Iron Management Program Standard Operating Procedures Manual - R2.5 Aug 2020

Iron Management Program
Standard Operating Procedures Manual

R2.5 – August 2020
Providing hydraulic fracturing, coiled tubing, fluid pumping and nitrogen

pumping services to the Western Canadian Sedimentary Basin
© STEP Energy Services, 2018

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Contents
1 Safety Policy ...................................................................................................................................... 6
2 STEP’s Culture ................................................................................................................................... 7
3 Program Summary ............................................................................................................................ 7
4 Definitions ......................................................................................................................................... 8
5 Roles and Responsibilities ................................................................................................................. 8
5.1 Iron Coordinator ........................................................................................................................... 8
5.2 Site Manager ................................................................................................................................. 9
5.3 Supervisor ..................................................................................................................................... 9
5.4 Operator........................................................................................................................................ 9
5.5 Engineering ................................................................................................................................. 10
6 Iron Identification System ............................................................................................................... 10
6.1 Treating Iron Colour Coding System ........................................................................................... 10
6.2 Pressure Control Equipment ....................................................................................................... 12
6.3 Manufacturer Document Links ................................................................................................... 14
6.4 STEP Fracturing Banding System ................................................................................................. 15
6.5 STEP Coiled Tubing, Fluid Pumping and Nitrogen Banding System ............................................ 16
6.6 Banding Prefix Chart ................................................................................................................... 19
6.7 Safety Iron Identification ............................................................................................................ 20
7 Iron Limitations ............................................................................................................................... 21
7.1 Iron Rate Limitations ................................................................................................................... 21
7.1.1 Fracturing services .............................................................................................................. 21
7.1.2 Coiled Tubing, Fluid pumping and Nitrogen Services ......................................................... 21
7.2 Temperature Limitations ............................................................................................................ 22
8 Iron Segregation .............................................................................................................................. 22
8.1 Coiled Tubing Skid Iron ............................................................................................................... 22
9 In Service/Out of Service Procedure ............................................................................................... 22
9.1 Red “Out of Service” Tags ........................................................................................................... 22
9.2 Green “In Service” Tags............................................................................................................... 23
10 Inspections ...................................................................................................................................... 24
STEP Energy Services | Iron Management Program (Revision 2.5)

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10.1 Inspection Intervals ..................................................................................................................... 24

10.2 Approved Vendors ...................................................................................................................... 24
10.3 Severity of Service Erosion Study ................................................................................................ 25
10.4 Inspection Levels ......................................................................................................................... 25
10.4.1 Visual Inspection ................................................................................................................. 25
10.4.2 Wing Nut Inspection ........................................................................................................... 26
10.4.3 Safety Iron ........................................................................................................................... 27
10.4.4 Level 1 Inspections .............................................................................................................. 28
10.4.5 Level 2 Inspections .............................................................................................................. 28
10.4.6 Level 3 Inspection ............................................................................................................... 29
10.5 Rejection Parameters.................................................................................................................. 29
10.5.1 Ultrasonic Wall Thickness Test............................................................................................ 29
10.5.2 Magnetic Particle Inspection .............................................................................................. 30
10.5.3 Iron Seals ............................................................................................................................. 30
10.5.4 Pressure Tests ..................................................................................................................... 30
10.5.5 Actuation Tests ................................................................................................................... 30
10.5.6 Visual Rejections ................................................................................................................. 30
11 Inspection Documentation ............................................................................................................. 34
12 BOP Inspections .............................................................................................................................. 34
12.1 Inspection Levels ......................................................................................................................... 34
13 Audit Process .................................................................................................................................. 35
13.1 Field Audit ................................................................................................................................... 36
13.2 Field Document Audit ................................................................................................................. 36
13.3 Inspection Tracking Audit ........................................................................................................... 36
13.4 Inspection Interval audit ............................................................................................................. 36
14 Frac iron Seals………………………………………………………………………………………………………………………… 35

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Revison Description Revision By Approval Date

Number
R 1.1 - June New Release Kyle Kelner Bailey Epp June 2016
2016
R 2.0 - February Extensive update to meet Brad Watson Bailey Epp February 24,
2018 WorkSafeBC requirments 2018
R.2.1 –March Update banding Brad Watson Bailiey Epp March, 10, 2018
2018 convention, addition of
usage considerations
R.2.2- April 9, Reference the erosion field Brad Watson Rory Thompson October 15, 2018
2018 study
R.2.3-June 21, Updated pressure control Brad Watson Rory Thompson October 15, 2018
2018 equipment, Added suction
hose inspection to Level 2
inspections. OEM serial
number stamp. Approved
vendors.
R.2.4-August Added STEP new branding Jorge Andrade Rory Thompson October 15, 2018
21, 2018 procedure. Update
inspection Frequency.
Update Wing inspection.
R.2.5- August Updated rate limitations Brad Watson Alex Houle October 20, 2020
17, 2020 section 7.1 for fracturing
and fluid pumping services.
Added Iron Seal section
10.5.3.
Updated banding Prefix
chart section 6.6

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The Iron Management Program is also known as the Iron SOP Manual for all hydraulic fracturing and
coiled tubing operations conducted by STEP Energy Services. It has been developed for STEP
professionals to highlight safety and operational needs. Professionals will acknowledge safety and
operational procedures, as well as government regulations and industry standards.
STEP Energy Services SOP Manual was created within the guidelines set out by ‘The Canadian Petroleum
Safety Council’s IRP Volume 8, 20, 24 ©Enform.

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1 Safety Policy
STEP Energy Services (STEP) is committed to ensuring the health and safety of our employees and all
other involved, or impacted by, our operations, while at the same time protecting the environment in
which we work and conduct our activities.
STEP will be responsible for seeking every reasonable means to provide a safe work environment for all
workers. We will do this by employing competent personnel who are equipped to complete their jobs in
a safe manner, and by using those practices and procedures that meet or exceed regulatory and
recognized industry standards. The Company will also encourage the active participation and support of
its employees in promoting and implementing an effective safety program. STEP Energy Services
management and supervisory personnel have a direct responsibility for ensuring that these objective are
met.
STEP expects that all employee or contract workers involved in its operations will assume responsibility
for performing every job in a manner that safeguards themselves and their fellow workers. Generally,
this can be accomplished by every worker exercising sound judgment, maintaining a high level of safety
awareness, applying all education and training, understanding the scope of their job or task and the
hazards involved, and following safe work practices and procedures.
Equally important is everyone’s responsibility to identify, correct, and immediately report to their STEP
supervisor or manager unsafe working conditions, which may include personnel who are inadequately
trained or equipped to perform their job safely! No one will ever be required to sacrifice the safety or
wellbeing of personnel for expediency or for any other reason while at a STEP work site.
Employees and contract workers are encouraged to offer their suggestions as to how STEP can improve
its safety program or procedures. With your co-operation and commitment to safety, we can achieve
our Company goal of preventing all losses for the benefit of our fellow workers, our families, the general
public, and the environment.
Regan Davis
President & CEO
August 2011

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2 STEP’s Culture
STEP delivers the expertise – the people, the equipment and the knowledge – required to improve
operational efficiencies and productivity in extended reach wellbore designs. At the heart of STEP’s
corporate strategy is the company’s commitment to the execution of safe projects, its dedication to its
team of expert employees and ultimately to providing its clients an exceptional customer experience.
STEP’s Vision
STEP’s employees are engaged.
STEP executes on our commitments.
STEP consistently exceeds client expectations.
STEP’s Purpose
We are driven to create an Exceptional Employee Experience (EEE) and to deliver an

Exceptional Client Experience (ECE).
STEP’s Values
S – Safety “Safety is no accident”
T – Trust “Trust is built with character and competence”
E – Execution “Goal, plan, execute, learn, repeat”
P – Possibilities “Engaged employees, discovering possibilities”
STEP holds strongly to the belief that the integration of these core values into the company’s corporate
culture, growth strategies and client focused service, will serve to differentiate STEP in the market place.
3 Program Summary
The purpose of this program is to define how flow piping is identified, tracked, maintained and
inspected. This program covers flow piping systems used in fracturing, coiled tubing, fluid pumping and
nitrogen services. This includes:
o Swivels
o Plug Valves
o Check valves
o Relief valves
o Tees
o Swedges

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o Caps
o Piping
o Manifolds
o High pressure hoses
o Rotating joints
o Sour service iron
o Nitrogen/natural gas hoses
o Well control components (BOP’s, flow tees, stripper assemblies)
4 Definitions
Flow Piping - a temporary or portable system of piping and other component parts, including valves and
fittings, that is
(a) Located above ground, and
(b) For use conveying a liquid or gas under pressure, either to or from a wellhead, during drill stem
testing, swabbing, cementing, well servicing or well stimulation
OEM- Original Equipment Manufacturer
Qualified - being knowledgeable of the work, the hazards involved, and the means to control the
hazards; by reason of education, training, experience or a combination thereof
5 Roles and Responsibilities

5.1 Iron Coordinator
 Be the qualified person responsible for the administration of the Iron Management Program.
 Update the Iron Management Program as information becomes available.
 Monitor the effectiveness of the program and make changes to procedures as needed.
 Track all iron and inspection requirements.
 Notify field personnel of upcoming inspection requirements and work with them on completing
the inspection with minimal downtime.
 Be knowledgeable on all OEM iron components related to limitations, inspections and
maintenance procedures.
 Perform inspection tracking audits to ensure efficiency.
 Track iron failures to identify changes in frequencies and severity which require changes to the
iron management program.
 Provide answers to questions from field professionals related to the iron management
document, iron specifications, limitations or maintenance procedures.

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 Communicate with third party inspection facilities to schedule inspections and track
certifications.
 Follow up on out of service equipment and initiate the required inspection or repair.
 Follow the in service procedure for any repaired or inspected iron.
 Train and mentor field professionals on the Iron Management Program.
The following individuals will be responsible for the Iron Management Program.
Iron Compliance
KKelner@step-es.com
Kyle Kelner Coordinator – 403-550-2823
Fracturing Services
Senior Iron
JKadiampallil@step-es.com
Joby Kadiampallil Compliance 403-596-4139
Coordinator
Iron Coordinator –
Carson Kenny ckenny@step-es.com 587-299-0715
Fracturing Services
5.2 Site Manager

 Provide crew members with the appropriate training and documentation related to iron
management.
 Ensure all crew members are adequately trained in their roles regarding iron management.
 Communicate with the Iron Coordinators to determine inspection requirements.
 Ensure all documentation and certifications are available to the crew.
 Monitor conditions of iron exposure related to erosion factors, temperatures and pressures.
5.3 Supervisor
 Report all iron related incidents in a timely manner.
 Ensure and enforce iron segregation by understanding and adhering to the band system.
 Provide iron management mentoring to all crew members.
 Document all iron maintenance and field audit events.
 Monitor conditions of iron exposure related to erosion factors, temperatures and pressures.
 Assist in on-site inspections.
 Perform field documentation audits as required.
 Understand all iron limitations and ensure iron is kept within working limits.
 Ensure the Out of Service (Section 7) procedure is followed.
5.4 Operator
 Ask questions when unsure of any iron limitations or procedures.
 Ensure iron segregation by understanding and adhering to the band system.

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 Perform iron maintenance as required.

 Initiate the out of service procedure.
 Ensure all documentation and certifications are available and up to date.
 Perform inspections as required.
 Perform field audits as required.
5.5 Engineering
 Understand the iron management document.

 Understand the iron limitations and ensure operations are programed accordingly.
6 Iron Identification System

Treating iron is identified by both colour and an identification band or stamp. This is to differentiate
between different uses of iron, such as sour service or different pressure ratings.
Treating iron must be stamped with an OEM serial number. If the OEM serial number is missing, iron
must be taken out of service by following the out of service procedure.
6.1 Treating Iron Colour Coding System

Prior to commencing any operation, it is imperative that professionals fully understand the working
environment and the working limits of the equipment that they are operating. The following table
identifies the colour coding system that STEP uses to distinguish between the different treating iron.
Always refer to the inspection band or stamp to identify the maximum working pressure.

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Corresponding Maximum
Color Thread
Service Line Pipe Example Application Working
Coding Type
Diameters Pressure
 Fluid
Pumping
 2”
 Coiled High
 2”,3”  Weco 15,000psi
Orange Tubing
 1”
pressure
1502 (103.4MPa)
 Nitrogen pumping
 2”,3”,4”
Pumping
 Fracturing
Low
 Fluid 3,000psi
Grey  2” pressure  NPT
Pumping (20.7MPa)
bleed off
 Fluid
High
Pumping  2”  Weco 15,000psi
Blue  Coiled  2”,3”
pressure
1502 (103.4MPa)
flow back
Tubing
Sour
 Fluid
service
Green  Coiled  2”,3”
(Weco
1502 (69MPa)
1502
Tubing
thread)
Sour
 Fluid
service
Green  Coiled  2”, 3”
(Weco
2202 (103.4MPa)
2202
Tubing
thread)
Sour
 BX-152 15,000psi
Green  Coiled service
 2”, 3”  BX-154 (103.4MPa)
Tubing Flanged
*Note: Always refer to the manufacturer specifications.
** Due to some asset integration in the fracturing department some 15K iron may be outside this colour
coding system. Be sure to always reference the maximum working pressure on the identification band. If
ever unsure of the maximum working pressure contact the Iron Coordinator.

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6.2 Pressure Control Equipment

Pressure control equipment is an exception to the colour coding system, but can be identified by the
inspection/manufacturers stamps or variations in the construction. If ever unsure of the pressure rating
of pressure control equipment, contact your Supervisor or the Iron Coordinator.
Rotating Joint Identification Table

Maximum Working
Model Picture Manufacturers Description
Pressure
Straight 10K
50.8mm 10,000psi
Rotation Joint HydraRig
(2in) rotating joint (69MPa)
(Wing to Wing)
Straight 10K
63.5mm 10,000psi
Rotating Joint Nexus
(2.5in) rotating joint (69MPa)
(Wing to Thread)
Straight 15K 63.5mm 15,000psi

Nexus
Rotating Joint (2.5in) rotating joint (103.4MPa)
90° 10K 50.8mm 10,000psi

Nexus
Rotating Joint (2.5in) rotating joint (69MPa)
90° 15K 50.8mm 15,000psi

Nexus
Rotating Joint (2.5in) rotating joint (103.4MPa)
Double 90° 15K 50.8mm 15,000psi

Nexus
Rotating Joint (2.5") rotating joint (103.4MPa)
*The 10K and 15K RTJs can be distinguished by the second set of bolts around the body of the 15K RTJ.
*Note: Always refer to the manufacturer specifications which are located on the manufacturer’s website.

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Lubricator Identification Table

Maximum Working
Pressure
10k Lubricator
5-1/8” lubricator in 10,000psi
(Bowen Nexus
2, 4, 6, 8, 10ft lengths (69MPa)
Connection)
15k Lubricator 5-1/8” lubricator in

15,000psi
(Bowen Nexus 2, 4, 6, 8, 10ft lengths
(103.4MPa)
Connection) (one piece body)
5-1/8” lubricator in
15k Lubricator 15,000psi
Nexus 2, 4, 6, 8, 10ft lengths
(BX 169 Flange) (103.4MPa)
(one piece body)
*The 15k lubricators can be distinguished by the single piece body. The banding system hand union
connections are also different to ensure different pressure ratings cannot be matched.
Stuffing Box Assembly Identification Table

Maximum Working
Pressure
10k Tandem, 4-1/16”10K(5-1/8” 10K

10,000psi
Stripper Nexus Union) -Nexus
(69MPa)
Assembly
4-1/16” 15K Two-Door

15k Tandem
Stripper c/w 5-1/8” 15,000 psi
Stripper Nexus
15K BX-169 on Bottom (103.4MPa)
Assembly
*The 15k stuffing box can be distinguished by the flanged bottom connection and banding system.

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BOP Identification Table
Maximum Working
Pressure
5-1/8” 10k Quad 5-1/8” 10K Quad BOP 10,000psi

Nexus
BOP (69MPa)
5-1/8” 15k Quad 5-1/8” 15K Quad BOP 15,000psi

Nexus
BOP (103.4MPa)
*The 15k BOP can be distinguished by the larger body, flange connections on both sides, or by the OEM
specification plate located on the BOP body.
Note: Always refer to the manufacturer specifications which are located on the manufacturer’s website.
6.3 Manufacturer Document Links

Component specifications can be found by following the links below for the corresponding
manufacturer.
Weir SPM
https://www.global.weir/brands/spm/spm-downloads/
MSI
https://www.diwmsi.com/support/manualsflow-control/
Nexus
http://www.nexusenergytech.com/Nexus_Product_Catalog_flipbook.html#Nexus%20Product%20Catalo
g/page1

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6.4 STEP Fracturing Banding System

All STEP Fracturing Services high pressure iron uses a 2-⅟₂" band identification system. The first band is
stamped with an abbreviation of the OEM serial number. This band will stay on and never get removed.
The second band will be stamped with the unit number, expiry date, and pressure rating in psi. On
items that cannot accept 2 bands, the OEM serial number will be stamped on the body of the item, or
both numbers will be combined into one band.
As with high pressure iron, all 4” fracturing hoses will follow the same banding procedure.
See example of banding labels below, as well as two photos illustrating the proper banding procedure.
 Example OEM number (FV XXXX XXXXX XX or SPM XXXX XXXXX XX )

 Example of Unit number (33FFP01 3-19 15K Or 32FIT05 3-19 15K)
*See Banding Prefix Section Below for more information*
Figure 1: Assets with two bands
Figure 2: Assets with one band
For items where the OEM number cannot be found, a date generated number will be issued and used in
place of the OEM number. The date generated number should be issued by the vendor that is currently
inspecting the specific piece of iron. Below is an example of the format for the date generated number.

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 Date Generated Format Example

MM/DD/YY/STATION CODE/STEP CODE/000
Station Code Numbers

RD DCI 55
GP DCI -56
RD TOPCO-35
GP-TOPC0-37
MED HAT TOPCO-48
RED DEER SPM-20
GP SPM-26
MED HAT SPM-28
Step Code - refers to the abbreviation ST
/000 - This is the number of serial numbers generated that day
NOTE** The STEP Fracturing Banding system was implemented on August 1st, 2018. Until all Iron is
converted to this new system some items in Fracturing Services may still follow the Coiled Tubing
Banding system.
6.5 STEP Coiled Tubing, Fluid Pumping and Nitrogen Banding System
All STEP high pressure iron uses a unique identification number either on a ⅟₂" band or stamped on the
body of the item. Using the table below, the identification number will describe the unit number, item
type, size, and item identification number. Behind the item identification number will be an iron
inspection expiry date in the format of MM/YY and the maximum working pressure in psi. Iron that
reaches its expiry date or is missing its band must be tagged and taken out of service immediately. The
table below will also explain where the band or stamp is located on each item. It is imperative that all
STEP professionals understand this system in order to identify expired iron and ensure iron segregation
between units.
Component Band Style Size Band Placement

Manifolds Unit#.14000s 1"-4" 1/2" Thread outlet
Tees, 90 degree elbows,
changeovers, jackknives, pressure On the body where it will not
Unit#.1000s 1"-4"
relief valves, flanges, pressure impede the use of the wing
recorders

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Swedges, male and female plugs Unit#.1000s 1"-4" Stamp on body (no band)
Fluid Ends Serial# of Fluid End.1000s 4”-6 ⅟₂" No band on fluid end
Unit#.1502.00# 1 ⅟₂" iron ⅟₂" middle of pipe
Unit#.2002.00# 2" iron ⅟₂" middle of pipe
Treating iron 2 feet in length

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Unit#.10000's 1 ⅟₂" ⅟₂" thread outlet

Unit#.11000's 1x2 2" thread outlet
2" thread outlet on ULT
Plug valves
Unit#.12000's 2x2 valves, stamp on body
otherwise
Unit#.13000's 3x3 Around body
Unit#.10500s (flapper style) 1 ⅟₂" Around body if applicable

Unit#.10500s (dart style) 1 ⅟₂" Around body if applicable
Unit#.12500s (flapper style) 2" Around body if applicable
Check valves (flapper and dart style)
Unit#.12500s (dart Style) 2" Around body if applicable
Unit#.13500s (flapper style) 3" Around body if applicable
Unit#.13500s (dart Style) 3" Around body if applicable
1st elbow on wing side

Unit #.15.00#'s 1 ⅟₂" (on straight swivels band
thread end)
Unit#.2.00#'s 2" (on straight swivels band
thread end)
Swivels
thread end)
thread end)
⅟₂" around body and

2RT0#.1001 2"
stamp body
Rotating joints (RT)
⅟₂" around body and
3RT0#.1001 3"
stamp body
 BOP Working/Treating In Service Inspection

Nexus Serial Number
 Lubricators Pressure date Due Date

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 Stuffing box assemblies

 Flange crossovers
LVL 4
 Night caps Date: MM-
SN:XXXXXXXX-XX WP:xxK TP:xxK DUE:
DD-YYYY
 BOP test stands MM/YYYY
 Flow tees
Description Abbreviations
Sour Service STEP.SS
6.6 Banding Prefix Chart

The table below defines STEP’s unit naming convention. When combined with the above banding system
each component can be traced back to the piece of equipment it belongs to and the corresponding
inspection frequency.
Inspection
Unit Name Division Frequency Unit Description
(Months)
110R Coiled Tubing 12 Reel 110" diameter
2RTJ Coiled Tubing 12 Rotating Joint
33C Coiled Tubing 12 Coil Trailer
33R Coiled Tubing 12 Reel Trailer
CTS Coiled Tubing 12 Coil Spare
33C##S Coiled Tubing 12 Coil Sour Service
RHV Coiled Tubing 12 Remote Hydraulic Valve
STEP.SPARE Coiled Tubing 12 Spare
STEP.SS Coiled Tubing 12 Sour Service
STEPSOUR15K Coiled Tubing 12 Sour Service
33P Fluid Pumping 12 Twin Fluid Pump
FPS Fluid Pumping 12 Fluid Pump Spare
SKID Fluid Pumping 12 Skid Iron

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FRAC Fracturing 12 Sour Service

FRHV Fracturing 12 Sour Service
31FMT Fracturing 6 Manifold Trailer
32FDT Fracturing 6 Data Van
32FIT Fracturing 6 Iron Trailer
33FFP Fracturing 6 Frac Pump
33FNP Fracturing 12 Frac Nitrogen Pump
Trailer
62FDV Fracturing 6 Body Job Data Van
63FIT Fracturing 6 Body Job Iron Truck
FRAC.SPARE Fracturing 6 Frac Spare
RDSC.BALLINJ Fracturing 12 Ball Launcher
FDL Fracturing 12 Diverter Launcher
NTS Fracturing 12 N2 Muffler
Test Tank Fracturing 12 Test Tank
80FIS Fracturing 6 Iron Skid
32FRV Fracturing 6 ePRV Trailer
63N Nitrogen 12 Body Job Nitrogen Pump
N2HOSE Nitrogen 12 Nitrogen Hose
6.7 Safety Iron Identification

In addition to iron banding, SPM® Safety Iron® products are permanently identified on each individual
component. All metal components have full material traceability and are identified by their VENDOR ID
(SPM), PART NUMBER, SIZE, PRESSURE RATING, and HEAT CODE. If this information cannot be seen, the
item must be taken out of service as per the out of service procedure.

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Figure 3: Top View – Non Threaded Safety Iron® Half (Showing identification markings)
7 Iron Limitations
7.1 Iron Rate Limitations
Along with the pressure limitations listed above, rate limitations also apply. Rate limitations are
dependent on iron size and fluid type. Anything above the recommended limit significantly increases
wear, reduces iron life span, and increases the potential for a premature failure. The manufacturers
have set a guideline for maximum recommended velocity (shown below).
Maximum Velocity
ft/s m/s
Sand Laden Fluid 42 12.8
Clean Fluid 100 30.5
Gas 200 61.0
The corresponding maximum rates for STEP iron are shown below.
7.1.1 Fracturing services
Maximum Rate (m3/min)

Iron Size 1" 2" 3" 4"
All Fluid Systems 0.4 1.2 3 5.5
7.1.2 Coiled Tubing, Fluid pumping and Nitrogen Services
Maximum Rate (m3/min)

Iron Size 1" 2" 3" 4"
Sand Laden Fluid 0.4 1.2 3 5.5
Clean Fluid 0.9 2.8 7 13.1
Gas 1.52 4.56 11.2 20.88

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7.2 Temperature Limitations

As per API6A, all standard equipment has a ‘PU’ classification and all sour service equipment has a ‘LU’
classification.
Minimum Temperature Maximum Temperature

PU – Standard Equipment -20◦F 250◦F
-28.9◦C 121.1◦C
LU – Sour Service Equipment -50◦F 250◦F
-45.6◦C 121.1◦C
8 Iron Segregation
It is the responsibility of all personnel to ensure proper segregation of high pressure treating iron. It is
essential to the Iron Management Program that all iron packages remain together. This is to ensure
proper maintenance and that inspections are carried out on each individual item in an efficient manner.
By utilizing the STEP identification number, iron can be segregated into the proper iron package. Upon
job completion each item must be returned to its corresponding iron package or unit. In the case of
extra iron being needed, iron banded as spare should be used first before utilizing iron from other units.
During all rig in and out inspections, any iron found that is banded to a different unit should be
immediately returned to the proper unit. In the event the unit is not available the component must be
segregated using the out of service tagging procedure so it can be returned to the proper unit.
8.1 Coiled Tubing Skid Iron

Iron on skids have been banded using colour bands to ensure iron is properly segregated during rigouts.
Each unit has uniquely coloured bands on each component as a visual aid for separation while still
utilizing the above naming and tracking system.
9 In Service/Out of Service Procedure

9.1 Red “Out of Service” Tags
A red out of service tag will be placed on any iron that has reached its inspection expiry date or has not
passed a visual or onsite pressure test. The out of service tag will include:
 Date
 Reason for tagging
 Band identification number
 Contact information of the individual issuing the tag

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This is to ensure that further communication can be made in the event that more detail on the item is
required.
The item will then be segregated from other iron until it can be placed in the red bins labeled “out of
service”, located at all service centers. A follow up email will then be sent to the service center’s Iron
Coordinator which will include what was dropped off, reason for tagging and the band identification
number.
Service tags are located at all services centers with the Iron Coordinators. Each unit must also stock out
of service tags for use in the field. In the event that a red tag is not available, the iron must be flagged by
another means such as red or orange flagging tape. The Supervisor must then take ownership of that
item until a proper tag can be utilized. All STEP professionals are responsible for performing the out of
service procedure as outlined by this document.
9.2 Green “In Service” Tags

A green in service tag will be placed on any iron that has undergone successful inspection or repair. This
tag will include date, inspection or repair type, and the associated unit number. This item will then be
placed in the green bins labeled “in service”, located at all service centers. The green tag will remain on
the component until it has been replaced on the proper unit. A weekly email will be sent to field
professionals listing all additions to the green box that are ready for pick-up. The “In Service” procedure
will only be performed by qualified Iron Coordinators upon the third party recertification.
Figure 4 In Service/Out Service Tag

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Figure 5 In Service/Out Service Boxes
10 Inspections
10.1 Inspection Intervals
Inspection Level
Equipment Type
Visual Level 1 Level 2 Level 3
Over pressure
Fracturing Iron Trucks situations
Manifold Trailers, Upon Client’s under 110% of
Pre and post job Every 6 months
Data Vans, Iron Skids Request maximum
and ePVR Units working
pressure
Over pressure
situations
Other Fracturing
Upon Client’s Every 12 under 110% of
Equipment as per the Pre and post job
Request months maximum
Banding Prefix chart
working
pressure
Over pressure
situations
Coiled Tubing, Fluid
Upon Client’s Every 12 under 110% of
Pumping and Nitrogen Pre and post job
Request months maximum
Equipment
working
pressure
10.2 Approved Vendors

o GKD
o SPM
o FMC
o FLOW VALVE

25
o MSI
o TSI
10.3 Severity of Service Erosion Study

When corrosive service is expected, a stainless-steel fluid end is recommended.
However, to better understand severity of service, a field trial is being conducted to study and evaluate
the erosional losses on treating iron during fracturing operations. Certain components will be monitored
throughout their life to track slurry rates, pressures and proppant concentrations. Through weekly
inspections, the main deliverables related to this study will be:
 Defining criteria for service severity

 Providing inspection recommendations based on: fluid system, fluid volume, slurry rate,
proppant mass and concentrations
 Proposing testing methods to evaluate
o Salt concentration – salinity ranges
o Pressure and temperature effects
o Corrosion
o Exposure at different locations along the line
10.4 Inspection Levels
10.4.1 Visual Inspection

Before and after every job, all equipment requires a visual inspection to check for abnormalities such as:
 Wear spots, surface cracks, pitting and excessive corrosion (refer to Figures 4 to 10 in the
rejection parameter section of this document)
 Damaged wingnuts (see more in the wing nut inspection section below)
 Bent or yielded treating irons
 Damaged or missing threads
 Inspection date
An ultrasonic wall thickness test will be performed on critical high risk areas such as swivels and tees on
any iron pumping abrasive products. Additional metering shall be done on these high risk areas during
scheduled usage based maintenance time to ensure no washing is occurring.
Components should be thoroughly flushed of working fluids (i.e. cement and acid). Ensure equipment
with moveable parts (i.e. swivels and plug valves) are moving freely and sufficient grease is applied (as
per manufacturer specifications). Check all union connections to ensure the tip of the wing segments are
visually the same. Finally, ensure both the serial number band and the date bands are in good condition.
Reject any component that cannot be repaired or shows wear consistent to that shown in the rejection

26
parameters. Contact the Iron Coordinator if a serial band or date band is missing. Flag the component
and complete the out of service procedure.
** This will not replace an annual inspection, nor will it extend a certification expiry. **
10.4.2 Wing Nut Inspection

All wing nuts will be thoroughly inspected before every job to ensure their continued use is safe to
personnel and does not increase the risk of injury. Repeated hammering of the wing will cause the lugs
to become deformed or mushroomed. It is vital that these edges be grinded to ensure no sharp edges
exist. If the wing is used extensively, to a point where the lugs are rolled over, the entire component
should be taken out of service immediately using the out of service procedure.
The wings and segments are visually inspected internally and externally to verify that they are not
eroded or corroded. The component is visually examined for any defects. Grind wings if necessary.
If a wing nut fails and inspection, or if an iron component is found without a wing nut, the component
must be taken out of service using the out of service procedure. This is to ensure all wing nuts used have
been properly inspected.
All wing nuts are replaced during Level 2 & 3 inspections. The wing nuts that are removed during the
iron inspection are then sandblasted and a magnetic particle inspection is performed on all surfaces. If
the wing nut passes according to the specifications below, it will be reused at a later date.
** Only inspection companies may replace wing nuts.**
The following specifications should be met when inspecting the wing. If it does not meet these
requirements, the entire component will be taken out of service.
Wing Lug Width - Sharp edges on the wing lug with a width of less than 1/4”, as shown in below figure,
should be taken out of service and discarded. Any measurements more than 1/4” meet the lug width
requirement.
Wing Nut Lug width less than 0.25”

should be discarded

27
Wing Lug Height - If the wing lug height measures less than 1/2”, as shown in below figure as ‘D’, it
should be removed from service. If it falls within the 1/2” measurement, then it has passed the lug
height requirement.
D
10.4.3 Safety Iron
In addition to the above visual inspections, all safety iron needs to be inspected before and after each
use according to the following criteria:
 Flange faces should be free of significant burrs, gouges, dents, dirt, and cracks. The outer
surfaces are precision machined to fit against the clamp inner faces and are an integral part of
maintaining a proper seal.
 Flange inner sealing surfaces should be clean and free of dirt or debris. Failure to clean these
surfaces could cause the connection to leak.
 Bolt threads should be clean and free of burrs, gouges, and cracks. Bolts with damaged threads
should be replaced immediately.
 Clamp threads should be clean and free of burrs, gouges, and cracks. Clamps with damaged
threads should be replaced immediately.
 Clamp inner mating surfaces should be free of burrs, gouges, dents, dirt, and cracks. Clamps
with damaged inner mating surfaces should be replaced immediately.
 Soft seals should be inspected for tears or cracks. Seals showing significant wear or damage of
any sort should be immediately replaced.
 Any part with excessive rust or corrosion that prevents proper assembly or sealing should be
immediately replaced.
 Parts showing signs of internal washing, corrosion, acid pitting, or rust should be replaced.

28
 All connections need to be inspected to ensure proper torque and that proper installation
procedures were followed, as per the safety iron operating and maintenance instructions set
out by the manufacturer.
10.4.4 Level 1 Inspections

Level 1 inspection will be completed upon customer request. This inspection can be completed pre/post
job, or on location.
This level of inspection will be performed by a third party inspection contractor and include:
 Visual inspection
 Ultrasonic wall thickness test
 Thread inspections using profile gauges.
A certified inspection report will be completed for all components tested.
** This will not replace an annual inspection nor will it extend a certification expiry.**
10.4.5 Level 2 Inspections

Level 2 Inspections are carried out based on time intervals as per the inspection interval referenced in
section 8.1.
This level of inspection will only be performed by a manufacturer certified, inspection contractor and
include:
 The cleaning of critical areas (i.e. nubbin, and thread connections).
 Pressure test all integral iron to maximum working pressure for 3 minutes.
 All swivels will be greased, actuated and pressure tested.
 All plug valves will be greased, actuated and pressure tested.
 A magnetic particle inspection of all critical areas as defined in the wall thickness table located in
the ‘Minimum Wall Thickness’ document.
 An ultrasonic wall thickness inspection of high-pressure components as defined in the wall
thickness table located in the ‘Minimum Wall Thickness’ document.
 The wings and segments are replaced with components that have passed inspection.
 Safety iron clamps and bolt threads will be inspected for wear and thread stretch using a NOGO
gauge. A magnetic particle inspection will also be performed.
 A new band is installed with a serial number and date of the next inspection according to STEP
inspection interval requirements
 All suction hoses will be inspected and banded to the corresponding unit
A certified inspection report will be completed as per Section 9 of this document.
A level 2 inspection cannot be completed on any iron that has been exposed to an over pressure event
(any pressure that has exceeded the calculated rated working pressure of the iron).

29
10.4.6 Level 3 Inspection

Level 3 inspections will be carried out after any over pressure situation that is less than 10% above the
maximum pressure rating.
This level of inspection will only be performed by a manufacturer certified, inspection contractor and
include:
 The iron will be sandblasted to remove all paint to ensure any stress cracking is identified during
the magnetic particle inspection.
 The cleaning of critical areas (i.e. nubbin, and thread connections).
 Pressure test all integral iron to maximum working pressure for 3 minutes.
 All swivels will be greased, actuated and pressure tested.
 All plug valves will be greased, actuated and pressure tested.
 A magnetic particle inspection of all critical areas as defined in the wall thickness table located in
the ‘Minimum Wall Thickness’ document.
 An ultrasonic wall thickness inspection of high-pressure components as defined in the wall
thickness table located in the ‘Minimum Wall Thickness’ document.
 The wings and segments are replaced.
 Safety iron clamps and bolt threads will be inspected for wear and thread stretch using a NOGO
gauge. A magnetic particle inspection will also be performed.
 Iron will be repainted
 A new band is installed with a serial number and date of the next inspection according to STEP
inspection interval requirements
A certified inspection report will be completed as per Section 9 of this document.
Any iron that has been over pressured by more than 110% of its maximum pressure will automatically
be removed from service permanently and disposed of. In the event of an over pressure incident, all
items that were subject to the overpressure incident must be removed from service utilizing the out of
service tagging procedure. Once available, threads will be cut to ensure the iron is properly segregated.
10.5 Rejection Parameters

Rejection parameters are based on manufacturer specifications. Any components that fail, based on
these parameters, will be taken out of service and replaced. Any wing segment that is part of a failed
component will also be considered failed and taken out of service.
10.5.1 Ultrasonic Wall Thickness Test

The Minimum Wall Thickness document outlines all minimal wall thickness requirements regarding item
type, size, and manufacturer, for both standard and sour service iron. When multiple test points are
given, tests will begin at the male end (wing end) and move towards the female end (thread end).

30
10.5.2 Magnetic Particle Inspection

When magnetic particle inspections are performed, any anomaly in the iron will constitute a failure.
This inspection is done according to the Canadian General Standards Board Standard 48.9712-2006.
10.5.3 Iron Seals

During visual inspections seals will be replaced if they show signs of cracking or excessive wear. The
following seals will be used as replacements at the time of inspection or during field replacement.
Fracturing services- All 2”, 3” and 4" 1502 fracturing iron will use standard Endurel all season hammer
union seals.
Frac pump (33FFP) and ePRV Trailer units (32FRV) will use anti-extrusion Endurel all season hammer
union seals.
Coiled Tubing, Fluid pumping and Nitrogen Services- All standard 15K components will use SPM all
season hammer union seals.
10K sour service BOP iron (STEP.SS, 33C##S) will use Viton green H2S 1502 seals and all 15K sour service
iron (STEPSOUR15K) will use Viton H2S anti-extrusion 2202 seals.
10.5.4 Pressure Tests

Any visual leaks or more than a 3% leak off over 3 minutes will constitute a failure.
10.5.5 Actuation Tests

Any seized, loose or leaking valves or swivels will be rebuilt by the manufacturer or certified third party
contractors.
10.5.6 Visual Rejections

 Wear spots, surface cracks, pitting and excessive corrosion. (Figures 2-3)
 Damaged wingnuts. (Figures 4-5)
 Bent or yielded treating iron. (Figure 1)
 Damaged or missing thread. (Figure 7)

31
Figure 1: Bent Iron
Figure 2: Erosion/Corrosion
Figure 3: Fail Vs. Pass

32
Figure 4: Cracked Wing
Figure 5: Fail Vs Pass Damaged Wings

33
Figure 6: Damaged Safety Iron Bolt Figure 7: Damaged safety iron bolt threads

34
11 Inspection Documentation
For both level 2 and 3 inspections, a certified inspection report will be produced including the following:
 Identify each piece on the unit.

 Provide an ultrasonic thickness test and identify the minimum wall thickness.
 Comment on the visual and magnetic particle inspection.
 Indicate a pass or fail.
 Identify the manufacturer and the manufacturer’s serial number.
 Name the individual(s) performing the inspection.
This report will be filed on the respective inspection facility’s online portal. A hard copy will also be filed
in the unit’s documentation binder.
For a level 1 inspection, an inspection report will be generated to identify what inspections were
completed along with a note identifying any failures from the inspection. This report will be filed by the
inspecting company on to their online portal. It is the responsibility of the unit’s operator to ensure a
hard copy of the report is added into the unit’s documentation binder.
A visual inspection will be documented on all rig-in safety meeting forms. Any failed components will be
removed form service as per the out of service procedure.
Level 2 and 3 recertification companies used:
 DC inspection
 Nexus
 WEIR Asset Management (SPM)
 Topco Oilsite
12 BOP Inspections
Like other high pressure iron, pressure control equipment must undergo routine maintenance and
inspections. Due to the different stress environment this equipment is exposed, to the manufacturer has
set out separate maintenance and inspection criteria. These items still follow the STEP identification and
segregation system but will have separate inspection frequencies and inspection levels.
12.1 Inspection Levels

Completed yearly; the inspection includes:
 Equipment disassembly
 Equipment inspection
 Replacement of all seals
 Equipment reassembly

35
 Pressure Test
 Function Test
 Banding
 Documentation

Completed every 3 years minimum; the inspection includes:
 Equipment disassembly
 Equipment and dimensional inspection
 Sandblast
 Magnetic particle inspection
 Teflon coating
 Repainting
 Replacement of all seals
 Equipment reassembly
 Pressure test
 Function test
 Banding
 Documentation
The following items will complete a level 3 inspections yearly:
 Rotating Joints
The following items will complete a level 4 inspection every 3 years minimum:
 BOP
 Lubricators
 Stripper Assemblies
 Flange Crossovers
 Night Caps
 BOP Test Stands
 Flow Tees
13 Audit Process
The following audit processes are put in place to monitor effectiveness and efficiency in all areas of the
Iron Management Program. The program effectiveness will be monitored on both administrative and
field levels. The Iron Coordinators will be responsible for overseeing all areas of the audit process and
for making any required changes to the process and document.

36
13.1 Field Audit

Iron spot checks will be performed by the field professionals upon completion of the rig in. The spot
check will consist of selecting a minimum of 5 flow piping components and ensuring a band or stamp is
in place, as well as ensuring the inspection date is not overdue. The serial number will be written down
and a spot check document will then be completed.
13.2 Field Document Audit
The randomly selected components will then be looked up in the inspection database to ensure the up
to date certifications are available. If the certifications are unavailable the component must be taken out
of service, as per section 7, until the certifications are located. A note on the rig-in safety meeting form
will be made that the audit process has been completed.
13.3 Inspection Tracking Audit
The Iron Coordinators will be responsible for auditing the excel inspection tracking sheet. This will be
done by randomly selecting components to ensure the available certifications match the tracking sheet.
This audit will be performed on a monthly basis. In the event that discrepancies are found, the tracking
procedure must be re-evaluated. The monthly audits will then be documented in the inspection tracking
folder identifying what items were audited, as well as their respective pass/fail designation. The Iron
Coordinator will be notified of the audit by the inspection notification sheet.
13.4 Inspection Interval audit
All iron that fails a level 1-3 inspection will be recorded by the Iron Coordinators and include component
type, failure type, and date. A database of all failures will be kept and monitored to identify any changes
in iron failure frequency. If a change in frequency is seen, the inspection intervals must be re-evaluated
for that type of iron.
STEP Energy Services | Iron Management Program (January 2018)

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Iron Management Program

Standard Operating Procedures Manual

Providing hydraulic fracturing, coiled tubing, fluid pumping and nitrogen

© STEP Energy Services, 2018

STEP Energy Services | Iron Management Program (Revision 2.5)

10.1 Inspection Intervals ..................................................................................................................... 24

STEP Energy Services | Iron Management Program (Revision 2.5)

Revison Description Revision By Approval Date

STEP Energy Services | Iron Management Program (Revision 2.5)

STEP Energy Services | Iron Management Program (Revision 2.5)

President & CEO

STEP Energy Services | Iron Management Program (Revision 2.5)

STEP’s employees are engaged.

STEP executes on our commitments.

STEP consistently exceeds client expectations.

We are driven to create an Exceptional Employee Experience (EEE) and to deliver an

S – Safety “Safety is no accident”

T – Trust “Trust is built with character and competence”

E – Execution “Goal, plan, execute, learn, repeat”

P – Possibilities “Engaged employees, discovering possibilities”

STEP Energy Services | Iron Management Program (Revision 2.5)

(a) Located above ground, and

OEM- Original Equipment Manufacturer

5 Roles and Responsibilities

STEP Energy Services | Iron Management Program (Revision 2.5)

5.2 Site Manager

STEP Energy Services | Iron Management Program (Revision 2.5)

 Perform iron maintenance as required.

 Understand the iron management document.

6 Iron Identification System

6.1 Treating Iron Colour Coding System

STEP Energy Services | Iron Management Program (Revision 2.5)

*Note: Always refer to the manufacturer specifications.

STEP Energy Services | Iron Management Program (Revision 2.5)

6.2 Pressure Control Equipment

Rotating Joint Identification Table

Straight 15K 63.5mm 15,000psi

90° 10K 50.8mm 10,000psi

90° 15K 50.8mm 15,000psi

Double 90° 15K 50.8mm 15,000psi

STEP Energy Services | Iron Management Program (Revision 2.5)

Lubricator Identification Table

15k Lubricator 5-1/8” lubricator in

Stuffing Box Assembly Identification Table

10k Tandem, 4-1/16”10K(5-1/8” 10K

4-1/16” 15K Two-Door

STEP Energy Services | Iron Management Program (Revision 2.5)

5-1/8” 10k Quad 5-1/8” 10K Quad BOP 10,000psi

5-1/8” 15k Quad 5-1/8” 15K Quad BOP 15,000psi

6.3 Manufacturer Document Links

STEP Energy Services | Iron Management Program (Revision 2.5)

6.4 STEP Fracturing Banding System

 Example OEM number (FV XXXX XXXXX XX or SPM XXXX XXXXX XX )

Figure 1: Assets with two bands

Figure 2: Assets with one band

STEP Energy Services | Iron Management Program (Revision 2.5)

 Date Generated Format Example

Station Code Numbers

Step Code - refers to the abbreviation ST

/000 - This is the number of serial numbers generated that day

Component Band Style Size Band Placement

STEP Energy Services | Iron Management Program (Revision 2.5)

STEP Energy Services | Iron Management Program (Revision 2.5)

Unit#.3010.00# 3" iron ⅟₂" middle of pipe

Only inspection companies may replace wing nuts.