OPS-GLB-EN-PP_100021 Stimulation High-Pressure Field Iron Rig-Up

Level: L2 - Procedure Tier: GLB - Global
Document Type: Standard

Sub Element: Operations
Doc Number: OPS-GLB-EN-PP_100021
Rev. L
Effective Date: 4/12/2017
1.6.1 Stimulation High-Pressure Field Iron Rig-Up
Revision History
Rev. RDR Amendment Detail Reviewer Approver Effective Date
Current Revision
L Revised coflexip and high pressure hose sections. Lant, Keith Pilling, Lee 12 April 2017
Three Previous Revisions
Moreira Neto, 23 September

K Added restricted zone schematic Lant, Keith
Lino 2016
Revised standard based on Rig-Up exercised performed in San Moreira Neto,
J Lant, Keith 28 August 2015
Antonio June, 2015 Lino
RDR- Lant, Keith Pilling, Lee D
Added reference information to page 20.Moved note from Section 14
I OPS- 12 April 2017
to Section 9 PRV. Added Std. 2.3.12 and Technical Bulletin EB411SE
1176
MA-GLB-En-100030 Rev. E.2
Copyright 2014 BAKER HUGHES INCORPORATED—Unpublished—This document (together with the information thereon) is the property of Baker Hughes
Incorporated (Baker Hughes). By accepting or accessing this document the recipient agrees this document (together with its contents) is confidential and is an
unpublished copyright work with all rights reserved to Baker Hughes and is further subject to return on demand. It may not be copied, reproduced, or disclosed in
any form, in whole or in part, without express consent of Baker Hughes. It may not be used directly or indirectly in any way detrimental to Baker’s interest and is not
rented, loaned or sold, either alone or in conjunction with equipment or product, and does not comprise a part of any customer project or service.
OPS-GLB-EN-PP_100021 Rev: L
Table of Contents
Purpose ................................................................................................................................................ 1
Scope .................................................................................................................................................... 1
Responsibility and Authority .............................................................................................................. 1
Governance Documents ...................................................................................................................... 1
Terms and Definitions ......................................................................................................................... 1
1 Pre-Job Preparation ....................................................................................................................... 2
2 Velocity ........................................................................................................................................... 2
3 Land Operations Wellsite Equipment Placement and Spacing .................................................. 3
4 Physical Rig-Up.............................................................................................................................. 4
5 Land Use Manifold Trailers ........................................................................................................... 9
6 Rigging Up Main Treating Lines and Components .................................................................... 12
7 Wellhead Connections................................................................................................................. 16
8 Plug Valve and Check Valve Placement ..................................................................................... 17
9 Pressure Relief Valves Placement, Installation and Operation................................................. 20
10 Bleed-Off Line Installation and Operation .................................................................................. 25
11 Forced Closure............................................................................................................................. 30
12 Ball Sealer Injectors ..................................................................................................................... 31
13 Properly Secure Treating Lines and Hoses................................................................................ 33
14 High Pressure Hoses ................................................................................................................... 34
15 Suction Hoses Rig-Up ................................................................................................................. 35
16 Supercharge Hose Rig-Up ........................................................................................................... 35
References ......................................................................................................................................... 38
References ......................................................................................................................................... 39
Table of Figures
Fig. 1 Ground Guide on Location ........................................................................................................... 4
Fig. 2 Frac Job on Location ................................................................................................................... 5
Fig. 3 Four Pound Hammer Used on 2in High-Pressure Line................................................................. 6
Fig. 4 Six Pound Hammer Used on 3in High-Pressure Line ................................................................... 6
Fig. 5 Four Pound Hammer Used on Low-Pressure Hose Unions ......................................................... 7
Fig. 6 Brushing and Lubricating Union Ends Before Make-Up................................................................ 7
Page ii
Uncontrolled when printed—confirm the correct revision is used Baker Hughes—Company Confidential
Fig. 7 Plywood under Chicksans ............................................................................................................ 8

Fig. 8 Chicksans and Making-Up Pup Joint Ends................................................................................... 8
Fig. 9 Swing Assemblies at 90° Angles .................................................................................................. 9
Fig. 10 U-shaped, Z-shaped and Stair Step-shaped Kicks from Frac Unit to Ground Manifold............. 10
Fig. 11 Rigging Up AFAM to Frac Units .................................................................................................11
Fig. 12 Equalizing Line on Treating Lines............................................................................................. 14
Fig. 13 Equalizing Lines on MultipleTreating Lines............................................................................... 15
Fig. 14 Frac Heads on Wellheads ........................................................................................................ 16
Fig. 15 Check Valves on High-Pressure Lines ..................................................................................... 17
Fig. 16 Check Valves Installed on Frac Pump Trucks........................................................................... 18
Fig. 17 Arrow Shows Direction of Flow ................................................................................................. 18
Fig. 18 Plug Valves on High-Pressures Treating Lines ......................................................................... 19
Fig. 19 Suspended Unsupported Iron Downstream from the Plug Valve .............................................. 19
Fig. 20 Nitrogen Pop-Off Valve on High-Pressure Treating Lines ......................................................... 20
Fig. 21 SPM and Baker Hughes Stands ............................................................................................... 21
Fig. 22 Plug Valve under Pressure-Relief Valve ................................................................................... 22
Fig. 23 Safoco Fracturing Relief Valve (FRV) ....................................................................................... 24
Fig. 24 Bleed-Off Line on Treating Line ................................................................................................ 25
Fig. 25 Plug Valves on Bleed-Off Line .................................................................................................. 26
Fig. 26 Primary Valve and Secondary Valve......................................................................................... 27
Fig. 27 Ball Injector on Treating Line .................................................................................................... 31
Fig. 28 Pressure Transducer on Treating Line ..................................................................................... 32
Fig. 29 Densimeter on Treating Line .................................................................................................... 33
Fig. 30 Discharge Hoses, Wing-Union, Pressure Rating and Cover ..................................................... 36
List of Equations
Equation 1 Maximum Rate ..................................................................................................................... 2
Page iii
Purpose
Baker Hughes shall ensure its employees fully understand the step by step procedures required to
provide quality services and products to our customers. Conformance to this operations standard
ensures the highest job quality and personal safety.
Scope
This operations standard details the procedures necessary for proper stimulation high-pressure field
iron and hose rig-up. This operations standard applies to land-based and offshore locations.
Responsibility and Authority

The Field Specialist or the District Manager’s designee is responsible for the execution of these
procedures.
Governance Documents
 BHI Quality Policy Manual
 Control of Records
Terms and Definitions

Baker Hughes Enterprise Glossary
AFAM – Articulated Frac Arm Manifold
BPM – Barrels per Minute
FMC – FMC Technologies
FPS – Feet per Second
FRV – Fracturing Relief Valve
ID – Inside Diameter
NPT – National Pipe Thread
NPST – Non-Pressure Seal Thread
PRV – Pressure Relief Valve
PSI – Pounds per Square Inch
Page 1 of 41
1 Pre-Job Preparation
Use the following requirements for pre-job preparation.
 Review the job recommendation for anticipated rates and pressures.
 When planning which field iron to use, take into consideration the pressure and velocity of the
fluids going through the field iron.
 We recommend diagramming the actual wellsite for equipment planning, spotting and field iron
rig-up.
 All high-pressure connections and line pipe must be either integral or non-pressure seal style,
including all high-pressure swages and connections.
 Ensure that all union end connections are compatible.
 Ensure that the proper tools needed for the rig-up are available, such as 4 or 6lb hammers, wire
brushes, line jacks, oil, spare seal rings, support pads for swivels and wooden blocks for ground
pup joints.
 Verify that the iron required for the job has current inspection banding.
 Ensure that lubricants are available for field iron unions.
 Contact all third party service providers.
2 Velocity
Use the following velocity requirements.
 Hold the velocity of abrasive fluids pumped through high-pressure field iron at 40ft/sec or less.
This established standard avoids excessive erosion of field iron, thereby extending its life.
 Lay a sufficient number of lines of adequate size to keep the fluid velocity through the high-
pressure line pipe at 40ft/sec or less.
 Calculate maximum velocities for a string of iron using the smallest inside diameter (ID) present
in the string.
 Calculate velocities on field iron using the following formulas.
Equation 1 Maximum Rate
BPM = d2 x 2.3314
d = inside diameter of line pipe
 Use multiple entry connections with adequate ID to maintain a velocity of 40 ft/sec or less
through the top connection to prevent rapid erosion at the wellhead.
 Observe and verify a maximum velocity of 40ft/sec in field iron when pumping non-abrasive
fluids to minimize line vibration and pulsation.
Page 2 of 39
After arriving outside the wellsite, but before driving service units on location, the Field Specialist
must complete the following requirements.
 Pre-qualify each location by physically walking the entire location to identify and point out any
potential driving hazards or potential physical hazards.
 Develop a specific action plan addressing all hazards identified during the walk through and
communicate the plan to all crewmembers before moving the equipment on location.
 When spotting equipment involves backing onto a public roadway on or off location, use local
law enforcement or equally effective traffic control measures.
 Locate the service equipment at a minimum of three meters or 10ft, from the nearest tank and
23m or 75ft, from the wellhead. See Fig. 2.
 Ideally, locate the service equipment 1.20m or 4ft apart in aisle space from other vehicles and at
least 25m or 75ft, from the wellhead. The minimum distance allowed between frac pump units
must be shoulder-to-shoulder distance. This becomes very important when refueling on
location. See Fig. 2.
 Locate vehicles upwind or crosswind from the wellhead whenever possible.
 Move all vehicles, not required for the job, to predetermined safe areas away from the wellhead
to ensure that wellsite exits are not blocked.
 Locate the Field Specialist van or pickup at least 25m, 75ft, from the wellhead with a full view of
the equipment and the wellhead, if possible. See Fig. 2.
 On location, where a rig is present, make every effort to park or spot equipment outside the guy
wires.
When backing-up on location, a ground guide must assist all units. See Fig. 1
3 Land Operations Wellsite Equipment Placement and Spacing

After arriving outside the wellsite, but before driving service units on location, the Field Specialist
must complete the following requirements.
 Pre-qualify each location by physically walking the entire location to identify and point out any
potential driving hazards or potential physical hazards.
 Develop a specific action plan addressing all hazards identified during the walk through and
communicate the plan to all crewmembers before moving the equipment on location.
 When spotting equipment involves backing onto a public roadway on or off location, use local
law enforcement or equally effective traffic control measures.
 Locate the service equipment at a minimum of three meters or 10ft, from the nearest tank and
23m or 75ft from the wellhead. See Fig. 2.
 Ideally locate the service equipment 1.20m, 4ft apart, aisle space, from other vehicles and at
least 25m, 75ft, from the wellhead. The minimum allowed distance between frac pump units
must be shoulder-to-shoulder distance. This becomes very important when refueling on
location. See Fig. 2.
 Locate vehicles upwind or crosswind from the wellhead whenever possible.
Page 3 of 39
 Move all vehicles not required for the job to predetermined safe areas away from the wellhead
to ensure that wellsite exits are not blocked.
 Locate the Field Specialist van or pickup at least 25m, 75ft, from the wellhead with a full view of
the equipment and the wellhead, if possible. See Fig. 2.
 On location, where a rig is present, make every effort to park or spot equipment outside the guy
wires.
 When backing-up on location, a ground guide must assist all units. See Fig. 1.
**Refer to the References section for Figure 1 and Figure 2.
Fig. 1 Ground Guide on Location

When location space is limited, such as in a mountainous terrain, deviation from the guidelines in this
section can be necessary. However, the Field Specialist must arrange or spot equipment in a safe
manner. For offshore locations we recommend a site visit to ensure proper spacing and equipment
lifting requirements. Refer to Standard 2.8.6 Offshore Skid and Vessel Job Site Preparation for
Stimulation Operations in the References section.
4 Physical Rig-Up
Use the following physical rig-up requirements.
 Orient all stimulation treating lines with the wing-half union to the well. See Fig. 2.
 Configure swivel joints into the field-iron rig-ups to ensure flexibility on all planes.
See Figures 11-4 through 11-38 for typical approved rig-ups. See Standard 1.6.1.1 Rhino-T or
Gorilla Rig-Up to Ground or Conventional Manifold for ground and conventional manifold rig-up and
Standard 1.6.1.2 Rhino T or Gorilla Frac with Frac Arm Manifold for FMC’s articulated fracturing
arm manifold rig-up. Refer to the References section for Standard 1.6.1.1 and Standard 1.6.1.2.
**Refer to operations standard 2.3.8 Job Execution for Fracturing Operations for explanation of
restricted areas
Page 4 of 39
Fig. 2 Frac Job on Location
Page 5 of 39
 Approved hammers are 4lb and 2in and smaller high-pressure hammer unions. See Fig. 3.
Fig. 3 Four Pound Hammer Used on 2in High-Pressure Line

 The heaviest hammers approved for use are 6lb and 3in or larger high-pressure unions. See
Fig. 4.
Fig. 4 Six Pound Hammer Used on 3in High-Pressure Line
Page 6 of 39
 Approved hammers are 4lb and 4in. or smaller low-pressure hose unions. See Fig. 5.
Fig. 5 Four Pound Hammer Used on Low-Pressure Hose Unions
 Approved hammers are 6lb on low-pressure hose unions larger than 4in connections if required.
Example: 6, 8 or 10in. tank connections
 Before make-up, clean all unions of dirt and debris with a wire brush and then properly lubricate.
See Fig. 6.
Fig. 6 Brushing and Lubricating Union Ends Before Make-Up
Page 7 of 39
 Assemble field iron to lay flat on the ground with the surface. The following are the exceptions.
 The pup joints that form the swing from the pump truck
 The swings to change direction
 The pup joint that forms the swing at the wellhead
 Support all 3in and 4in swivels that contact the ground to prevent settling into the surface. A 2×2
foot pad made of plywood at a minimum of ¾ in, two-ply cross-grained works well. See Fig. 7.
Fig. 7 Plywood under Chicksans

 To build flexibility into the field iron assembly and to keep the field iron lying flat on the ground,
install a swivel joint on each end of the pup joint to form a swing. See Fig. 8.
Fig. 8 Chicksans and Making-Up Pup Joint Ends
Page 8 of 39
 Place swing assemblies at approximately 90° angles to build flexibility into the field iron
assembly and reduce pulsation. See Fig. 9.
Fig. 9 Swing Assemblies at 90° Angles

 Use swing assemblies to change the direction of the treating line.
 Wooden blocks used to assist during rig-up must remain in place during the entire job. These
will prevent the iron from sinking into the ground.
If the wooden block sinks in the mud, the lines will become rigid and
iron will fail. If so, lay a plywood board on the ground, put wooden
Note blocks on top of the plywood and then have the iron rest
horizontally on the blocks.
 Sometimes, the iron will walk-off the wooden blocks and fall on the ground. Use ¾in thick
plywood boards instead of wooden blocks as an effective substitute. Plywood keeps a good grip
on the iron and it prevents the iron from sinking and walking-off.
5 Land Use Manifold Trailers

Use the following requirements for manifold trailers.
 Do not connect plug valves, check valves or any other high pressure iron components required
to connect a high-pressure pump to a manifold trailer during transport unless designed to
support these connections.
 To avoid unnecessary weight at the manifold trailer connection, the check valves and plug
valves required to isolate individual pumps must be installed on the ground between the high
pressure pumps and manifold trailer unless the trailer is engineered to support these
connections. Use adequately supported check valves mounted on pumping units.
 Refer to typical high pressure manifold trailer rig-ups in Figures 11-10, 11-11, 11-20 and
11-21 in the References section.
Page 9 of 39
Experience and failure analysis have shown us the importance of having flexibility on the lines.
Vibration of rigid lines can cause brand new iron to fail mechanically at any given moment while
pumping. More often than not, tell-tale signs at common failure points are not detected by regular
iron inspections. Having new and freshly certified iron is only at its safest state if the lines are
properly supported and flexible enough.
When rigging up from frac pump units to ground and trailer manifold using the following guidelines.
 The lines must have at least nine degrees of freedom between the frac pump unit and the
manifold. The number of degrees of freedom is the number of articulating joints comprehended
between the frac pump unit and the manifold. Articulating joints are the swiveling points on
Chiksans, and can include Style 10 or 50.
 A straight joint must be laid down horizontally on the floor. This same joint must be supported
with wooden blocks so it won’t sink in the mud. If it does, a plywood board must be placed
underneath the blocks.
 The final rig-up shape must be similar to a “Z”,“U” or “Stair Step” shape, with no particular
preference. Location size and units layout will dictate which shape is more suitable. Other
factors, such as spill mats or duck ponds will also dictate which rig-up shape is a better fit.
Fig. 10 U-shaped, Z-shaped and Stair Step-shaped Kicks from Frac Unit to Ground Manifold
Page 10 of 39
 Every straight joint in the swing must be at an angle from its immediate counterpart. Accepted
angles range between 60° and 120°, while the ideal angle is 90°.
 It is acceptable to carve a V-notch or similar on the wooden blocks to prevent the middle pup
joint from walking-off.
 Refer to the References section for Standard 1.6.1.1 for procedures on how to rig-up from a frac
pump unit to a manifold. It applies to both trailer manifolds and ground manifolds.
The Articulated Frac Arm Manifold (AFAM) requires alignment against the frac pump units. When
alignment conditions are met, the distances between the pumps and the manifold allows optimal
angles on the AFAM arms. The AFAM hydraulics safely holds iron in midair while keeping all
degrees of freedom on the line. The rigged-up iron remains flexible during pumping. This alignment
applies to first and second generation AFAM. See Fig. 11
When rigging up from frac pump units to AFAM manifold:
 Articulated arms angles must not exceed 120o. Optimal angle is 90o.
 Distance between base arm pivot and frac pump unit discharge must be less than 12ft.
Fig. 11 Rigging Up AFAM to Frac Units
Refer to Standard 1.6.1.2 in the References section for procedures on how to align and rig-up from
a frac pump unit to AFAM (including exceptions).
Page 11 of 39
6 Rigging Up Main Treating Lines and Components

Main treating lines and components are also subject to fatigue failures due to cyclic stresses.
Commonly seen mechanical failures include cracks at the root of the female end thread (at pocket
seal) and at the first unengaged thread of male subs on non-pressure seal male ends.
While the tubular section of straight joints can better handle vibrations, this is not the case for their
hammer unions. Iron that holds components vertically, such as Nitrogen pop-off valve and
equalizing lines are at a higher risk of failure.
Support plays a big role when laying down main treating lines and components.
 Wooden blocks must be placed underneath straight joints, as close to the hammer union as
possible.
 Avoid leaving long stretches of straight iron supported only by their ends. Add a wooden block
underneath the tubular section for every 20ft of straight iron that’s unsupported.
 Treating lines must be sized according to the maximum rate and pressure that will be pumped
for that particular job. Velocity through each individual line cannot exceed 40ft/sec. The table
below will aid to determine how many lines will be needed to the well head.
Page 12 of 39
Table 1 Maximum Velocity through Iron
Max BPM
Size Fig
Integral NPS Safety Iron
602 32.8
35
1002 28.6 x
4"
1502 28.6 21
15k x x 39.2
2002
21 x
2202
602 x
3" 1002 17.6 16.1
1502
15k
x x 22
20k
602
1002 7.1
2" 1502 x
2002
3.9 x
2202
1.5 " 1502 3.9 x x
1" 1502 1.8 x x
Equalizing lines are made up on the main treating lines, downstream the manifold and are intended
to balance rates and pressures whenever there are two or more treating lines connected to the well
head. Equalizing lines also minimize unwanted vibrations when opposing banks of frac units pump
at different rates. Use the guidelines below when rigging-up equalizing lines.
 Equalizing lines must be of the same size and figure as the main treating lines.
 At least one equalizing line must be made-up downstream the manifold.
 Every treating line must be connected with an equalizing line to its immediate neighboring
treating line.
 Equalizing lines must be shaped as “Z”, “U” or “Stair Step”. The middle straight joint must lay
flat horizontally on the floor and must be supported by wooden blocks.
Page 13 of 39
 Equalizing lines may be rigged-up with both ends upstream the ground check valve or both
ends downstream the ground check valve. Under no circumstances may an equalizing line be
rigged up downstream the ground check valve while its opposite end is upstream the check
valve. See Fig. 12
Fig. 12 Equalizing Line on Treating Lines
Page 14 of 39
Fig. 13 Equalizing Lines on MultipleTreating Lines
Page 15 of 39
7 Wellhead Connections
Use the following requirements for wellhead connections.
 The Field Specialist must ensure that the maximum pressure does not exceed the working
pressure of the customer wellhead valves and connections.
 Use standard high-pressure tees and crosses with a 90° branch as a fracturing head on the
wellhead for multiple line entries with proppant laden fluids. Approved fracturing heads are the
preferred top connection for multiple entries, wyes and laterals. See Fig. 13.
Fig. 14 Frac Heads on Wellheads
When pumping sand-laden fluid through casing valves with the tubing in the well, it is recommended
that the customer consider using a tree saver to prevent erosion of the tubing near the casing valves.
 In stimulation operations, using flanged top connection is recommended whenever possible.
Use appropriate flanged connections whenever treating pressures exceed 8,000 psi. Whenever
using a flanged top connection, a new flange ring gasket is recommended.
 When pumping energized fluids, use a flanged top connection to rig-up to the wellhead.
Exceptions to this standard require approval from the regional manager
Page 16 of 39
8 Plug Valve and Check Valve Placement
While pressure testing, high pressure iron must not be isolated from
pressure relief components, such as pressure relief valves and/or
Note burst discs.
Use the following requirements for plug valve and check valve placement.
 Install a master fracturing valve, plug valve or gate valve at the wellhead.
 Place check valves on each treating line as close to the wellhead as practical.
 Place wellhead check valves on the ground. See Fig. 14.
Fig. 15 Check Valves on High-Pressure Lines
Page 17 of 39
 Each pump must have a check valve in the line between the high-pressure pump unit and the
ground manifold or manifold trailer. See Fig. 15.
Fig. 16 Check Valves Installed on Frac Pump Trucks

 Install the flapper type check valves right-side-up and in a horizontal or inclined position. This
allows the check valve to function as designed.
 The arrow on the check-valve body indicates the correct flow direction through the check valve.
See Fig. 16.
Fig. 17 Arrow Shows Direction of Flow

 Install a plug valve on each high-pressure line between the check valve and the wellhead. See
Fig. 18.
Page 18 of 39
Fig. 18 Plug Valves on High-Pressures Treating Lines

 When pumping CO2, do not place plug valves in the high-pressure CO2 lines. We recommend
using either a dart, or a flapper-type check valve.
 Once laid down on the ground, the bulk of the plug valve will have its connected adjacent iron
suspended off the ground. These are prone to crack at their end connections unless they are
supported by wooden blocks. This includes all pieces of iron downstream and upstream the
ground plug valve.

Fig. 19 Suspended Unsupported Iron Downstream from the Plug Valve
Page 19 of 39
9 Pressure Relief Valves Placement, Installation and Operation

Pressure relief valves (PRV) are intended to protect equipment from an unwanted overpressure.
Mandatory PRV are the nitrogen pop-off valve on the treating line and a burst disc mounted on the
manifold, either a ground or trailer manifold. It is acceptable to replace any or all mandatory PRV,
as long as a management of change process has been executed beforehand.
In addition to the nitrogen pop-off valve, spring loaded PRV’s may be added on the pump discharge
side between the fluid end and the manifold. Spring loaded PRV’s should never be installed directly
on the manifold trailer or on main treating lines. For additional information on PRVs, refer to
Standard 2.3.12 Stimulation Pressure Testing in the References section.
Fig. 20 Nitrogen Pop-Off Valve on High-Pressure Treating Lines
Use the following requirements for nitrogen pop-off valve placement, installation and operation.
 Use an in-line 3in. 15,000 psi pressure nitrogen pop-off valve regardless of the treating
pressure.
 In primary treating lines, place the nitrogen pop-off valve upstream of the ground check valve.
See Fig. 19.
 Keep the nitrogen pop-off valves vertical. Acceptable Inclinations are 60° to 90° in relation to the
treating iron which is considered to be the 0° inclination reference point.
Page 20 of 39
 Keep the nitrogen pop-off valve upright with a stand. This prevents the bottom tee from cracking
stress, at the root of the female thread on the 3in branch due to cyclic vibrations.
 Mount pup joints before and after the bottom tee to aid connecting the assembly to the treating
line. See Fig. 20.
 Mount swivels before and after the pup joints out of the bottom tee to absorb vibrations. Swivels
must rest on top of wooden blocks or plywood underneath them. See Fig. 20
Fig. 21 SPM and Baker Hughes Stands
 When using the nitrogen pop-off valve on the annulus to prevent over pressuring of the casing,
place it downstream or between the wellhead and check valve.
Page 21 of 39
 Use plug valves under all nitrogen pop-off valves, unless prohibited by the customer or local
regulations. See Fig. 21.
 Plumb the discharge of the nitrogen pop-off relief valves into a secured discharge line to ensure
that relief forces are restrained, away from personnel in the field and that discharged fluids are
contained in an appropriate pit or tank. The pop-off valve discharges to atmospheric pressure
and there cannot be any significant backpressure at its discharge. Where plumbing is not
feasible, a customer approved alternative is acceptable.
 The nitrogen pop-off valve has a 3in FIG 1502 female connection on the discharge side. Make
the plumbing of the discharge with a flowline of the same size and figure.
 Use approved lifting eyebolts when moving and placing the nitrogen pop-off valve. Use two
eyebolts, 7/8in. x 5in, with 1-3/4in. eye opening, FIG G291-Part number: 145216.
Fig. 22 Plug Valve under Pressure-Relief Valve
Do not use spring loaded pressure-relief valves on high-pressure

Note energized lines. Use nitrogen pop-off valves. Refer to Standard
2.3.12 Stimulation Pressure Testing for additional information.
Page 22 of 39
In addition to nitrogen pop-off valves, a burst disk is also mandatory. Unlike nitrogen pop-off valves,
burst disks are intended to protect only BHI high-pressure equipment from an unwanted
overpressure. Refer to Technical Bulletin EB427SE in the references section and follow the
guidelines to install and use engineering approved burst disks. For additional information, review
operations standard 2.3.12 Stimulation Pressure Testing in the references section.
 At least one burst disk must be installed and used regardless of the treating pressure.
 Burst disk must be installed on the manifold, be it a ground manifold, trailer manifold or AFAM.
 In the case of trailer manifolds, each district is free to determine the best way to install a burst
disk given the diverse models of manifolds in the field. Burst disks must not be mounted
anywhere between the frac pump unit and the manifold itself.
 Use a 15,500 psi rated burst disk if the treating lines to the wellhead are going to be Fig 1502.
 Use a 12,000 psi rated burst disk if the treating lines to the wellhead are going to be Fig 1002.
 In case of ground manifolds, burst disks cannot be mounted downstream of the ground check
valve.
 Burst disk discharging fluids must be controlled and contained either by plumbing or by a
customer approved alternative. Relief forces must be restrained away from personnel in the
field.
 Burst disks in use must have an identification band with the “In-Service Date” inscribed on it.
 Burst disks are non-reclosing devices. They cannot be pressure tested and they cannot be
recertified. Replace the manifold burst disk at intervals no longer than six months after the “In-
Service Date”
If a spring-load pressure relief valve is used, the following requirements for placement, installation
and operation apply:
 Optionally, in addition to the pressure relief valves mentioned above, spring-loaded pressure
relief valves can be installed, as long as they are designed to reliably relieve incompressible
fluids at high pressures.
 If using spring-loaded high pressure relief valves, set the relief pressure to the predetermined
relief pressure at the district yard with a low-volume pump.
 Do not mount spring-loaded pressure relief valves on the treating lines or manifold trailer
instead mount these valves on the pump discharge side between the fluid end and the manifold
trailer.
In addition to pressure relief valves mentioned in this chapter, all high-pressure pumps shall be
equipped with engineering approved automatic overpressure shutdown devices.
Page 23 of 39
An exception to the before mentioned PRV requirements is the Safoco Fracturing Relief Valve (FRV).
For additional information review Technical Bulletin EB417SE in the Reference section. See Fig. 22
 Operates without nitrogen and can be operated at higher pressures without exceeding the iron
MAWP.
 The valve operates by sensing line pressure using two pressure transducers. When the
pressure from one of the two transducers reaches the set point, the valve opens to fully relieve
system pressure.
 Once pressure drops below a second lower set point, it will close thereby preventing
unnecessary shutdown of operations
 Assembly consists of two hydraulic operated gage valves, one for operation and the other as a
backup.
 Engineering will not require the use of a rupture disk in conjunction with the FRV but requires
operations to follow all other related standards
 The FRV is considered an alternative to the N2 popoff valve. Therefore engineering will not
require the N2 popoff valve to be rigged into the system when using the FRV but requires
operations to follow all other related standards.
Fig. 23 Safoco Fracturing Relief Valve (FRV)
Page 24 of 39
10 Bleed-Off Line Installation and Operation

The intension of bleed-off lines is used to facilitate short-term flow through our treating lines,
including the following:
 Priming of pumps
 Release of pressure on high-pressure field iron with the well valve closed
 Surging ball sealers off the perforations
 Limited flowback for the forced closure procedure
 Do not use bleed-off lines for a long term flow.
 Ensure that the flowback does not allow proppant, ball sealers or formation fluids to return to the
surface.
 Install bleed-off lines between the ground check valve and the ground plug valve.
 There are two accepted methods for rigging-up a bleed-off line: Dual plug valves or a single
choke throttle valve
Fig. 24 Bleed-Off Line on Treating Line
Page 25 of 39
Use the following requirements for bleed-off line installation and operation with dual plug valves:
 High-pressure bleed-off lines must have two 2in.×1in. plug valves installed in a series
immediately adjacent to the main treating line. See Fig. 23.
Fig. 25 Plug Valves on Bleed-Off Line
 Use 2in.×2in. plug valves if a ball-out (all open perforations capable of receiving fluid are sealed
with ball sealers) occurs and if possible flowback of the ball-sealers to the bleed-off line could
occur. See Fig. 24.
 Use the valve closest to the main treating line as the primary valve and always remain fully
opened or fully closed. Always open the primary valve first and close it last.
See Fig. 24.
Page 26 of 39
Fig. 26 Primary Valve and Secondary Valve
Page 27 of 39
 Always open or close the bleed-off line valves slowly to prevent a fluid-hammering effect.
 Place the bleed-off lines as straight as possible.
 Use only solid steel high-pressure pipe for bleed-off lines.
Use the following requirements for bleed-off line installation and operation with a single choke
throttle valve.
 A choke throttle valve performs as a plug valve and a throttling valve. Unlike plug valves, a
throttling valve can efficiently throttle down fluid. Therefore, only one single choke throttle valve
may be installed on the bleed-off line. This valve can be obtained with part number L886937.
 An additional 2x1 plug valve must be installed upstream from the choke throttle valve and must
always remain open. This valve is only to be actuated when servicing the choke throttle valve.
See Fig. 25
 In order to bleed-off pressure:
 Use a standard plug valve bar to open the quarter turn shut-off control from a fully closed
position to a fully open position.
 Using a properly sized wrench, turn the top nut counter clock wise to control the vertical
travel of the throttle stem.
 It is acceptable to install a manual turning wheel on the throttle control nut, as long as it is not
permanently welded on the valve.
Page 28 of 39
 It is acceptable to use a bleedoff manifold that wraps around the isolation valve. If unable to
bleed-off through the wellhead this method will allow the entire system to be bled off preventing
any potential for trapped pressure.
 Two 2” x 1” plug valves must be included in the wrap around both upstream and downstream of
the isolation valve.
Page 29 of 39
Fig. 25 Bleed-Off Manifold “Wrap Around”
Fig. 26 Choke Throttle Valve on Bleed-off Line

 Ensure that bleed-off lines are restrained. Refer to Standard 1.6.4 Restraint of Energized and
Non-Energized Field Iron and Hoses in the References section for detailed information on
restraining lines.
11 Forced Closure
Use the following requirements for bleed-off line installation and operation with the forced closure
procedure.
 Build the bleed-off line to a gauging tank using Baker Hughes approved high-pressure iron.
 Do not use valves downstream of the choke valve.
 Bleed rate at less than 2 bbl/min, verify rate at the gauging tank
 Bleed off only 65% or less of the displacement volume
 Do not allow formation fluids or gases to reach the surface through Baker Hughes treating lines.
If any indications of formation gas are present at the surface, immediately close in the bleed-off
line and shut in the well.
Page 30 of 39
An MOC form is required for the use of any non-remotely operated

Note ball injectors. The requirements listed in the management of change
process and procedures must be followed.
12 Ball Sealer Injectors

Use the following requirements for ball-sealer injectors.
 Place ball injectors in treating lines away from the rear of the high-pressure pump units and
away from the wellhead.
 Place ball injectors upstream of junctions with nitrogen or CO2 lines.
 Place ball injectors in the high-pressure line downstream of turbine flowmeters, dart-type check
valves and 2in. flapper-type check valves. See Fig. 28.
Fig. 27 Ball Injector on Treating Line
 We recommend placing the ball-sealer injectors in the line downstream of the bleed off. This
shall be considered a mandatory requirement.
 The use of remote operated ball injectors is a requirement and shall be considered mandatory
as of September 2015. For additional information, refer to Technical Bulletin EB406SE in the
References section.
Page 31 of 39
 When floating ball sealers, those with a specific gravity less than that of the treating fluid used,
place the ball injector downstream of the flapper-type check valves so the check valve does not
ball-off.
 Before installation in the line and prior to each fracture stage, the Field Specialist must
personally inspect each ball-sealer injector for correct operation.
 The Field Specialist must personally witness the loading of each ball injector.
 If the treatment procedure permits, remove the ball injector from the treating line before
completing a fracturing operation.
Use the following requirements for electronic monitoring devices.
 Place pressure transducers in the high-pressure treating line downstream of the isolation valve
and upstream of the check valve. See Fig. 27.
 In addition to above bullet point and if desired, it is acceptable to place an additional high-
pressure transducer between the isolation valve and the check valve to monitor pressure in
instances where the isolation valve has been closed and the wellhead is relieved.
Fig. 28 Pressure Transducer on Treating Line
Page 32 of 39
 Do not place pressure transducers in the bleed-off line.

 Place in-line high-pressure densimeters in the high-pressure treating line downstream of all
pumping units. See Fig.28.
Fig. 29 Densimeter on Treating Line

 When rigging up high-pressure electronic monitoring devices, make an effort to minimize the
shock effect of hammering nearby hammer unions.
 Place electronic monitoring devices last in line whenever possible.
13 Properly Secure Treating Lines and Hoses

Be certain to secure treating lines and hoses properly. Refer to Standard 1.6.4 Restraint of
Energized and Non-Energized Field Iron and Hoses in the References section for detailed
information on securing treating lines.
Page 33 of 39
14 High Pressure Hoses

Use the following requirements for high-pressure hoses.
 Do not use high-pressure mud hoses for pressure pumping applications or as part of a high
pressure bleed-off assembly.
 Only engineered approved flexible steel pipe (i.e.Coflexip) with working pressures up to15,000
psi as outlined in the Iron Inspection Manual GPS-GLB-En-100493 and/or Iron Manual GPS-
GLB-En-100511, may be used for high pressure pumping applications.
 Only engineered approved high pressure hoses with working pressures up to 15,000 psi as
outlined in the Iron Inspection Manual GPS-GLB-En-100493 and/or Iron Manual GPS-GLB-En-
100511, may be used for high pressure pumping applications.
Parker Hannifin Black Eagle hoses are approved only to 10,000 psi
Note working pressure. See Standard 4.1.4 High Pressure Field Iron and
Component Management in the References section.
 A complete visual inspection shall be performed before beginning each job. Any of the following
conditions require immediate removal from service.
 Damaged, cut, abraded cover or any exposed reinforcement.
 Kinked, crushed, flattened or twisted hose
 Blistered, soft, degraded or loose cover
 Cracked, damaged or badly corroded fittings
 Fitting slippage on hose
 Expired inspection interval as outlined in the Iron Inspection Manual GPS-GLB-En-100493.
 Be certain to tag or identify these hoses with a band showing a current inspection. If the tags or
bands are missing, remove the hoses from service and inspect before using.
 After completion of each job, flush all hose surfaces with a sufficient amount of clean water to
ensure that all chemical or cement slurry residue is removed from the hose assembly.
 The Mechanical Engineering Iron Inspection Manual in the References section contains
information concerning specifications, application and maintenance of the Parker Hannifin Black
Eagle hose assembly.
 Ensure that high-pressure hoses are restrained. Refer to Standard 1.6.4 in the References
section for details information on restraints for field iron and hoses.
Page 34 of 39
15 Suction Hoses Rig-Up

Use the following requirements for suction hose rig-up.
 Make all 4in suction connections on fracturing blenders of Fig. 206 wing-union halves.
 When rigging-up suction hoses on fracturing jobs, plan for a maximum of 8bbl/min through each
4in hose and in addition, a minimum of one hose for back-up.
 Consider the distance the fluid flows. Supplement with additional hoses if needed.
 Suction hoses must be rated 29 in Hg suction/150 psi burst pressure. Do not connect fluid
suction hoses to the discharge side of a blender, supercharge fracturing pumps, gel tanks or
circulate tanks.
 Hoses must lay flat on the floor. Do not suspend hoses by their end terminals.
16 Supercharge Hose Rig-Up

Use the following requirements for supercharge hose rig-up.
 Be certain to make all 4in. discharge connections on fracturing blenders of Figure 206 wing-
union halves. See Fig. 29
 Equip all supercharge hoses with 4in Figure 206 wing-union half-on one end and a Figure 206
thread-union half on the opposing end. See Fig. 29.
 All supercharge hoses must have a minimum working pressure rating of 400 psi. See Fig. 29.
 Supercharge hoses must lay flat on the floor. Do not suspend hoses by their end terminals.
 Use hose covers on supercharge hoses when pumping flammable or combustible materials.
 Hose covers on supercharge hoses are recommended, when pumping acid or caustic materials.
See Fig. 29
Page 35 of 39
Fig. 30 Discharge Hoses, Wing-Union, Pressure Rating and Cover
 To decide the size and number of supercharge hoses used, consider the expected pump rate
through each pump in barrels per minute and the velocity in feet per second of fluid through
each hose under expected pumping conditions during the job. This ensures that proppant does
not settle out in the hose and slug sand to the pumps. Ensure that the pumps have adequate
fluid for the anticipated rate. The Mechanical Engineering Department has determined the
following classification for the velocity ranges
 The optimal velocity range is 10 to 12ft/sec.
 The acceptable velocity range is 7 to 15ft/sec.
 The unacceptable velocity range is less than 7 and greater than 15ft/sc.
 Refer to Table 2 in order to determine what type of hoses are appropriate for the job. This table
gives a complete list of rates and hose combinations by rate and velocity.
Page 36 of 39
Table 2 Supercharge Hose Selection Guide
 All approved gelling hoses shall have swaged expansion couplings. Refer to the Baker Hughes
Iron Manual in the References section for additional information.
 Ensure that supercharge hoses are restrained. Restraint of supercharge hoses is discussed in
Standard 1.6.4. in the References section.
Page 37 of 39
References
Single Line Rig-Up with Ball Injector Figure 11-4
Single Line Stimulation Rig-Up with Ball Injector, North Slope Figure 11-5
Single Line Stimulation Rig-Up Figure 11-6
Single Line Stimulation Rig-Up, North Slope Figure 11-7
Stimulation Rig-Up with Manifold Trailer Figure 11-8
Manifold Trailer Rig-Up with Pumping Unit Installed Check Valves and Ground Installed Plug Valves
Figure 11-10
Single Line Stimulation Rig-Up with Nitrogen Tie-in Line Figure 11-12
Single Line Stimulation Rig-Up with CO2 Line Tie-in (Example) Figure 11-13
Single Line Stimulation Rig-Up with CO2 Line and Nitrogen Tie-in for Binary Job Figure 11-14
CO2 Fluid End Rig-Up Figure 11-15
Binary / CO2 Rig-Up Figure 11-16
Pumping CO2 Using Nitrogen Pumps Rig-Up Figure 11-17
Nitrogen Cold End Rig-Up for Pumping CO2 (Example) Figure 11-18
Multiple Line Stimulation Rig-Up Figure 11-19
Manifold Trailer Rig-Up with Ground Installed Check Valves Figure 11-20
Multiple Line Stimulation Rig-Up with Manifold Trailer-Optional Harmonic Balance Figure 11-21
Multiple Line Stimulation Rig-Up with CO2 and Nitrogen Line Tie-in for Binary Job Figure 11-22
Forced Closure Rig-Up Figure 11-23
Stimulation Vessel Rig-Up Figure 11-24
Tubing / Drill Pipe Leadoff Connection with Safety Chain Rig-Up Figure 11-31
Steel Hose and Swivel Joint Chicksan with Safety Chain Figure 11-32
Manifold Trailer Rig-Up with Pumping Unit Installed Check Valves Baker Hughes Figure 11-37
Iron Inspection Manual GPS-GLB-En-100493
Iron Manual GPS-GLB-En-100511
Management of Change (MOC) Procedure HSES-EOC-MOC-001
Standard 1.6.4 Field Iron Restraints for Energized and Non-Energized Iron and Hoses
Standard 1.6.1.1 Rhino T or Gorilla Rig-Up to Ground or Conventional Manifold
Standard 1.6.1.2 Rhino T or Gorilla Frac with Frac Arm Manifold
Standard 2.3.12 Stimulation Pressure Testing
Standard 2.8.6 Offshore Skid and Vessel Job-Site Preparation for Stimulation Operations
Standard 4.1.4 High Pressure Field Iron and Component Management
Page 38 of 39
References
Technical Bulletin EB406SE
Standard 2.3.12 Stimulation Pressure Testing
Page 39 of 39

OPS-GLB-EN-PP_100021 Stimulation High-Pressure Field Iron Rig-Up

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

OPS-GLB-EN-PP_100021 Stimulation High-Pressure Field Iron Rig-Up

Uploaded by

Copyright:

Available Formats

Level: L2 - Procedure Tier: GLB - Global

Document Type: Standard

1.6.1 Stimulation High-Pressure Field Iron Rig-Up

Moreira Neto, 23 September

Fig. 7 Plywood under Chicksans ............................................................................................................ 8

Responsibility and Authority

Terms and Definitions

3 Land Operations Wellsite Equipment Placement and Spacing

Fig. 1 Ground Guide on Location

Fig. 2 Frac Job on Location

Fig. 3 Four Pound Hammer Used on 2in High-Pressure Line

Fig. 4 Six Pound Hammer Used on 3in High-Pressure Line

Fig. 5 Four Pound Hammer Used on Low-Pressure Hose Unions

Fig. 6 Brushing and Lubricating Union Ends Before Make-Up

Fig. 7 Plywood under Chicksans

Fig. 8 Chicksans and Making-Up Pup Joint Ends

Fig. 9 Swing Assemblies at 90° Angles

5 Land Use Manifold Trailers

Fig. 11 Rigging Up AFAM to Frac Units

6 Rigging Up Main Treating Lines and Components

Table 1 Maximum Velocity through Iron

Fig. 12 Equalizing Line on Treating Lines

Fig. 13 Equalizing Lines on MultipleTreating Lines

Fig. 14 Frac Heads on Wellheads

8 Plug Valve and Check Valve Placement

Fig. 15 Check Valves on High-Pressure Lines

Fig. 16 Check Valves Installed on Frac Pump Trucks

Fig. 17 Arrow Shows Direction of Flow

Fig. 18 Plug Valves on High-Pressures Treating Lines

9 Pressure Relief Valves Placement, Installation and Operation

Fig. 20 Nitrogen Pop-Off Valve on High-Pressure Treating Lines

Fig. 21 SPM and Baker Hughes Stands

Fig. 22 Plug Valve under Pressure-Relief Valve

Do not use spring loaded pressure-relief valves on high-pressure

Fig. 23 Safoco Fracturing Relief Valve (FRV)

10 Bleed-Off Line Installation and Operation

Fig. 24 Bleed-Off Line on Treating Line

Fig. 25 Plug Valves on Bleed-Off Line

Fig. 26 Primary Valve and Secondary Valve

Fig. 25 Bleed-Off Manifold “Wrap Around”

Fig. 26 Choke Throttle Valve on Bleed-off Line

An MOC form is required for the use of any non-remotely operated

12 Ball Sealer Injectors

Fig. 27 Ball Injector on Treating Line

Fig. 28 Pressure Transducer on Treating Line

 Do not place pressure transducers in the bleed-off line.

Fig. 29 Densimeter on Treating Line

13 Properly Secure Treating Lines and Hoses

14 High Pressure Hoses

15 Suction Hoses Rig-Up

16 Supercharge Hose Rig-Up

Fig. 30 Discharge Hoses, Wing-Union, Pressure Rating and Cover

Table 2 Supercharge Hose Selection Guide

You might also like