STANDARD FLOWBACK TRAINING

FLOWBACK TRAINING
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May 2024
WELCOME TO STANDARD FLOWBACK TRAINING
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LOCATION SAFETY INDUCTION
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SIU – OILTECH BASE
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EMERGENCY CONTACT – OILTECH

Name Position Mobile E-mail

Majid Abdullah SIU Security Manager 07809184724 [email protected]

Saif Hasan OS Representative at Airport 07834496090 [email protected]

Medical Doctors SIU Doctors 07809137269 [email protected]

Mohialdeen Al Qaderi HR Manager, SIU 07809137349 [email protected]

Alyaa Farqad SIU Visa 07809147585 [email protected]

Alaa Fouad Facilities /Accommodation 07809279944 [email protected]

Ronald Rardede SIU WTC SDM 07809184980 [email protected]

Ahmed Hisham Fadhil SIU Wireline SDM 07809282088 [email protected]

Murtadha Abdul Hadi SIU CSC SDM 07809147611 [email protected]

Majid Abdullah HSE Manager 07809184724 [email protected]

Ali Taher Territory Manager 07809200947 [email protected]

Benoit President South Iraq 07809137362 [email protected]

Nazar Rashid Project Manager 07827814297 [email protected]

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CLASSROOM RULES
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CLASSROOM RULES

COURSE GROUND RULES GENERAL ADVISE

 Think as part of OiLTECH  Get the most out of this workshop
 No Smoking  Ask- If you don’t understand
 Mobiles Silent or OFF  Give freely of your experience
 Confine your discussion to the problem  Say what you think
 Be prompt and regular in attendance  Listen alertly to the discussion
 Avoid private conversation while  Appreciate the other person’s point of view
someone else is speaking  This workshop is for you and its success
 Only one person should talk at a time rests largely with you
 Obey moral rules : honesty, fairness and  Get involved and participate
respect  Do not ever feel shy to ask
 Keep noise to minimum, especially in
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the entrance of the conference room to

respect workers in other offices
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KNOW YOUR INSTRUCTOR & PARTICIPANT SELF INTRODUCTION

Note:

 Send Picture and Below required information to your Instructor.

 Instructor Name: Ebrahim Faisal
 Instructor E-mail: [email protected]
 Mobile # (+9647505093681 / +9647732977678
Passport EE Employee Seniority Educational Year of
Position Email Address
Photograph Number Name date Gender BU Background Degree Graduation Remark
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TRAINING OBJECTIVE

At the end of this training, you should be able to:

 Understand the role of flowback equipment.

 Understand the function of flowback equipment.
 Select required flowback equipment based on customer program.
 Understand the layout, rig up, pressure test, monitoring & control procedures.
 Operate flowback equipment.
 Identify associated safety concerns during flowback operation and the required control measures.
 Identify and appreciate the role of each personnel on a flowback job.
 Apply and gain an in-depth knowledge on the design, selection, drawing, installation, performance,
and control of several types of flowback scenarios.
 Understand maintenance and condition monitoring requirements.
 Grasp the specific requirements of clients like BP/ROO & ENI.
 Know the data obtained during flowback operations and the QAQC procedures for on-site validation.
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TRAINING SCHEDULE
Day Date 07:30 - 09:30 09:45 - 12:00 14:00 - 15:30 15:30 - 17:00 Presenter
7. Flowback Rigless Operations
4. Life Of The Reservoir 12. Manifolds
1. Course Introduction 8. Flowback Control Equipment
5. Well Testing & Flowback 13. Gauge & Surge Tank
2. OiLTECH SharePoint & OIMS. 9. Surface Safety Valve
1 29-May-24 Wednesday Operation Overview 14. Storage Tanks Ebrahim Faisal
3. ORBIS 10. ESD System / Hi-Lo Pilots
6. Flowback Rig/ WO 15. Piping & X-Overs
11. Choke Man & Data Header
Operation 16. Fitting & Valves

17. Review Day-1 / Homework - 1

20. Flare Stack & Ignition 22. Other Flowback/ Well Testing
18. Transfer Pumps
2 30-May-24 Thursday System Equipment (Heater / Oil Burner) Theory Quiz 1 Ebrahim Faisal
19. Test Separator
21. Flame Arrestors

23. Review Day-2 / Homework - 2

26. Equipment Selections. 28. Clean Up / Flowback
24. Flowback Lay Out, Zoning &
3 31-May-24 Friday 27. Layout Practices & 29. Customers Concerns & Standards Theory Quiz 2 Ebrahim Faisal
Safety.
Scenarios on Flowback Operation.
25 Flowback Safety Consideration

34. Data Obtained &

33.Flowback Operation) - Execution.
Reporting
A. Post Acid Treatment.
30. Review Day-3 / Homework - 3 32. (Flowback Operation) - 35. Flowback Operation) - Rig
4 1-Jun-24 Saturday B. N2 Lift Ebrahim Faisal
31. (Flowback Operation) - Rig up Flushing & Pressure Test Down.
C. ESP
36. Troubleshooting & Lesson
Learned

Ebrahim Faisal /
37. Review Day-4 / Homework - 4 39. Certification (Hazardous Course Survey / Appraisal &
5 2-Jun-24 Sunday Final Assessment Team & Line
38. Certification (Pressure L2) Area Classification L2) Round Table
Management
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Theory Session Quiz / Assessment Practical Session Break

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TRAINING METHODOLOGY

 Lectures: the slides will cover a wide range of materials and explain in detail, to build your foundational
knowledge.
 Case Studies: Examples and Scenarios for specific and real operation will show how these concepts
apply in practice, highlighting challenges and solutions in well testing operations.
 Group Discussions: Engage with peers to exchange idea, ask questions, and solve problems
collaboratively, benefiting from diverse perspectives.
 Q&A Sessions: Regular sessions will allow you to clarify doubts and delve deeper into specific topics
with the guidance of Instructor.
 Self-Study Materials: Additional resources such as readings and research papers will be available for
further exploration..
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COURSE LOADING
 Start now, don’t leave work for later.
 Review course day by day.
 Organize your time.
 Endeavor to understand, not just to remember
 Manage your rest/ sleep.
 No lateness to class, manage your time properly.

COURSE SCORES
Final Average score to obtain Course Certificate is 75%.

 Three Quizzes including the final assessment.

 Field Mandatory training is part of the training scores.
 Minimum 5 SSHE OSCAR reports & 5 SQ OSCAR reports are part of the training scores.
 Final Practical Project End of the course (FB Layout / Equipment Selections / Risk Assessment /
TBT / JSA)
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COURSE SCORES

Final Average score to obtain Course Certificate is 75%.

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JOB RELATED CERTIFICATION
It is not part of the course average, but it is part of the standalone operation.
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ASSESSMENT

 Theoretical & practical assessment during this course.

 Attitude, ethics and commitment to safety and quality are part of the appraisal.
 Feedback on course progress should help to build on strengths and overcome
weakness.
 End of the course, successful participants receive:
1) A course certificate.
2) An appraisal form
3) Recommendation letter for Grade-A or the first in class.
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EXPECTED FROM YOU
Personal learning in the evening -------------------------- > Reading the day’s subjects
Course review ------------------------------------------> 1 each morning or day
Theoretical Quiz ----------------------------------------- > 3 for FB marked
Practical -------------------------------------------------------- > Safety , layout, equipment Selection, Well Clean-Up, Risk
Assessment, TBT/JSA, & Report RQC
Individual Project ------------------------------------------ > TBA
Flowback/ group tasks ----------------------------------- > 1 each
Flowback Homework ------------------------------------------- > Part of appraisal assessment
House keeping tasks ----------------------------------------- > 1 each
Behavior (good) ----------------------------------------- > Taken into account in Appraisal
Safe working session ----------------------------------------- > All the time
Reporting SSHE & SQ ----------------------------------------- > All
Arrive in time for work ---------------------------------------- > Everyday
Arrive in good shape & ready to work -------------------- > Everyday
Obtain result more than 75% ------------------------------ > Final Average to obtain Course Certificate
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ACKNOWLEDGEMENT
Training Course Responsibility Matrix & Performance Criteria
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ANY QUESTIONS
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STANDARD FLOWBACK TRAINING

DAY - 1
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May 2024
DAY- 1 AGENDA

 Course Introduction.
 OiLTECH Business System, Reporting And Documentations.
 Fundamental And Life Of The Reservoir.
 Principles Of Flowback Operation.
 Flowback Operations Scenarios (Rig/Rigless).
 Flowback Control Equipment (Upstream Choke Manifold).
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SHAREPOINT ORBIS REPORTING & DOCUMENTATION

https://oilserv.sharepoint.com/SitePages/Sky.aspx
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STANDARD FLOWBACK TRAINING

FUNDAMENTAL LIFE
CYCLE OF A RESERVOIR
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May 2024
LIFE CYCLE OF A RESERVOIR

When
Flowback Testing?
Downhole Testing
Surface Testing

Multi - Phase Measurement Sampling

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LIFE CYCLE OF A RESERVOIR

Seismic Drilling Logging Testing

Abandon

Testing
Or Refinery
Monitoring

Artificial lift Production Completion

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SURFACE WELL TESTING
Surface well testing in the oil and gas industry refers to the process of evaluating
the characteristics and performance of a well after it has been drilled, but
before it is put into production. This involves temporarily flowing the well and
collecting data on various parameters to determine the well’s potential for
producing hydrocarbons (oil and gas)

OBJECTIVES
 Reservoir Evaluation: Assess the capacity and productivity of the reservoir.
 Fluid Characterization: Identify the types and properties of fluids (oil, gas, water) present in the well.
 Pressure and Flow Rate Analysis: Measure reservoir pressure and the well’s flow rate capabilities.
 Formation Integrity: Evaluate the structural integrity of the geological formations.
 Production Forecasting: Provide data for estimating future production rates
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KEY COMPONENT

 Surface Test Equipment: Includes separators, flow meters, pressure gauges, and sample
collection systems.
 Wellhead: The surface termination of the wellbore, including the components that contro
the flow from the well.
 Choke Manifold: Controls the flow rate and pressure of the well fluids.
 Separators: Equipment that separates oil, gas, and water for individual measurement.
 Storage Tanks: Temporary storage for collected oil and water during testing.
 Oil Burner (Flare Stack): Safely disposes of unwanted gas by burning it off.
 Data Acquisition System: Records real-time data on pressure, temperature, and flow rates
 Flare Pit: An area designed to safely burn off excess hydrocarbons, especially gases that ar
not economical to capture or that need to be flared for safety reasons.
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IMPORTANCE

 Decision Making: Helps in deciding whether to proceed with completing the well for
production.
 Optimization: Aids in designing the most efficient production strategy.
 Safety: Identifies potential issues like excessive gas production or water ingress that
could affect well integrity and safety.
 Economic Evaluation: Provides critical information for economic assessments and
investment decisions.

Surface well testing is a crucial step in the lifecycle of an oil or gas well, providing
valuable insights into the well’s potential and helping operators make informed
decisions about its future
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SURFACE WELL TESTING

Slickline
Pressure Data

Pressure Data Flow rate

Well Head
Maintenance

Surface Sampling
Sampling
Sample Information
Pressure Data
Temporary completion using down-
Testing/Shut In Valve hole tools to gather data on the
Circulating Valve potential productivity of a reservoir
Tubing Testing Valve Pressure Recorder
Packer Downhole Sampling

Perforation
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SURFACE WELL TESTING APPLICATIONS
Well Test Application

Exploration Well Test Clean-Up / Flow-Back In-line Production Testing Production Solution

Performed after drilling a well Performed shortly after Performed on producing wells Extended well tests
in a new area or reservoir completing a development well
prior hooking up permanent
production facilities Basically to measure the flow Early production facilities
Measures well / reservoir’s rate of the produced oil, gas
productivity potential and water
Helps to optimize production Marginal field development
and protect facilities
Helps determine deliverability Helps in production
completion methods and allocation, utilize field Utilizes combination of well
reserves estimation production testing and specific project
equipment

Early cash flow

Production data knowledge

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DEFINITIONS & ACRONYMS
 Rig / Drilling Rig:
 The machine used to drill a wellbore. In onshore operations, the rig includes virtually everything except
living quarters. Major components of the rig include the mud tanks, the mud pumps, the derrick or mast,
the draw works, the rotary table or top drive, the drill string, the power generation equipment and
auxiliary equipment. Offshore, the rig includes the same components as onshore, but not those of the
vessel or drilling platform itself. The rig is sometimes referred to as the drilling package, particularly
offshore.

 Workover:
 The process of performing major maintenance or remedial treatments on an oil or gas well. In many
cases, workover implies the removal and replacement of the production tubing string after the well has
been killed and a workover rig has been placed on location. Through-tubing workover operations, using
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coiled tubing, snubbing or slickline equipment, are routinely conducted to complete treatments or well
service activities that avoid a full workover where the tubing is removed. This operation saves
considerable time and expense.
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DEFINITIONS & ACRONYMS
 Flowback:
 The process of allowing fluids to flow from the well following a treatment, either in preparation for a
subsequent phase of treatment or in preparation for cleanup and returning the well to production.
 Clean-Up:
 A period of controlled production, generally following a stimulation treatment, during which time
treatment fluids return from the reservoir formation. Depending on the treatment, the cleanup period
can be relatively short and uncomplicated. However, following more complex treatments such as gravel
pack or hydraulic fracturing, the cleanup process should be conducted carefully to avoid jeopardizing the
long-term efficiency of the treatment.
 Stimulation:
 A treatment performed to restore or enhance the productivity of a well. Stimulation treatments fall into
two main groups, hydraulic fracturing treatments and matrix treatments. Fracturing treatments are
performed above the fracture pressure of the reservoir formation and create a highly conductive flow
path between the reservoir and the wellbore. Matrix treatments are performed below the reservoir
fracture pressure and generally are designed to restore the natural permeability of the reservoir following
damage to the near-wellbore area. Stimulation in shale gas reservoirs typically takes the form of hydraulic
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fracturing treatments..

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DEFINITIONS & ACRONYMS
 Treatment Fluid:
 A fluid designed and prepared to resolve a specific wellbore or reservoir condition. Treatment fluids are
typically prepared at the wellsite for a wide range of purposes, such as stimulation, isolation or control of
reservoir gas or water. Every treatment fluid is intended for specific conditions and should be prepared
and used as directed to ensure reliable and predictable performance.
 Squeeze Job:
 An operation that requires the careful application of pump pressure to force a treatment fluid or slurry
into a planned treatment zone. In most cases, a squeeze treatment will be performed at downhole
injection pressure below that of the formation fracture pressure. In high-pressure squeeze operations,
performed above the formation fracture pressure, the response of the formation and the injection of
treatment fluid may be difficult to predict.
 Injectivity Test:
 A procedure conducted to establish the rate and pressure at which fluids can be pumped into the
treatment target without fracturing the formation. Most stimulation treatments and remedial repairs,
such as squeeze cementing, are performed following an injection test to help determine the key
treatment parameters and operating limits. Likewise, injection tests are also conducted when pumping
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secondary recovery fluids such as water, nitrogen [N2], carbon dioxide [CO2], natural gas and steam.

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FLOWBACK OVERVIEW

Flowback equipment must effectively and securely execute a wide range of functions:

 Swiftly controlling pressure and flow rates at the surface to shut in the well at any time.
 Segregating the well effluent into three phases oil, gas, & water.
 Precisely measuring each phase of the fluids if needed by customer after clean up the well.
 Collecting samples and gathering phases basic properties (BSW, SG, Salinities..)
 Dispose produced fluids and gases in an environmentally manner.
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FLOWBACK OVERVIEW
Control

Well Effluent
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FLOWBACK OVERVIEW
Separate , Accurately measure rates and
collect samples

Well Effluent
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FLOWBACK OVERVIEW Dispose produced fluids and gases in an
environmentally manner.

Well Effluent
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HOMEWORK

 Explain The Different between Drilling Rig & Workover?.

 Explain The main functions of the flowback set-up?
 Each participant to submit complete detail of one of the Upstream Equipment as per Manufacturer Data
Book:
 S/N
 WP
 TP
 Material of each section
 Temperature Design
 Manufacturer Design Code
 Manufacturer Name
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ANY QUESTIONS
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STANDARD FLOWBACK TRAINING

DRILLING RIG VS.

WORKOVER RIG
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DRILLING RIG VS. WORKOVER RIG
Drilling Rigs:

 Purpose: Used for drilling new wells.

 Functionality:
 Drilling: Penetrates the earth to reach oil and gas
reservoirs.
 Construction: Sets up the initial wellbore and installs
casing and other structural components.
 Components:
 Derrick or Mast: Tall structure to support the drill string.
 Rotary Table/Top Drive: Equipment to rotate the drill
pipe.
 Mud System: Circulates drilling fluid (mud) to cool the
drill bit and remove cuttings.
 Blowout Preventer (BOP): Safety device to control
unexpected pressure surges.
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DRILLING RIG VS. WORKOVER RIG
Workover Rigs:

 Purpose: Used for maintenance and repair of existing wells.

 Functionality:
 Intervention: Performs tasks such as repairing tubing,
cleaning the wellbore, and enhancing production.
 Recompletion: Modifies the well to access different
reservoir zones.
 Components:
 Smaller Derrick/Mast: Less robust than drilling rigs,
sufficient for pulling and running tubing.
 Wireline or Coiled Tubing Unit: Used for various
downhole operations.
 Pump System: Provides the hydraulic power for tools
and interventions.
 Work Platforms: Structures for operators to perform
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repairs and maintenance.

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DRILLING RIG VS. WORKOVER RIG
Key Differences:

1) Function:
 Drilling Rig: Creates new wells from scratch.
 Workover Rig: Maintains and repairs existing wells.

2) Size and Power:

 Drilling Rig: Larger, more powerful for deep drilling.
 Workover Rig: Smaller, mobile, designed for less intensive tasks.

3) Operations:
 Drilling Rig: Involves heavy-duty operations like rock cutting and
casing installation.
 Workover Rig: Focuses on interventions like tubing
replacements, well cleaning, and production enhancements.

Summary:
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 Drilling Rig: Large structure, heavy equipment, mud system, BOP.

 Workover Rig: Smaller structure, intervention tools, pump system
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ANY QUESTIONS
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STANDARD FLOWBACK TRAINING

FLOWBACK AT DRILLING
/ WORKOVER RIG
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FLOWBACK AT DRILLING / WORKOVER RIG
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FLOWBACK AT DRILLING / WORKOVER RIG

Upstream Hook – Up on Temporary wellhead (Flowhead)

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FLOWBACK AT DRILLING / WORKOVER RIG

Rig up configuration at well head (Workover rig)

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FLOWBACK AT DRILLING / WORKOVER RIG

Rig up configuration
Option (Workover /
drilling rig)
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FLOWBACK AT DRILLING / WORKOVER RIG

Rig up configuration
Option (Workover /
drilling rig)
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FLOWBACK AT RIG

Rig up configuration
Option (Workover /
drilling rig)
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ANY QUESTIONS
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STANDARD FLOWBACK TRAINING

FLOWBACK AT RIGLESS
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May 2024
FLOWBACK AT RIGLESS
 Ensure that the rig-up includes all necessary options to operate the
well without requiring containment breaks during flowback
operations. This includes options such as flow cross above swab valves
and connection to the annulus, allowing for flexibility in pumping into
the tubing, receiving from the annulus, or vice versa. Additionally,
ensure there are options to flow from both the tubing and annulus.

Rig up configuration
at Well head with
Flow cross valves
(CT or SLS)
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FLOWBACK AT RIGLESS
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FLOWBACK AT RIGLESS
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FLOWBACK AT RIGLESS
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FLOWBACK AT RIGLESS
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FLOWBACK AT RIGLESS
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FLOWBACK AT RIGLESS
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FLOWBACK AT RIGLESS
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FLOWBACK AT RIGLESS
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FLOWBACK AT RIGLESS
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FLOWBACK AT RIGLESS
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FLOWBACK AT RIGLESS
 When connecting to the X-mass tree, ensure to bleed off pressure between the X mass tree and the blind
flange, once it is safe to do so, remove blind flange.

 For any breaking containment need to ensure all risks been assessed and all control measured been
discussed and included in the PTW authorized by customer or DGS Authority:
 Ensure before breaking containment that all system is depressurized.
 Only authorized personnel are allowed to work inside the red zone area.
 Non sparking tools to be used.
 Ensure continuous monitoring of the gas /LEL level, Gas test certificate might be required.
 DGS station or client representative aware of the rigging up process across the x tree around
Wellhead and production lines or manifold.
 Consider the Positions of others in the area while operating valves.
 Personnel operating sampling equipment and bottles must stand clear of the identified "lines of
fire” (valves, pressure ports, fittings).

 For production Tie -in / Tie-out hook-up, ensure there is a T-piece in between the tie-in / tie-out point and
SSV. Connect a low torque valve into the T-piece which will be the point where the flushing/pumping unit
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will be connected.

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FLOWBACK AT RIGLESS / DRILLING / WORKOVER RIG

WHAT SHOULD WE DO BEFORE MOBILIZING EQUIPMENT TO CONFIRM RIG UP REQUIREMENT

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FLOWBACK AT RIGLESS / DRILLING / WORKOVER RIG

WELL SITE VISIT / SCOUTING OR/AND ROAD SURVEY

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FLOWBACK AT RIGLESS / DRILLING / WORKOVER RIG

WELL SITE VISIT / SCOUTING OR/AND ROAD SURVEY

 Flowback scope of work.
 Client representative in charge of the operation.
 Well information & or rig information.
 Reservoir data if available.
 X-tree and or Flowhead.
 Flowback requirement / x-overs / connections / who should supply and do.
 Pit location and size.
 Production required or not / x-overs and connection.
 Burning / flaring and location
 PTW requirement
 Certifications required
 Road condition and access to location
 Weather
 Other contractors and the interconnection between the rig and the equipment of other service
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FLOWBACK AT RIGLESS / DRILLING / WORKOVER RIG

WELL SITE VISIT / SCOUTING OR/AND ROAD SURVEY

 Flowback scope of work.
 Client representative in charge of the operation.
 Well information & or rig information.
 Reservoir data if available.
 X-tree and or Flowhead.
 Flowback requirement / x-overs / connections / who should supply and do.
 Pit location and size.
 Production required or not / x-overs and connection.
 Burning / flaring and location
 PTW requirement
 Certifications required
 Road condition and access to location
 Weather
 Other contractors and the interconnection between the rig and the equipment of other service
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companies.

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FLOWBACK AT RIGLESS / DRILLING / WORKOVER RIG
WELL SITE VISIT / SCOUTING OR/AND ROAD SURVEY
CASES TO BE DISCUSSED
Reports Note:
 Mushorah-02 is a new well in Mushorah Field, currently
being drilled by the HoneStar drilling company (formerly
known as DQE), using rig HS-039. The ongoing operation
consists of drilling with an 8.5" drill bit.
 The main goal of this well is to evaluate its productivity
through exploration testing, involving wireline and slick
line operations, stimulation, coiled tubing, and surface
well testing using DST tests.
 The road leading to the well site is in good condition and
clear for all types of vehicles, including trucks.
 The well site itself is not covered with gravel, but rather
compacted soil. It is surrounded by T-walls and guarded
by a strong security system.
 The accommodation camp is located 36 km away from
the rig site. We utilize an armored bus provided by Rig to
transport the crew.
 The area designated for the testing package is sufficient.
 Power supply and water for the burner cooling system will
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be provided by the Rig.

 Cell phone signals were very weak at rig site location.
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FLOWBACK AT RIGLESS / DRILLING / WORKOVER RIG
WELL SITE VISIT / SCOUTING OR/AND ROAD SURVEY
CASES TO BE DISCUSSED
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FLOWBACK AT RIGLESS / DRILLING / WORKOVER RIG
WELL SITE VISIT / SCOUTING OR/AND ROAD SURVEY
CASES TO BE DISCUSSED

RIGLESS
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FLOWBACK AT RIGLESS / DRILLING / WORKOVER RIG
WELL SITE VISIT / SCOUTING OR/AND ROAD SURVEY
CASES TO BE DISCUSSED
Survey Summary:
1) Start moving the equipment from R-636z to R-073.
2) Distance between current location and next location (03.45) Km.
3) Max Convoy Speed allowed (40) KM/H.
4) Total low Voltage Electric cable = 0 HIGH= 0.
5) Total check points = 0. \
6) The convoy will pass = 0 junction roads.
7) The convoy will pass = 0 roundabout.
8) The convoy will pass = 0 mines warning signs.
9) Total bridges = 0.
10) Total river = 0.
11) Total railway= 0.
12) Unpaved road= 3.45 km.
13) Paved Road= 0 km.
14) All the drivers perform a vehicle pre job check list and cargo inspection in location A before starting move.
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15) Site supervisors hold TBT and JSA with all the crew, security, and drivers before mobilization.
16) Prepare radio with 2 people and security team to keep communications during mobilization.
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FLOWBACK AT RIGLESS / DRILLING / WORKOVER RIG
WELL SITE VISIT / SCOUTING OR/AND ROAD SURVEY CASES TO BE DISCUSSED
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FLOWBACK AT RIGLESS / DRILLING / WORKOVER RIG
WELL SITE VISIT / SCOUTING OR/AND ROAD SURVEY CASES TO BE DISCUSSED
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FLOWBACK AT RIGLESS / DRILLING / WORKOVER RIG
WELL SITE VISIT / SCOUTING OR/AND ROAD SURVEY CASES TO BE DISCUSSED
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FLOWBACK AT RIGLESS / DRILLING / WORKOVER RIG
WELL SITE VISIT / SCOUTING OR/AND ROAD SURVEY CASES TO BE DISCUSSED
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ANY QUESTIONS
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STANDARD FLOWBACK TRAINING

FLOWBACK EQUIPMENT
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FLOWBACK EQUIPMENT
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STANDARD LAYOUT
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FLOWBACK EQUIPMENT
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STANDARD LAYOUT
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FLOWBACK EQUIPMENT
SCENARIO - 1
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FLOWBACK EQUIPMENT
SCENARIO - 2
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FLOWBACK EQUIPMENT
SCENARIO - 3
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FLOWBACK EQUIPMENT
SCENARIO - 4
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FLOWBACK EQUIPMENT
 Flow Head  Vertical Flare Stack
 Coflexip hose  Transfer Pump
 Data Header  Chemical Injection Pump
 HP piping  Mobile Laboratory
 SSV  Data Acquisition System
 ESD Panel  Ancillary Equipment
 Choke Manifold
 3-Phase Test Separator
 Oil Diverter Manifold
 Gas Diverter Manifold
 Dual Compartment Surge Tank
 Storage Tank
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 Burner Skid
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FLOWBACK EQUIPMENT
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FLOWBACK EQUIPMENT
STANDARDS FOR FLOWBACK & SURFACE WELL TEST EQUIPMENT
Flowback & Surface Equipment used by Oilserv / OiLTECH shall comply with the following standards:

 API Specification 6A for Flow heads, Surface Safety Valves, and Choke Manifolds upstream heat exchangers chokes.
 The API 6A introduced the “Product Specification Level” (PSL) concept with the publication of API 6A, 15th Edition,
effective April 1, 1986.
 The PSL system applies a tiered level of material qualification testing and non-destructive testing to equipment as
specified by the user/buyer and allows reference to standard procedures to apply continuously higher standards for
higher risk equipment applications. PSL’s have number designations, as PSL 1, PSL 2, PSL 3, PSL 3G, and PSL 4,
representing a progression from lowest risk to highest risk applications.
 ASME B31.3 and API 6A (design), API RP 14E (installation) for “high pressure” flowlines upstream of heat exchangers chokes.
 API RP 14E and/or ASME B31.3 for “low pressure” flowlines downstream of heat exchangers.
 API Specification 12K for Heaters and Steam Exchangers.
 API RP 14C for Surface Safety Systems.
 API Specification 14A and 14D for Surface Safety Shutdown Valves and ESD systems.
 API 16A Specification for Drill Through Equipment (Includes API Hubs).
 API 16C Specification for choke and kill equipment (Coflexip hoses)
 API 7K Specification for Drilling and Well Servicing Equipment.
 ASME Boiler and Pressure Vessel Code Section VIII Division 1 for Pressure Vessels.
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 NACE MR-0175 for all H2S Service Equipment.

 API RP 520 and API RP 521 Pressure Relief Systems

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FLOWBACK EQUIPMENT
PIPING CONNECTIONS
Nominal size Color band Figure WP (psi)
6” light blue 206 1,500 Downstream
3”, 4” yellow 602 2,500 effective choke
3” , 4” , 6” red 1002 5,000
2” , 3”, 4” black 1502 10,000 Upstream
2” , 3” white 2202 15,000
effective choke

Recommended for
hostile conditions

WECO union
(hammer union) GRAYLOC connection FLANGE
Metal-to-rubber seal Metal-to-metal seal Metal-to-metal seal
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FLOWBACK EQUIPMENT
PIPING CONNECTIONS
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FLOWBACK EQUIPMENT
PIPING CONNECTIONS
Designated by the nominal pipe diameter and a ‘Fig’ number, for example : 3” Fig.1002
(Marked on the Wing Nut)
Flow direction rule :
 INLET
Equipped with Thread or Box or Female
“sub”.
Wing
 OUTLET Pin Thread
Equipped with Wing or Pin or Male “sub”
Male Box
 All Weco union should be H2S rated Female
and conform to NACE MR-01-75
standards.

 Weco unions are ACME type Thread:

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 Cylindrical shape.
 Square profile.
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FLOWBACK EQUIPMENT
PIPING CONNECTIONS

SEALING METHOD:
 Rubber (and metal-to-metal if hammered correctly)
 "Lip seal" elastomer on the female sub
 Temperature: 250°F Max
 Fig 206: Includes an O-ring on the male sub

 In high-pressure applications, especially when flowing gas, the lip seal elastomer of the hammer
union can experience "explosive decompression". Gas may migrate into the elastomer, causing
the lip seal to pop out of the groove and result in a leak.
 The likelihood of a leak is even higher at high temperatures and with a high CO2 concentration.
 A metal-to-metal seal can prevent this unwanted phenomenon.
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FLOWBACK EQUIPMENT
PIPING CONNECTIONS

Color WP TP
Figure
Band (psi) (psi)
Blue 206 1500 2250
Yellow 602 2500 3750
Red 1002 5000 7500
Black 1502 10000 15000
White 2202 15,000 22,500

PIPING TP (psi) = WP (psi) x 1.5

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FLOWBACK EQUIPMENT
PIPING CONNECTIONS
Prevention and Identification of the right thread

2” fig 1502 Union and 2” 602 are easy to connect But it will not handle the pressure.
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2” fig 1002 Union are banned from most of operation.

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2” fig 602 Unions will be phased out from testing operation
FLOWBACK EQUIPMENT
PIPING CONNECTIONS 2” WECO - 1502 OR 602?

Use a gauge ring (P/N 477990000):

Passes over 602 (and 1002 - this should be destroyed)
Will not pass over 1502

The difference is
the depth of The purchase of
The thread, 2”Fig 602 should
1502 is deeper be avoided
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FLOWBACK EQUIPMENT
PIPING CONNECTIONS

Rigid Piping :

Consists of straight pipes of different lengths (1, 3 and 5 meters are the most common
length) and elbows (typically 900).
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FLOWBACK EQUIPMENT
PIPING CONNECTIONS

Flexible Hoses :
HP flexible hoses are made of rubber or polymer protected by a flexible metallic
carcass such as Coflexip.

LP flexible rubber hoses, ended with weco union

LP flexible rubber hoses

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HP flexible hoses
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FLOWBACK EQUIPMENT
PIPING CONNECTIONS

Articulated piping: consists of 90o elbows connected with swivel joints that allow rotation in
one, two, or three planes.

CHICKSANS WITH
SWIVEL ARE
FORBIDDEN IN ANY
TESTING PROCESS.

The only chicksans allowed are used

on the kill-line for pumping into the
well (mud, cement). Never used to
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carry hydrocarbons.
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FLOWBACK EQUIPMENT
PIPING CONNECTIONS
Mainly defined by :
 Nominal diameter (wall mid point), O.D ? I.D. ?
 Schedule (Sch.80, XXS, SP)
 Grade ?

Working Pressure of the pipe (WP) is determined by the Wall

Thickness.

Wall Thickness, measured with :

 Ultrasonic tester.
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 X-ray.
 Manual Caliper.
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FLOWBACK EQUIPMENT
PIPING CONNECTIONS

The minimum Wall thickness (rejection criterion) is directly related to

the Working Pressure and the pipe OD.

2xsxt WP x OD
WP = or t=
OD - (0.8 x t) (2 x s) + (0.8 x WP)

WP = Working Pressure, s = design stress,

t = minimum wall thickness, OD = pipework Outer Diameter

If the minimum wall thickness found is below this value, the

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equipment has to be junked.

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FLOWBACK EQUIPMENT
PIPING CONNECTIONS
Approved Well Testing Pipework
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FLOWBACK EQUIPMENT
PIPING CONNECTIONS
Approved Well Testing Pipework
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FLOWBACK EQUIPMENT
PIPING CONNECTIONS

 Regular inspection of wall thickness to :

 Check the WP of pipe.
 Find effect of erosion/corrosion.
 Prevent accident.

 No down rating of pipework allowed.

 All H2S rated / must conform to NACE MR 01-75.

Thickness inspection does not replace pressure testing, BOTH are required.
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FLOWBACK EQUIPMENT
PIPING CONNECTIONS

Line Sizing

Gas / Fluid velocities limitations to maximum:

 80 ft/sec if solids (sand) or 2-phase flow.
 160 ft/sec for dry gas.
If higher velocity expected, a full HAZOP is required as:
 Increase pipe ID, flare tip ID.
 Divers flow through more than one pipe.
 Reduce as much as practical the line length and number of bends
 Reduce the choke size.
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FLOWBACK EQUIPMENT
PIPING CONNECTIONS
Line Securing
A potential danger exists on all gas flow lines and high-pressure relief lines (basically
all our flow lines FH to CM and all our Vent lines from Separator and Surge Tank).
Make personnel, client and third parties aware of it
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We recommend to be further
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FLOWBACK EQUIPMENT
PIPING CONNECTIONS Selection Guidelines
 Maximum expected WHP x 1.2 = Selection of the WP of up stream equipment (flow head, choke
manifold, pipe and other upstream equipment)
Maximum operating pressure, defined by the highest of the following conditions:

 Well Head Shut-In Pressure

 Flowing Pressure which could be higher than Shut-In Pressure in case Artificial Lifting system is used.
 Bullhead Pressure or Injection Pressure

 Working pressure (WP)

The pressure rating of any pipework is not determined by the end connection or the pipe itself, but by
the lowest rated section.

 Flow Rate / Velocity

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The diameter of the piping depends on the maximum expected flow rate. The most common sizes of
piping used is 3”, 4” or 6” diameter piping is sometimes chosen for high gas rate tests.
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FLOWBACK EQUIPMENT
Warning
PIPING CONNECTIONS

Figure 206 Hammer Union

 Figure 206 piping should not be used except for 6-in fig.206 schedule 80 as flow lines for high rate gas
test, located downstream the separator. (Pressure is a maximum of 1440 psi decreasing towards 0 psi at
flare tip).
 Due to the nature of the 206 seal (O-ring), it is not recommended to use the piping for hydrocarbon flow.
 The exception to use 6-in 206 is given considering that the 6-in is not available in 602 type weco.
 Use of O-Rings upstream of Choke Manifold when connected to the wellhead are strictly forbidden.
 Do not use 206 pipework upstream of choke manifold, MPFM flowmeter and connected directly to the
wellhead
HPHT piping (15 kpsi and above)
Only metal-to-metal seal piping (Grayloc, Flanges, Dynetor…) should be used for upstream flow lines.
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FLOWBACK EQUIPMENT
PIPING CONNECTIONS

 Before hooking up to the wellhead and pressure testing, inspect all seals and
sealing faces of the temporary pipework.
 The working pressure must be clearly identifiable on each piece of equipment,
including crossovers and fittings (not only on the equipment connected to the
wellhead).
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FLOWBACK EQUIPMENT
PIPING CONNECTIONS

Color Code
 The following standards would allow identification of the piping service and
working pressure rating:

 Orange for hydrocarbon piping (Testing)

 The stainless steel band remains to identify serial number, certification date etc…

2500 WP
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FLOWBACK EQUIPMENT
PIPING CONNECTIONS

Hydrocarbon Flow-back Piping

15000 WP

10000 WP

5000 WP

2500 WP

1500 WP
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FLOWBACK EQUIPMENT
Coflexip hose
ID: 2, 3 or 4”
WP: 5, 10 or 15 Kpsi
Length: 45 or 60 ft
Sensitive to:
• High Temperature
• Sour fluids Coflex mandatory on floating
• Long job duration rigs
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Data header
Used to connect sensors, gauges, pilots…
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FLOWBACK EQUIPMENT
COFLEXIP HOSES

 COFLEXIP hoses must be chosen in

accordance to the

 Temperature.
 Pressure.
 Fluid type expected.
 Exposure time

 Minimum bending radius specifications

must be respected: MBR = ID x 12
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FLOWBACK EQUIPMENT
COFLEXIP HOSES

For Coflexip hoses, accurate records of pressure and temperature exposure versus
time must be maintained and hoses retired from service according to manufacturer’s
specifications

Two types of Coflexip for DST (short test < 72hs) or PTL (extended
test & sour service) are used :

 COFLEXIP: Standard made with RILSAN

(temporary sour service).

 COFLON : High Temperature made with COFLON

(sour service without duration limit).
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FLOWBACK EQUIPMENT
COFLEXIP HOSES
Item Standard High temperature High Temperature
Lining Rilsan PVDF Coflon PVDF Coflon
Applications DST, extended test DST Extended test
2-in. or 3-in. bore 3-in. bore 2½-in. bore
Nominal size
45 or 60 ft long 60 ft long 60 ft long
10,000 psi WP 15,000 psi WP 15,000 psi WP
Pressure rating
15,000 psi TP 22,500 psi TP 22,500 psi TP
20ºC to 100ºC, 20ºC to 130ºC,
continuous, up to 20ºC to 130ºC, continuous, up to
Temperature rating 130ºC 1 month, continuous, up to 145ºC 1 month,
(cumul.) up to 160ºC, 160ºC 1 hour (cumul.) up to 160ºC,
1 hour 1 hour
API Hub or Flange API Hub or Flange
2-in, or 3-in, 1502
Connections 3-in. C25 Graylock 3-in. C25 Graylock
WECO
HD hub HD hub
Non acidified effluent
only.
No concentrated acids No concentrated acids
Limits of use No heavy metallic
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at high temperature at high temperature

salts (zinc, calcium
bromides, etc.).

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FLOWBACK EQUIPMENT
PIPING SAFETY

 Keep piping routes as straight as possible (avoid erosion).

 All piping must be H2S service (NACE MR 01-75).

 Use only welded union connections (WECO, GrayLoc, …).

 Firmly anchor the flow lines and vent lines to the rig structure or to the ground.

 All piping / hoses must have an identification ring on it.

 Hoses must be attached to heavy pieces of equipment because they can swing under pressure.

 Never try to loosen or tighten connections under pressure.

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FLOWBACK EQUIPMENT
PIPING SAFETY

 Do not use steel hammers to tighten wing union connections when there is ANY risk of hydrocarbons.
Brass or copper hammers must be used to prevent sparks. They must be in good condition to avoid
injuries from metal chips that can break off of these hammers (eyes!).

 Painting on rigid pipes avoid corrosion ( to use the correct color coding)

 In desert locations, do not put grease and “SAND” on the threads.

 WECO seal must be verified and changed when damaged.

 Threads and sealing surfaces must be cleaned with a wire brush or fine emery cloth.

Pipework rated 10 kpsi WP and above, without documented material

traceability shall be retired immediately. No interim usage can be granted.
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FLOWBACK EQUIPMENT
PIPING SAFETY
DEFINITIONS
 Working Pressure (WP):
The Working Pressure (WP) is the maximum allowable pressure never to be exceeded during field operations
of the equipment usually expressed in psi (pounds per square inch).

 Test Pressure (TP):

The value of Test Pressure (TP) is recommended by the manufacturer, and often dictated by industry codes and
governmental agencies regulations. API and ASME specify TP = 1.5 x WP for most of the surface equipment. A pressure-
containing equipment is tested at defined time intervals, at a maximum pressure greater than or equal to Working
Pressure (WP), defined as Test Pressure (TP).
 Maximum Potential Well head Pressure (MPWHP):
It is the maximum pressure, flowing or shut-in, that the wellhead could be subjected to, from either downhole reservoir
pressure or any pressure applied from surface during Bullheading, Fracturing, or other pumping operations.

 Maximum Allowable Operating Pressure (MAOP):

Equal to the wellsite pressure test value.
If not identified by customer, it is recommended 1.2 X MPWHP for the upstream section.
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WP > Well site Test Pressure = MAOP > MPWHP

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FLOWBACK EQUIPMENT
PIPING SAFETY
OPERATING RULES
 Operations are not allowed where MPWHP exceeds MAOP. (WP of our equipment)

 Welding on pressure containing equipment may be performed only by an approved

supplier, during manufacture or as part of a documented repair.

 Retired pressure equipment must be destroyed to the point that it cannot be used
again.
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FLOWBACK EQUIPMENT
VALVES
Valves or taps are devices fitted to piping or equipment and designed to control the
flow of fluids
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FLOWBACK EQUIPMENT
VALVES

Valves Types

 High-Pressure Valves

 Medium and Low-Pressure Valves

Example of wellhead valves

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FLOWBACK EQUIPMENT
VALVES

HIGH MEDIUM LOW

Pressure pressure pressure
(5000 psi and above) (~1500 psi) (~180 psi)

Flowhead Separators
Choke Manifold Oil/Gas Manifolds
Tanks
Sand Trap Pump
Heater & Steam Heat Exchanger Burner

Gate valves Ball valves Butterfly valves

Needle valves (Sampling) Plug valves Globe valves

WOM
Balon
McEvoy
Mapegaz
Malbranque
Gachot
Sereg
Texseal
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Kerotest
Autoclave

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FLOWBACK EQUIPMENT
VALVES

 Used for shut off, (on/off function)

 High pressure (5, 10, 15, 20Kpsi)
 used @ :
FH, CM, Steam-exchanger, Sand-trap
SEALING METHOD:
 Metal to metal for WOM valve
 Grease sealing compound for McEvoy
valve
Standard sizes: 3.1/16” to 4.1/16”
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FLOWBACK EQUIPMENT
VALVES

Gate
Seal assembly with 0-ring

Grease Fitting
metal seals (for storage only)
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FLOWBACK EQUIPMENT
VALVES

GATE

metal/metal seal
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FLOWBACK EQUIPMENT
VALVES
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FLOWBACK EQUIPMENT
VALVES

GATE VALVES FLS & FL (CAMERON)

FL & FLS Gate Valve

Non Rising Stem

Seat

Gate
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Retainer Plate
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FLOWBACK EQUIPMENT
VALVES

GATE VALVES FC SERIES (CAMERON)

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FLOWBACK EQUIPMENT
VALVES

GATE VALVES (MCEVOY)

Sealing done with Grease fittings for

the special grease
Special sealing
compound grease
Grease fitting for
standard grease
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128 Valve Closed

FLOWBACK EQUIPMENT
VALVES
reservoir

GATE VALVES (MCEVOY)

reservoir
seat
gates
 Possibility to
inject grease
under pressure seat
 Self-
greasing/sealin bottom grease
g under fitting for normal
pressure with grease only
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valve closed
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FLOWBACK EQUIPMENT
VALVES

NEEDLE VALVES
 Used for shut off, (on/off) + Flow control (bleed off part
of flow)
 High pressure (5, 10, 15, 20Kpsi)
 ex: instrumentation on FH, CM, Steam-exchanger, Sand-
trap
 Kerotest (up to 10Kpsi)
 Autoclave Engineers (10, 15, 20K)
 Sealing method: metal/metal
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FLOWBACK EQUIPMENT
VALVES

NEEDLE VALVES
1. Body (FxF)
2. Body (MxF)
3. Handle
4. Handle Bolt
5. Bonnet Cover
6. Bonnet
7. Bonnet O-Ring
8. Stem
9. Stem Back-up Ring
10.Stem O-Ring
11.Bonnet Locking Shroud
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FLOWBACK EQUIPMENT
VALVES BALL/ PLUG VALVES
 Used for shut off, (on/off)
 ¼ turn
 Medium pressure (~1500 psi)
 ex: separator, burners, pumps,
etc.
Sealing method:
 PTFE (Teflon) seal ring or seat
 Standard sizes = 1” to 4”
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FLOWBACK EQUIPMENT
VALVES
BALL (SPHERICAL) GACHOT

 Medium pressure
 Sampling / bleed-off points

SEALING:
White teflon seal ring

Standard sizes:

 ¼”, ½”, ¾”, 1”

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FLOWBACK EQUIPMENT
VALVES

Patented Internal
Twin Stop
Rectangular Stem Wrench Area
BALON BALL VALVE Selective Dual
Stem Sealing
Locking Plate
Back Seated
Protective Weather Guard Blowout-Proof Stem
Ultra Smooth
Safety Shear Groove High Sphericity
Ball

Patented
Multi-Seal Super
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Efficiency Sealing

Strong Bolted Construction

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FLOWBACK EQUIPMENT
VALVES
Top
PLUG VALVE (CYLINDRICAL) TEXSEAL Hexagonal
nut
Sealing:
 Black Teflon seat
O’ring
Stem
Seat
(black teflon)

Plug
(cylindrical)
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135
FLOWBACK EQUIPMENT
VALVES

BUTTERFLY VALVE

Weco
 Used for shut off, (on/off)
 Low pressure
 Tanks
 Sealing: rubber seal
 Standard sizes: 1”, 2” 3”
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FLOWBACK EQUIPMENT
VALVES

GLOBE VALVE
 Used for control of flow and shut off
 Low pressure
 Rig Water / air lines
 Sealing: metal/metal
 Standard sizes: 1”, 2” 3”
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FLOWBACK EQUIPMENT
VALVES

AUTOMATIC CONTROL VALVE

Fisher
 Used for flow control + throttle action
 Medium pressure
 Separator, Surge tank
 Sealing (not 100%):metal/metal
 Standard sizes:1”, 2”, 3”,4”
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138
FLOWBACK EQUIPMENT Flow through
VALVES valve
SWING CHECK VALVE
 To allow flow in one direction only
 High/Medium/Low pressure
 Separator inlet, pump outlet
 Sealing: metal/metal
 Standard sizes: 1”, 2”, 3”,4”

CHECK
valves
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Flow ceases or fails below back pressure

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FLOWBACK EQUIPMENT
VALVES

RELIEF VALVE
Farris
 Spring loaded and set to open at a given
pressure to protect systems from over pressure
 High/Medium/Low pressure
 Separator, flow lines, Steam-exchanger, Surge-
tank
 Sealing: metal/metal
 Standard sizes: 1”, 2”, 3”,4”
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140
FLOWBACK EQUIPMENT
VALVES

RELIEF VALVE
Anderson Greenwood

 Piloted safety relief valves

 High/Medium/Low pressure
 Separator and Surge-tank
 Sealing: metal/metal
 Standard sizes: 3”,4”, 6”
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141
FLOWBACK EQUIPMENT
VALVES
SURFACE WELL TESTING VALVES SAFETY
GATE / BALL / PLUG VALVE
 MUST NOT be used for throttling (i.e.: must be fully open or fully closed) because a
restricted flow through it will erode the seal or gate or seat, and the valve will not seal
correctly / reliably.

GATE / GLOBE VALVE

 It is common practice to count the number of turns taken to open / close a valve because the
operator can tell if the valve has become plugged or is not seating correctly
 It is best to close the gate and globe valves by ¼ turn after they are fully opened and vice-versa
because over tightening the valve upon closing may damage the disk and seat. Leading to seizure
or leakage
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FLOWBACK EQUIPMENT
VALVES
SURFACE WELL TESTING VALVES SAFETY
NEEDLE VALVE
 When used with an instrument, the valve should only be opened enough:
 To permit flow and allow the instrument to register correctly
 To allow a quick closure of the valve and to isolate the dial gauge in case of a
sudden increase of pressure, above the range of the gauge

One or two turns is usually sufficient

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143
ANY QUESTIONS
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144
STANDARD FLOWBACK TRAINING

FLOWHEAD
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May 2024
FLOWBACK EQUIPMENT
FLOWHEAD & SAFETY BARRIERS

Flowhead
5K-10K-15K psi Emergency Shut-Down (ESD)
2”-3”-5”-6”-7” • Closure in less than 10s
• 2 or 3 independent actuators
• Controlled by push-pull stations,
high/low pilots, erosion probe,
pressurized lab cabin, etc…

SSV ESD Mandatory when

5K-10K-15K psi
3”-4”-5”  WHP > 5000 psi
 H2S present
 High Flow-rate tests
 Gas > 30 MMSCFD
 Oil > 8000 BPD
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ESD recommended on all well test operations.

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FLOWBACK EQUIPMENT
FLOWHEAD & SAFETY BARRIERS

 Used for temporary completion DST (Drill Stem Testing)

 Provide temporary Shut-In at surface
 Control the fluid flow IN & OUT of the well

 For permanent completion (production test) the FH is replaced by a

X-tree, with 2 Master valves (to operate under Client authorization,
the upper Master valve only)
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FLOWBACK EQUIPMENT
FLOWHEAD & SAFETY BARRIERS

FLOWHEAD AND SWIVEL PRINCIPAL FUNCTIONS

 Control the pressure

 Support the weight of the Test String
 Allow up-and-down & rotation movement of Test String
 Allow flow out of the well through a flow valve.
 Allow to pump fluid into the well through a kill valve
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 Allow tools to be introduced into the well through a swab or crown valve.

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FLOWBACK EQUIPMENT
FLOWHEAD & SAFETY BARRIERS
TYPICAL SWIVEL

Simplified
New swivel
type :
There is a
“leak check”
between the
All standard two set of
Flow-head packing
are
equipped
with a Swivel
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FLOWBACK EQUIPMENT
FLOWHEAD & SAFETY BARRIERS

SWIVEL MAIN APPLICATIONS

 Allow rotation of subsurface equipment

 Support the weight of the Test String thanks to roller bearings.
 Support the weight of the FH and the equipment above the FH
thanks to the ball bearings.
 Should not be rotated when pressurized.
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FLOWBACK EQUIPMENT
FLOWHEAD & SAFETY BARRIERS

Criteria to select Flow-head

 WP rating (1.2 x maximum expected WHP)

 Required service type H2S or NOT
 Fluid temperature
 Internal diameter of the flow-head
 ESD for actuator
 X-overs (Kill & Flow lines + Bottom FH + lifting sub)
 Swivel requirement (standard)
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FLOWBACK EQUIPMENT
FLOWHEAD & SAFETY BARRIERS

Safety & maintenance

 Only WT personnel are allowed to operate it
 Count number of turns to open and close gate valves
 Connections are marked with chalk or paint to know if a connection is backing off
 Check valve on the kill line to avoid flowing back to the pump unit

Note: The Flowhead isn’t needed to set the packer.

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FLOWBACK EQUIPMENT
FLOWHEAD & SAFETY BARRIERS

Xmas Tree
Tree cap & gauge

Kill valve
Swab valve

Choke
Upper master valve
(operational valve) Flow
valve

Lower master
valve (back up)
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FLOWBACK EQUIPMENT

FLOWHEAD RIG UP PROCEDURES IN LAND RIGS

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LIFTING FLOWHEAD OUT OF BASKET Remove

 Confirm Crane or Forklift capacity

 Both Drivers are certified and competent
 All wheels handles are removed .
 Instrumentations are removed needle valves , gauges or
attached hoses
 Swab Cap, thread protectors and stem protectors for valves
are tight and in place
 Use three legs slings as shown in the picture to lift the
flowhead out of the basket
 Wrap twice around the flange between the body block and
elbow on both flow and kill side.
 Third sling should be attached below the master valve two
wraps as well.
 Keep adjusting the slings until flowhead stays in horizontal Tag Line
position when lifted.
 Use two tag lines , one should be attached on the lifting sub
and the other one attached below master valve.
3 legs sling
 Place different level of wooden blocks on the ground and lay
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down flowhead ready for function test and pressure test

Tag Line
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LIFTING FLOWHEAD OUT OF BASKET
Flowhead stays in
horizontal position
when lifted.

Place different level of wooden

blocks on the ground and lay
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down flowhead ready for

function test and pressure test
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PRE-RIG UP CHECKS DURING RIG UP WELL TESTING PACKAGE
 Confirm the elevator size, rig height , X-overs required (Site visit Report).
 Physically check the lifting sub top connections
 Function test swivel rotation
 Function test actuators valve , confirm enough length of hydraulic hose from ESD to rig floor.
 Function test ESD activation to actuator valve closure time ≤ 10 sec.
 Physically check all other equipment that will be connected to flowhead such as slickline/wireline x-overs bottom x-overs
 Confirm Flowhead ID with drifted tools or bar.
 Install lifting sub cap, pup joint or stiff joint and thread protectors to the flowhead
 Pressure test flowhead
 Mark body connection
 Review with all team and involved personnel the lifting plan. HIRCA and specific JSA during TBT
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RIG UP PROCEDURES
SAFETY CHECKS AND TOOLBOX TALK TBT

 Ensure work permit is in place and approved by

authorized parties in the rig (Company man, Safety
officer etc.) as per location policies
 Review with all team and involved personnel the lifting
plan, HIRCA and specific JSA during TBT
 Confirm crane capacity
 Never Operate rig equipment
 Ensure rig floor is ready to receive the flowhead and tidy
 Tag lines, slings and shackles inspected and certified
 Full PPE during rig up
 Only one person assigned as a banksman and should be
identified by safety vest
 Good communication and same hand signals method
understood between crane operator and the banksman
 Good communication between testing and rig crew
 Crew roles and responsibilities
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RIG UP PROCEDURES
Banksman position should be visible
for both crane operator and driller or
air winch operator

PICK-UP FLOWHEAD

 All flowhead marked with chalk to identify if connections had backed off during operations.
 All wheels handles are removed .
 Instrumentations are removed needle valves , gauges or attached hoses
 Swab Cap, thread protectors and stem protectors for valves are tight and in place
 Use three legs slings as shown in the picture to lift the flowhead
 Install new hammer union seals before each job, cost of the seal will be very low comparing to potential NPT due
to failure of this seal during pressure test
 Rig crew should be informed that swivel may rotating during lifting and might rotate the master valve so ensure
load are distributed properly
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 All crew has the authority to stop any unsafe operation, if the flowhead is not balanced, it should be back to the
closed area such as V-door and then re-adjust the equipment with slings then pick-up again
 Use tag lines if the flowhead start rotating to reposition it with the lifting sub top of flowhead facing the rig floor
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RIG UP PROCEDURES
PICK-UP FLOWHEAD
 Once flowhead on the rig floor, ensure is stable by slacking off crane slowly then remove the two slings on the top
and connect to air winch.
 Keep the crane connected to the bottom part of the flowhead and air winch to the top, together lift the flowhead
and attach the elevator which should be prepared before to fit the handling sub of the flowhead
 keeping flowhead at an angle will be more easy to close the elevators.(Banksman should be more alert during this
step to ensure not confusing both crane operator and air winch operator for the signals which might in different
ways to ensure flowhead at an angle in order to keep flow head balanced during lifting and to avoid that flowhead
bottom x-over rests on rig floor)..ex. Lowering crane and rising air winch
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RIG UP PROCEDURES Remove from crane and
PICK-UP FLOWHEAD
connect Air Winch
 Slack off the hoist lines to confirm proper latching of the elevator
 Take care that when slacking off the air hoist lines, flowhead dose not
spin around
 Once confirmed that elevator is latched onto the handling sub, the top
drive is pulled up Crane
 One of the air winch can stays attached to flowhead to control the top Down
block if it stars to rotate
 Lower the crane hook to swing flowhead into vertical position, once
flowhead is completely in vertical position, slack off the crane and
release it
Top Drive Up
Air
Winch Up

Crane
Elevators Latched and Down
closed
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RIG UP PROCEDURES
FLOWHEAD ON VERTICAL POSITION
 Connect flowhead to test string, put on chalk marks on all the
connection need to torque. Upper swivel sub must
 Chalk marks on the connections to see if those connections back not turn
off accidentally during the tightening procedure
 The torqueing specifications depend on the type of flowhead,
refer to the manufacturer’s specifications.(Make sure the
elevator is slacked off while torque flowhead)
 ACME connections torque 4000 – 7500 ft.lbs.
 The torque on between bottom x-over and string depend on
string connection type.
 Space-out accordingly to provide at least 1m gap at expected This man watches that no
connections are backing off
highest tide
 Take into account DST tool functions when spacing out
 Verify alignment of flowhead before attempting to rotate string. The swivel housing must turn with
This should avoid the situation of swivel seizure. the same speed as the X-over which is
connected to the string`
 Be aware that pressure rating decreases with tensile loading.
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RIG UP PROCEDURES
TORQUEING UP FLOWHEAD CONNECTIONS 4
Torque here
Slack off elevators

 To torque up connections across head block, sit down flowhead

on master valve block. 4
 It is recommended , where possible , to torque up the flowhead
connections before loading out. If not possible proceed as 3 Torque here
follows:
 1) Torque up flowhead in sequence (1,2,3,4) as indicated in the 3 2 Torque
next photo 2 1 here
Torque
 2) Ensure that elevators are slacked off while torqueing up 1 here
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ANY QUESTIONS
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FLOWBACK EQUIPMENT

EMERGENCY SHUT DOWN SYSTEM & SSV

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ESD SYSTEM TYPICAL LAYOUT

 Close quickly well in emergency (less

than 10 sec.)

 Allows a flow line valve to be safely

closed from a remote station or from
the ESD console
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SSV OR ACTUATOR VALVE
ACTUATOR

Hydraulic
actuator

Located on :
 Flow valve of Flow-head
Valve
body
 Surface Safety Valve SSV
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ESD SYSTEM
Flow head

“Fail-safe” valves, equipped

Surface with an Hydraulic actuator,
Safety Valve connected to the ESD panel.
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ESD SYSTEM
ESD Mandatory when

 WHP > 5000 psi

 H2S present
 High Flow-rate tests
 Gas > 30 MMSCFD
 Oil > 8000 BPD

ESD recommended on all well test operations.

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ESD SYSTEM
ESD SYSTEM
Hydraulic valves:
Actuator on the flow valve or / and SSV independent on the flow line.
Hydraulic oil maximum circuit pressure: 6000 psi (normal operating hydraulic pressure =
1500 to 3000 psi)

ESD Panel:
Hydraulic pump
Quick exhaust valve
Hydraulic oil tank
Reset valve
Interface valve
Bypass valve
Check valve
Hi / Lo pilot
Air spare vessel (old model)
Stations ESD
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ESD SYSTEM
Station

Located @:
 Separator (mandatory)
 Safe area (mandatory)
 Rig floor
 Near Test cabin, …
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Danger: Station activated

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ESD SYSTEM
Pilots

 Hi-pilot to protect low pressure

equipment.
 Lo-pilot to protect against a line
rupture.
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Pressure increasing hi-pilot activated

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ESD SYSTEM
Hi-Lo pilot principle
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ANY QUESTIONS
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FLOWBACK EQUIPMENT

CHOKE MANIFOLD
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CHOKE MANIFOLD

Choke Manifold Principal functions:

 Control the Flow-rate (allow different choke sizes)

 Control the Well Head Pressure or Shut In at surface
 (CM WP selection = 1.2 x MWHP expected)
 Ensure Critical Flow = Pressure fluctuations D/S choke do not affect down-hole
Pressure & Flow-rate of the well
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CHOKE MANIFOLD
Limitation of Flow-rate
 Prevents water & gas coning
 Prevents formation sand from entering the well
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CHOKE MANIFOLD
CM Description:
 Four or five gate valves (by-pass possible)
 A Fixed choke (Positive)
 An Adjustable choke
 Tapping points for pressure & sample (BSW)
 Thermometric well
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CHOKE MANIFOLD

FLOOR CHOKE MANIFOLD

MAX
TEMP VALVE
WP TP CONNECTION CHOKE
RATING SIZE
(PSI) (PSI) IN/OUT SIZE
deg F (INCHES)
(INCHES)
5000 7500 -20 to 250 3" fig 1002 2 3.1/8

10000 15000 -20 to 250 3" fig 1502 2 3.1/16

15000 22500 -20 to 350 3.1/16 BX 154 FLANGE 2 3.1/16

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CHOKE MANIFOLD

Fixed choke:
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CHOKE MANIFOLD

Adjustable Choke
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CHOKE MANIFOLD

Gate Valve

Bearing
grease

Sealant & Body filler may be injected while valve is under pressure
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CHOKE MANIFOLD
INLET To see all “data sheet”, with
3”weco union Female different CM criteria such as:
(or Grayloc for 15k WP)  Pressure rating
 Temperature rating
 I.D. & connections
 H2S (all are NACE certified)
 By-pass valve

 CM selection for our ST basic course:

 5k, 10k, 15k with 3” connections only
OUTLET  Temperature between – 4 to 250 degF
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3”weco union Male

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FLOWBACK EQUIPMENT
CHOKE MANIFOLD

CHANGING FROM ADJUSTABLE CHOKE TO FIXED CHOKE STEPS

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CHANGING FROM ADJUSTABLE CHOKE TO FIXED CHOKE STEPS
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CHANGING FROM ADJUSTABLE CHOKE TO FIXED CHOKE
STEP -1 PREPARATION OF FIXED CHOKE BOX Close Position
Close Position Open Position
• Adjust the choke until the flow stabilizes.
• Confirm choke size with test supervisor & client representative, Fixed choke
prepare, clean and grease it , if choke bean has an O-ring, ensure
it is not damaged and properly installed, also check the condition
of the O-ring on the test cap.
• Verify upstream and downstream valves of the fixed choke are
closed.
• Check for zero pressure by opening the sampling point needle
valves.
• Before hammering the fixed choke cap, remove any dial gauge or
sensors that might be damaged by the vibrations (Use only brass
& copper hammer to prevent sparks and ensure safety glasses is Adjustable choke
worn to protect your eyes.
• If it is difficult to unscrew the cap, assume that some pressure Verify closing
might still be trapped inside the fixed choke box. The needle valve
might be plugged. Flow Direction
• Remove old choke and install the equivalent fixed choke.

Verify closing 1 • Valve Close

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• Valve Open

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CHANGING FROM ADJUSTABLE CHOKE TO FIXED CHOKE
Open Position
STEP -2 PRESSURIZING FIXED CHOKE BOX Close Position Open
• Open the downstream valve of the fixed side to Position
Fixed
equalize pressure. choke
• It is advisable to open the downstream rather
than the upstream for safety.

At this stage, you should

know exactly how many
turns it takes to go from
fully closed to fully open
and vice-versa.
Adjustable choke

Flow Direction
Open Valve

2
• Valve Close
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• Valve Open

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CHANGING FROM ADJUSTABLE CHOKE TO FIXED CHOKE
Open Position
STEP -3 DIVERTING THE FLOW FROM ADJUSTABLE Open Position Open
TO FIXED CHOKE Close
Position
Fixed Position
• Open Simultaneously upstream valve on the fixed side choke
whilst upstream valve on the adjustable side is closed.
• Pressure must remain stable when changing from
adjustable to fixed choke.

Open Valve
Adjustable choke

Flow Direction

3 Close Valve
• Valve Close
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• Valve Open

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CHANGING FROM ADJUSTABLE CHOKE TO FIXED CHOKE
Open Position
STEP -4 FLOW THROUGH FIXED CHOKE Open Position Close
Close Position
Fixed Position
• The downstream valve on the adjustable side is closed choke
and pressure bled off on the adjustable choke. We can
carry out maintenance checks on the adjustable
choke.

Adjustable choke
Flow Direction

4
• Valve Close
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Close Valve • Valve Open

Note: The same procedure applies for changing from fixed to adjustable

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CHOKE MANIFOLD
Changing from Adj. Choke to Fixed Choke Summary
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CHOKE MANIFOLD
Safety & Maintenance

 Always open one valve before closing another

 Count number of turns to open and close gate valves
 Never flow thru CM without a choke or seat in place
 Do not use Adjustable choke to stop flow
 Use only brass & copper hammers to prevent sparks
 Always bleed off pressure before changing choke
 Stay upwind when taking samples
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ANY QUESTIONS
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