention equipment systems for drilling wells Test methods and definitions for mechanical testing of steel products Specification for general requirements for carbon, ferritic alloy, and austenitic alloy steel tubes Test methods for rockwell hardness and rockwell superficial hardness of metallic materials Guide for radiographic testing Hardness conversion tables for metals Formulae and calculation for casing, tubing, drill pipe and line pipe properties Specification for valves, wellhead and christmas tree equipment Sulphide stress cracking resistant metallic materials for oil field equipment
API RP 16E API RP 53 ASTM A 370 ASTM A 450 ASTM E 18 ASTM E 94 ASTM E 140-88 ISO 10400 ISO 10423 NACE MR0175
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D-SR-005 Rev. 1, January 1996 Should is a recommendation. Alternative solutions having the same functionality and quality are acceptable. May indicates a course of action that is permissible within the limits of the standard (a permission). Requirements are conditional and indicates a possibility open to the user of the standard.
The well control system is divided in the following three distinct logic groups, referenced from below the injector to the x-mas tree: Primary well control system designed to enable efficient coiled tubing operation, this is the strippers (stuffing boxes), the coiled tubing body and the dual flapper check valves, alternatively plugged end of the coiled tubing. Secondary well control system designed to meet or exceed requirements for a secondary barrier element as during normal drilling operations. As a minimum it consists of three independent rams; blind/shear, tubing, slip. Connections to this system shall be with metal to metal seal. Tertiary well control system, safety head. A separate independent shear/seal BOP fitted as close as possible to the wellhead with metal to metal seal connections and with an entirely independent closing unit. 4.2 None. Abbreviations
FUNCTIONAL REQUIREMENTS
5.1 General The coiled tubing unit and BOP systems shall be capable of handling the work string, well conditions and other work parameters specified by the work program. 5.2 Product/services Typical service performed by a coiled tubing unit: Pumping. Milling/drilling (junk-, scale-, window-, hole-). Clean-out. Lifting. Operate downhole tools (packers, plugs etc.). Fishing. Logging. Perforating. 5.3 Equipment/schematic/borderline The system normally consists of the following main items: Injector head w/control system and frame(s). Hydraulic power system. Coiled tubing reel assembly. Control cabin with data acquisition system. Rig-up equipment. Well control system. NORSOK standard Page 3 of 15
5.4 Process/ambient conditions The well control system with connected valves, hoses and piping shall be designed for the following conditions: Maximum well pressure 345 Bar (5000 psi) Maximum wellhead temperature 121C (250F) Minimum operating temperature -10C (14F) Formation fluids Yes H2S Yes CO2 Yes Oil and water based drilling muds Yes Brine Yes Diesel Yes Glycol Yes Acid (inhibited) Yes Cement slurry Yes Nitrogen Yes Well control and pilot hoses and connections shall be capable of withstanding 700C for minimum 15 minutes. 5.5 Performance and operational requirements Coiled tubing equipment: Ref. annex A. Well control system: Ref. annex B, C, D and E. 5.6 Maintenance requirements Maintenance program with defined frequencies and work scopes. Re-certification program. Non-conformance system. Documentation system. 5.7 Layout requirements Secure area of CT operations. Escape ways. Locate second (back-up) control panel for secondary well control system away from CT control house in safe area. Locate one control panel for tertiary well control system away from CT control house in safe area. Secure frames and injection head so that rig up can withstand 46 m/s (90 knots) wind. Secure high pressure lines. Sufficient illumination.
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5.8 Interface requirements Mechanic, electric, hydraulic and pneumatic connections shall be compatible with the rig or platform connections. 5.9 Commissioning requirements Function testing of all relevant coiled tubing unit components including all accessory equipment shall be performed prior to each job. Function testing and verification of the injector head positive and negative weight indicator system shall be performed prior to each job. Documentation/verification of acceptable rig up versus forces and bending momentums. Documentation/verification that coiled tubing downhole tools, well control systems, frames, injector head and pumps can handle expected work conditions inside set safety factors.
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Coiled tubing equipment Annex A Highest permissible noise level: 90dB at 1m distance.
Coiled tubing: Withstand all expected downhole forces. Drifted before each operation. Size of drift ball shall be acceptable for upcoming operation, and be larger than balls for tool operation. For coiled tubing strings with E-line installed or other obstructions, other ovality check shall be performed. Also see annex G. Reel: Fluid manifolds: Inlet and isolation valves, launcher with by-pass, rotary joint and isolation valves, pressure sensing device. String isolation valve upstream reel axle and swivel joint. Minimum core diameter (inches) 48 times coiled tubing outer diameter. Pressure relief valve upstream reel axle and swivel joint and with protection cap. Top end mechanically secured. Level wind system. Hydraulic motor. Drive speed higher than maximum injector speed. Adjustable back-force for preventing excessive pull on goose neck and with fail safe brake to prevent damage to coiled tubing and goose neck. Top termination with qualified high pressure connection. Control cabin: Light for minimum 30 minutes in control cabin if power is lost. Minimum 2 independent escape routes. Pump with diesel/combustion engine: Fluid end and engine designed to handle expected rate and pressure. Manual ESD system. Overspeed on diesel engine: Gas detector on air inlet with audible/visible alarm. Zone 2 certified diesel engine. Highest permissible noise level: 90dB at 1m distance. Depth metering: Fail safe with independent back-up system. Bottom hole assembly: Withstand all expected downhole forces It shall minimum consist of from top and down, end connector and double flapper/back-pressure valves. Double flapper back-pressure valves can be substituted with tested plug. Holding/mixing tank: Clean so as not to cause plugging in coiled tubing and bottom hole assembly.
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Accumulators: All preventors in the secondary and tertiary well control systems shall be used as basis when calculating accumulator capacity. Sufficient capacity for three operations (close, open, close) plus 25% of the volume of one closing operation for each of the rams. Accumulator capacity shall be calculated according to the following minimum requirements: Sufficient volumetric capacity for three (3) operations (close, open, close) for all rams, plus 25% of the volume of one closing operation for each of the rams. Sufficient pressure capacity to enable cutting the coiled tubing in accordance with the following requirements: Sufficient remaining accumulator pressure to enable cutting of the coiled tubing after having used a volume corresponding to: - Closing and opening of one annular preventer. - Closing, opening and closing of one pipe ram. Alternatively a dedicated shear ram auxiliary pressure system may be installed to meet the minimum requirements for cutting the coiled tubing if the remaining accumulator pressure is insufficient to enable cutting after having performed operations as mentioned above. There shall be documentary evidence that the pressure capacity of the accumulators are capable of operating the rams according to the design requirements. Regulators in the system shall remain unaffected in the event of loss of power. Well control hoses and connections including pilot hoses for well control purpose: Fire resistant, capable of withstanding 700C for minimum 15 minutes. Riser: Minimum pressure rating 345 bar (5000 psi). Metal to metal seals. Designed to withstand the most unfavourable combination of expected forces that can be encountered during an operation.
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Additional documentation: Log of tubing repairs, including: location of manufacturer's welds, location of section welds/tubing cut off/added/re-used. Reason for repair. Log of OD, ovality and wall thickness testing. Estimated cumulative damage and remaining life time, including evaluation and location of butt/field welds. Operational limits for outside diameter and wall thickness. History log of all previous jobs, including parameters influencing life time. Documentation on receiving-QC of the coiled tubing. Marking of equipment. Updating of items in the case of modification of equipment. Quality audit of the manufacturing process. Pre-job inspection and testing documentation. Downhole tools: Manufactures quality control certificate and documentation: Name of equipment. Production number. Name of manufacturer and supplier. Description of design and manufacture, indicating safety factor used. Verification of design assumptions with regard to strength, carried out by an independent survey institution. Depending on organisational independence, this function may be taken care of by the manufacturer. Material certificates and confirmation as to where materials have been used. Statement of manufacture and inspection signed by manufacturer and surveyor/surveying firm/body. Additional documentation: Receiving-QC of the tool. Marking of equipment. Updating of items in the case of modification of equipment. Quality audit of the maker's manufacturing process. Inspection report. Drawings showing internal parts/functions, overall length, maximum OD, minimum ID and weight. Tool description, function, maximum/minimum parameters. Strength calculations indicating safety margins. Operational manual/operating procedures. Function/operational testing. This does not replace acceptance test offshore before a job. Complete BHA drawings showing; total length, maximum OD, minimum ID, weight, position of tools and threads. Fishing data.
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