RZK NSS AVN IRF QAC 90101 00 E - EN - Signed

Ural Oil and Gas LLP Rozhkovskoye Field Development
Date Issued: 27-SEP-2023

NefteStroiService Ltd. LLP
Issue Type: Issued for review
Document Number: RZK-NSS-AVN-IRF-QAC-90101-00-E
ROZHKOVSKOYE FIELD DEVELOPMENT PROJECT
INSPECTION AND FAT REPORT / IRF

WELLHEAD CONTROL PANEL
Tag No: WHCP-U10

Tag No: WHCP-U12
Tag No: WHCP-U21
Tag No: WHCP-U23
Tag No: WHCP-U26
Tag No: 1 WHCP (U-XX-SPARE).
CLIENT DOC: NO:

RZK-NSS-AVN-IRF-QAC-90101-00-E
NSS-RZK-PO-0009
AVANCEON: DOC: NO: AVN-2022-IRF-001
27-SEP-2023
INSPECTION AND FAT REPORT WHCP

RZK-NSS-AVN-IRF-QAC-90101-00-E Page 1 of 20
REVISION:
Balaji Suresh
E 27-SEP-2023 Issued for review Mangeram Tyagi
Radhakrishnan Balakrishna
Balaji Suresh
D 20-JULY-2023 Issued for review Mangeram Tyagi
Balaji Suresh
C 28-MAR-2023 Issued for review Mangeram Tyagi
Issued for Inter Discipline Balaji
B 16-MAR-2023 Mangeram Tyagi Sadha Baskaran
Review Radhakrishnan
Issued for Discipline Balaji
A 13-FEB-2023 Mangeram Tyagi Sadha Baskaran
Internal Review Radhakrishnan
Rev. Date Issue, Modification Prepared Checked Approved

Approvals:
Prepared by Name: BALAJI RADHAKRISHNAN

Job Title: Project Engineer
Signed:
Date: 27-SEP-2023
Checked by Name: Mangeram Tyagi

Job Title: QA AC Manager
Signed:
Date: 27-SEP-2023
Approved by Name: Suresh Balakrishna

Job Title: QA/QC Manager.
Sures
Digitally signed by Suresh
Signed: DN: cn=Suresh,
o=Neftestroiservice Ltd,
Date: ou=QA/QC Department,
h
email=rzk-
mgrqaqc@nss.kz, c=US
Date: 2023.09.30 15:50:01
+05'30'

HOLD RECORD:
Where a <HOLD> status has been included within the body of the document please indicate its location by
detailing the relevant page number.
Hold Nr. Section Description of Hold
REVISION HISTORY:
Specify significant changes from previous revisions of the document:
Rev. Date Description of Revision

A 13-FEB-2023 Issued for Discipline Internal Review
B 16-MAR-2023 Issued for Inter Discipline Review
C 28-MAR-2023 Issued for review
D 19-JULY-2023 Issued for review
E 27-SEP-2023 Issued for review

TABLE OF CONTENT
1. PURPOSE
2. SCOPE
3. APPLICABLE PANEL TAGS NO
4. ABBREVIATIONS.
5. REFERENCE DOCUMENT LIST
6. CERTIFICATE / TEST REPORT VERIFICATION
7. REQUIRED EQUIPMENT & UTILITIES.
8. PRE- REQUISITES GENERAL.
9. VISUAL INSPECTION.
10. PRE-TEST VISUAL EXAMINATION.
11. PUMP FUNCTIONALITY TEST.
12. FUNCTIONAL TEST FOR VALVE - MANUAL OPENING / CLOSING OF THE SSSV, MV &
WV VALVES.
13. WHCP WELL ESD CLOSING BY FUSIBLE LOOP LOGIC: (FIRE

ACTIVATION) SEQUENECE OF SSV ----- SSSV VALVES CLOSES BY FUSIBLE LOOP
LOGIC
14. PUMP PRESSURIZATION TIME TEST.
15. PRESSURE TEST PROCEDURE.
16. FLUSHING PROCEDURE.
17. SIGNOFF

1. PURPOSE:
The document outlines the procedure for factory acceptance testing (FAT) of wellhead control
panels which serves for SSSV valves, MV valves, WV Valves & fusible plugs (Based on client
specification RZK-NSS-000-SDR-INS-00001-00-C.
Manufactured for the project – “ROZHKOVSKOYE FIELD DEVELOPMENT PROJECT”.
FAT shall be held at AVANCEON facility FZE, DUBAI- UAE.
 Company: M/s Ural oil & gas.

 WHCP Manufacturer: M/s Avanceon Jafza-FZE
 PLC / ICSS contractor: Not in Avanceon scope.
2. SCOPE:
The scope is to carry out the FAT of the Wellhead Control Panel, broadly outlined as below:
The procedure is Typical for wellhead hydraulic panel 5+1 spares, the control and check activities
are related to the following project, Avanceon Project: Ref: F23-02-001.
 Panel Dimensional check.

 Functional Check.
 Marking & Tagging Check.
 BOM Check.
3. APPLICABLE PANEL TAGS NO:

 Tag No: WHCP-U10
 Tag No: 1 WHCP (U-XX-SPARE).

4. ABBREVIATIONS:
The following abbreviations are used throughout this procedure:
 BV Ball Valve.
 HP High Pressure
 LP Low Pressure.
 MP Medium Pressure.
 PM Pump / Motor.
 PG Pressure Gauge.
 FA Flame Arrester
 FB Filler Breather.
 PSV Pressure safety valve.
 NV Needle Valve.
 FCV Flow Control Valve.
 NSPK Nitrogen Skid Package.
 PT Pressure Transmitter.
 LS Level Switch.
 PCV Pressure Control Valve.
 HR Hydraulic Regulator.
 PS Pressure Switch.
 SOV Solenoid valve.

5. REFERENCE DOCUMENT LIST:

The reference documentation is as follow:
Document Number Description
RZK-NSS-AVN-DGA-ENG-0001-01-C General Arrangement Drawing.
RZK-NSS-AVN-PID-ENG-0001-01-C Piping & Instrumentation Diagram.
RZK-NSS-AVN-SDR-QAC-0001-01-C SUPPLIER DOCUMENT REQUIRTMENTS (SDR)
RZK-NSS-AVN-SLD-0001-01-C ELECTRICAL / SINGLE LINE DIAGRAM / SLD
RZK-NSS-AVN-ITP-ENG-0001-01-C INSPECTION TEST PLAN / ITP
6. CERTIFICATE / TEST REPORT VERIFICATION:

CLIENT / TPI
ACCEPTED
 WHCP FLUSHING REPORT
 WHCP PRESSURE TEST REPORT
7. REQUIRED EQUIPMENT & UTILITIES:

 Nitrogen rack filled with dry nitrogen c/w suitable hoses & regulator.
 Mineral based hydraulic oil as required. (Castrol Hyspin AWH M32 is used for
testing purpose).
 24V DC power supply for instruments (PT).
 400V AC power supply for motor.
 Handheld Hart communicator & digital multi meter.
 35L bladder accumulator, 600 barg.
 Hydraulic pressure regulator.
 Hand tools.

8. PRE-TEST VISUAL EXAMINATION:
Mode of Client / TPI

sl:no: Activity Accepted criteria
inspection sign off.
Check Visual and dimensions of the wellhead As per approved

☐ Visual GA drawings, RZK-
10.1 module as per the approved General Check NSS-AVN-DGA-ENG-
Arrangement Drawings. 0001-01_0
☐ Visual As per approved

Check tubing runs for neatness & fixture and
10.2 Check PID, RZK-NSS-AVN-PID-
Ensure all tube work have sufficient support. ENG-0001-00_0
Mode of Client / TPI

sl:no: Activity Accepted criteria
inspection sign off.

Check labelling of components and controls
in line with the relevant GA. ENG-0001-00_0

Check relief valve set points report & tags in
line with schematic drawing. ENG-0001-00_0

Check the cabinet front fascia components
mounting Tags. ENG-0001-00_0

10.6 Check Motor supply Voltage 400V, AC 3PH. Check- PID, RZK-NSS-AVN-PID-
___________ V ENG-0001-00_0
Finally - Check all the BV, NV, HR, PT & LT ☐ Visual As per approved
and all the components fixed in panels are as
per PID. ENG-0001-00_0

9. PUMP FUNCTIONALITY TEST:

Mode of Accepted Client / TPI
sl:no: Activity inspection criteria sign off.
Confirm 400VAC power is available at the

11.1 ☐ …………V 400V AC
Motor Control Panel.
11.2 Pump-A Duty mode ☐ Visual Check Pump-A Duty
11.3 Pump-A manual/Auto Mode ☐ Visual Check Manual Mode

sl:no: Activity
inspection criteria sign off.
11.5 Pump A start Pressure ☐ ………. BARG 0 Bar
11.6 Current Reading Pump A at 0 Bar ☐ ………. A 2.5 to 3 Amps
11.7 Current Reading Pump A at 450 Bar ☐ ………. A <=40 Amps
PUMP HEADER START UP:

Start the pump by pressing the start As per
push button and observe the approved PID,
11.8 ☐ Visual Check
RZK-NSS-AVN-PID-
corresponding indication “PUMP-A ENG-0001-00_0
Running” on LCP.
Now Start the Pump-A and start closing
the recirculation valve NV-03) and allow
to pressurize. Monitor the gauge
As per
PUMP HEADER discharge pressure approved PID,
11.13 ☐ Visual Check
PG-01 on the front side of the panel. RZK-NSS-AVN-PID-
when the pump discharge pressure ENG-0001-00_0
reaches 450 Barg, stop the pump and

allow to settle for some time.


sl:no: Activity
VALVE HEADER LINE STARTUP:

SSSV: Now Regulate the HP SSSV header
11.14 regulator (HR-01) to reach 600 Barg; ☐ ………. BARG
monitor in (PG-04) in the front face panel, 600 BARG
Line-up the HP header pressure to the
respective SUPPLY LINE.
WV & MV: Now Regulate the MP header
regulator (HR-02) gradually to reach 340
Barg; monitor the header pressure (PG-
03) in the front face panel. 340 BARG
11.15
Ensure MP header pressure gauge ☐ ………. BARG
MV&WV (PG-03) is reading 340 barg.
Line-up the MP header pressure to the
respective SUPPLY LINE.
FUSIBLE LOOP:
Now open the ball valve (BV-07) in
Control / Fusible Header line.
11.16 ☐ ………. BARG
Now open the regulator (HR-03) on the
LP header of control/fusible line and set 7 – 8.5 BARG
the pressure to 7 barg by observing the
LP header pressure gauge (PG-08).
NOTE 1:
CLOSING TIME DELAYS PROVIDED THROUGH THE FLOW CONTROL VALVE (F-FCV-01) IS
FOR LOGIC VERIFICATION PURPOSE ONLY, ACTUAL TIME DELAYS WILL BE SET DURING
THE COMMISSIONING STAGE OF THE RESPECTIVE WELL.

10. FUNCTIONAL TEST:

12.1 FUNCTIONAL TEST FOR VALVE - MANUAL OPENING / CLOSING OF THE SSSV, MV & WV VALVES
Accepted Client / TPI
sl:no: Activity
criteria sign off.
NO CRITERIA
SSSV MANUAL 10.1.1. Make sure the all the bulk heads are FOR THIS.
OPENING & properly connected with temporary
CLOSING THIS IS
pressure gauges to monitor the INTERNAL TEST
pressure at the outlet side. ACTIVITY.
10.1.2. Check the connections for (SSSV-SOV-1)

well solenoid valves from the 24VDC
OBSERVE SSSV
SSSV MANUAL stimulator shall be energized. SUPPLY LINE
OPENING &
PRESSURE
CLOSING
10.1.3. Pull the Handle Valve (SSSV-PB-01) to GAUGE PG-05
open the SSSV, observe the pressure READS 600 BARG
gauge (PG-05) and shall read 580 barg
in supply line.
10.1.4. Push the Handle Valve (SSSV-PB-01) to OBSERVE SSSV
SSSV MANUAL SUPPLY LINE
OPENING &
close the SSSV, observe pressure gauge
PG-05 and shall reads 0 Barg after 60 PRESSURE
CLOSING
GAUGE PG-05
seconds Delay (Adjustable in HP-FCV- READS 0 BARG.
01).
Accepted Client / TPI
sl:no: Activity criteria sign off.
OBSERVE MV
SUPPLY LINE
MV MANUAL 10.1.5. Pull the Handle Valve (MV-PB-02) to open PRESSURE
OPENING & the MV, observe the pressure gauge (PG- GAUGE PG-06
CLOSING
06) and shall read 340 barg in supply line. READS 340
BARG.

OBSERVE MV
10.1.6. Push the Handle Valve (MV-PB-02) to close SUPPLY LINE
the MV, observe pressure gauge (PG-06) PRESSURE
GAUGE PG-06
and shall reads 0 Barg.).
READS 0 BARG.
10.1.7. Make sure the all the bulk heads are

properly connected with temporary
pressure gauges to monitor the
pressure at the outlet side. OBSERVE WV
SUPPLY LINE
10.1.8. Check the connections for (WV-SOV-3) PRESSURE
well solenoid valves from the 24VDC GAUGE PG-07
stimulator shall be energized. READS 340
10.1.9. Pull the Handle Valve (WV-PB-03) to BARG.
WV MANUAL
OPENING & open the WV, observe the pressure
CLOSING
gauge PG-07 and shall read 340 barg in
supply line.
OBSERVE WV
10.1.10. Push the Handle Valve (WV-PB-03) SUPPLY LINE
to close the WV, observe pressure PRESSURE
GAUGE PG-07
gauge PG-07 and shall reads 0 Barg. READS 0 BARG.

11. PRESSURE TEST PROCEDURE:
Client /
sl:no: Mode of Accepted criteria
Activity
inspection TPI sign
off.
 After the completion of all tubing
assembly activities if no further activities
are required the equipment will be
cleared for the pressure testing.
 Pressure gauges & chart recorders using
for the test should have a valid calibration
certificate as per specification or relevant
National / International Standards.
 A minimum of two pressure gauges is
required for the test system. One pressure LP Header (Logic
Pressure) - 7 barg
gauge shall be on the test pump and the
MP Header
other(s) on the test system. Their accuracy (Medium Pressure)
shall be within 1 % of one another. - 340 barg
 The test fluid shall be filled at the lowest HP Header (High
Pressure) - 2 barg
01 point in the system to minimize entrapped Visual
air. All vents shall be open during filling. 15 minutes –
 After test pressure is reached and before above pressure x
1.1 times, all
the commencement of inspection of the tubing should
system, the isolation valve between the hold pressure
without any
test manifold and the system under leakage.
pressure test shall be closed and the test
pump disconnected.
 During pressure test minimum 2 pressure
hold steps should be maintained to
stabilize the volume of test.
 During depressurizing test line drop down
pressure shall be minimum 2 steps.

Pressure test pressure shall be as below:
Pressure Test:
 Start external pressure Test pump and

bring pressure to the first hold point which
shall be around 1.1 TIMES of the test
pressure.
 Check leak if any.
 If leaks are present, drop the pressure to
atmospheric pressure and arrest the leak
by necessary tightening of the connectors
/ repair of the defective parts and then From the above
design pressure x
again start pressurizing. 1.1 times
 Hold pressure for Minimum 15 minutes. Pressure holding
time 15 minutes
 Observe and record pressure from the
pressure gauges.
 Get clearance of the QC personnel/Client
representative Inspector for de
pressurizing.
 Release of pressure and draining shall be
done on the downstream side. All vents
shall be opened before draining to
facilitate drainage and to prevent
formation of a vacuum.
 All temporary installed for testing
purposes (External Devices, valves, etc.)
shall be removed.


12. FLUSHING PROCEDURE:

1. Test Equipment:
AVANCEON will provide the following services and equipment to perform the flushing process.
 Testing Engineer and Technicians

 Hydraulic fluid / Shop air supply
 Plugs and caps as required.
 Flushing rig (AVANCEON).
 Flushing fluid (Mineral based Hydraulic oil as required, CASTROL HYSPIN AWH M32 is used for
Flushing of the panels)
 Particles Laser counter machine (PLCM)
 Laser Particle Analyzer.
2. Requirements:
Prior to flushing:
 Remove all relief valves and cap tubing
 Cap all output bulkheads
 Check calibration certificates of all equipment used.
3. Flushing the Rig:
 Fit a filter element to the filter in the flushing rig

 Re-circulate the fluid for a minimum of 20 minutes in initial stage; take a sample every 15 minutes
using the Particles Laser counter machine (PLCM)/Laser Particle counter (LPA).
 Check that the fluid being flushed is reading Nas Class 6.
 Repeat paragraphs 5. If the cleanliness of the fluid is not to the required standard.
4. Flushing the HPU System:
 Flush the system for a minimum of 30 minutes

 Flushing times will vary’s according to tube diameter, length and contamination levels present.
 Change filters elements as indicated by the filter indicator or slide results
 Turbulent flow shall be maintained at all times where possible
 Approximately after a further 15 minutes, take a sample. Award the sample a unique number
 Particles Laser Counter machine PLCM/Laser particle counter (LPA) will give sample result NAS
Class 6.
 Print the sample result.

5. Completion:
 Refit all components removed to enable the flushing to be carried out.

 Complete the appropriate documentation i.e. Certificate of Conformity or Certificate of
Cleanliness/Flushing report.
Note: All the field tubes shall be flushed before connecting to Avanceon panel to prevent the
contamination from field lines.

sl:no: Activity
Flushing of all tubing’s as per above flushing

01 procedure. visual Nas Class 6.


13. COMPLETION:
13.1. Isolate all the pressure connections to the panel bulkheads.
14. FACTORY ACCEPTANCE TEST CERTIFICATE

This concludes the Performance Testing procedure for the scope of this contract and certifies that
the tests detailed in this procedure were satisfactorily completed and witnessed by the
undersigned.
TAG No: ----------------------------------------------
AVANCEON Representatives:
Name Title Signature & Date
CLIENT Representatives:
Name Title Signature & Date
End of the document


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Ural Oil and Gas LLP Rozhkovskoye Field Development

Date Issued: 27-SEP-2023

Document Number: RZK-NSS-AVN-IRF-QAC-90101-00-E

ROZHKOVSKOYE FIELD DEVELOPMENT PROJECT

INSPECTION AND FAT REPORT / IRF

Tag No: WHCP-U10

CLIENT DOC: NO:

AVANCEON: DOC: NO: AVN-2022-IRF-001

INSPECTION AND FAT REPORT WHCP

Document Number: RZK-NSS-AVN-IRF-QAC-90101-00-E

Rev. Date Issue, Modification Prepared Checked Approved

INSPECTION AND FAT REPORT WHCP

Document Number: RZK-NSS-AVN-IRF-QAC-90101-00-E

Prepared by Name: BALAJI RADHAKRISHNAN

Checked by Name: Mangeram Tyagi

Approved by Name: Suresh Balakrishna

INSPECTION AND FAT REPORT WHCP

Document Number: RZK-NSS-AVN-IRF-QAC-90101-00-E

Hold Nr. Section Description of Hold

Rev. Date Description of Revision

INSPECTION AND FAT REPORT WHCP

Document Number: RZK-NSS-AVN-IRF-QAC-90101-00-E

3. APPLICABLE PANEL TAGS NO

5. REFERENCE DOCUMENT LIST

6. CERTIFICATE / TEST REPORT VERIFICATION

7. REQUIRED EQUIPMENT & UTILITIES.

8. PRE- REQUISITES GENERAL.

10. PRE-TEST VISUAL EXAMINATION.

11. PUMP FUNCTIONALITY TEST.

13. WHCP WELL ESD CLOSING BY FUSIBLE LOOP LOGIC: (FIRE

14. PUMP PRESSURIZATION TIME TEST.

15. PRESSURE TEST PROCEDURE.

16. FLUSHING PROCEDURE.

INSPECTION AND FAT REPORT WHCP

Document Number: RZK-NSS-AVN-IRF-QAC-90101-00-E

Manufactured for the project – “ROZHKOVSKOYE FIELD DEVELOPMENT PROJECT”.

FAT shall be held at AVANCEON facility FZE, DUBAI- UAE.

 Company: M/s Ural oil & gas.

 Panel Dimensional check.

3. APPLICABLE PANEL TAGS NO:

INSPECTION AND FAT REPORT WHCP

Document Number: RZK-NSS-AVN-IRF-QAC-90101-00-E

 PSV Pressure safety valve.

 FCV Flow Control Valve.

 NSPK Nitrogen Skid Package.

 PCV Pressure Control Valve.

 SOV Solenoid valve.

INSPECTION AND FAT REPORT WHCP

Document Number: RZK-NSS-AVN-IRF-QAC-90101-00-E

5. REFERENCE DOCUMENT LIST:

Document Number Description

RZK-NSS-AVN-DGA-ENG-0001-01-C General Arrangement Drawing.

RZK-NSS-AVN-PID-ENG-0001-01-C Piping & Instrumentation Diagram.

RZK-NSS-AVN-SDR-QAC-0001-01-C SUPPLIER DOCUMENT REQUIRTMENTS (SDR)

RZK-NSS-AVN-SLD-0001-01-C ELECTRICAL / SINGLE LINE DIAGRAM / SLD

RZK-NSS-AVN-ITP-ENG-0001-01-C INSPECTION TEST PLAN / ITP

6. CERTIFICATE / TEST REPORT VERIFICATION:

7. REQUIRED EQUIPMENT & UTILITIES:

INSPECTION AND FAT REPORT WHCP

Document Number: RZK-NSS-AVN-IRF-QAC-90101-00-E

8. PRE-TEST VISUAL EXAMINATION:

Mode of Client / TPI

Check Visual and dimensions of the wellhead As per approved