Mobile Triplex Pump Operations - Little Red Services

LRSI Policy and Procedures Document Mobile Triplex Pump Operations

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Mobile Triplex Pump Operations Document Number: 1.5.3.5

Authority: North Slope Managers Document Owner: Well Test Supervisor

Scope: All LRS North Slope Operations Custodian: LRS HSE

Issue Date: 10/11/2004 Revision Date: 9/12/2015

Control Status: Controlled Document Next Review Due: 09/12/2018

Tier Level: 3 Approved By: North Slope Managers

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Scope and Objectives

All Personnel must be checked off as competent to operate any Triplex Pump In all Well Testing Operations. There are three types of field triplex in use throughout the field they are used to pump methanol / diesel into the casing to keep it from hydrating or to displace fluids capable of freezing with methanol in surface lines. Methanol triplex pumps require a Methanol pup / trailer that attaches to the Triplex though a hose for freeze protect operations. Tasks are commonly performed with the 2008 and 2014/15 triplexes which are the green colored triplexes due to their ease of use and better controlling functions.

It is important to note that Triplexes can over pressure a system to the point of critical failure in seconds, it is mandatory that Triplex Pumps are attended at all times during pumping operations.

Know and understand all Spec Breaks in the system and that all in line valves are properly aligned to avoid dead heading of the pump.

These general guidelines need to be followed to mitigate existing risks associated with high pressure pumping of methanol or diesel on field triplex pumps as well as to mitigate all inherent risk associated with these operations.

Roles and Responsibilities

Supervisor

Accountable for ensuring training and competency for the overall safe use of triplex pumps used by Well Testing Personnel.

Well Testing Unit Operator

Responsible for recommending SOP and training improvements / changes to the Supervisor.

Responsible for ensuring the Triplex Operator verbally communicates valve position and quaintly of valves before and after pumping operations.

Ensure that Triplex Operator adheres to the SOP. Triplex Operator

Responsible for following safe operating practices and maximum allowable pressure limits when operating triplex pumps.

Responsible for following the Pressure Crosscheck List in Appendix A. This will be on location and or pump its self.

Notify Test Unit operator via radio o With the number of valves opened prior to pumping o With the pressure you are pumping into o When pumping begins o When pumping ends o With the number of valves closed in at the end of the pumping operation.

Equipment Services

Responsible for maintenance and modifications of triplex pumps. Provide Documentation for the proper operation of their equipment and training as necessary.

Definitions

Pressure Relief Valve: A Safety Valve designed to open at a set pressure below the lowest pressure rating in the system.


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Sump/Secondary Containment: Containment designed to catch fluids when connecting or disconnecting hoses as well as to catch fluids in the event of a pump failure.

Field Triplex Pump: are equipped with a trailer internal combustion motor with a clutch or hydraulically driven pump. Triplexes are commonly used to pump Diesel and Methanol for pressure testing / freeze protection.

HPM – High pressure Manifold PRV – Pressure Relief Valve RPM – Revolution Per-Minute RP – Recommended Practices

Operating Procedure

1) Process

1.1) Staging / Preparation 1.1.1) Conduct a walk around prior to moving the triplex. Verify the sump is empty and all

valves and caps are in place (residual fluid may remain as the pump is not capable of

draining the sump entirely). 1.1.2) When moving Triplex Pumps maintain low speeds and avoid sharp turns to avoid the

equipment pushing the vehicle and causing damage to vehicles and equipment.

1.1.3) Triplex pumps are considered an ignition source and must be staged a minimum of 25’

from other ignition sources and 10’ from a classified area (i.e.: well houses). Consider

the wind direction when spotting the unit.

1.1.4) Use wheel chocks and place spill containment under the triplex, ensure ground is even

prior to detaching from penal hitch to avoid the triplex shifting uncontrollably.

Note: It is essential to setup on level ground with wheel chalks when possible.

Triplex can slide under due to their weight.

1.1.5) Level the unit to ensure proper lubrication of the triplex pump.

1.1.6) Check the day tank to verify the volume present is sufficient to complete the task.

1.1.7) Check the differential pressure gauge for the hydraulic filter (Figure 1).

Note: If the Hydraulic Filter Gauge Needle is in the red, the hydraulic filters need

to be changed. Release the equipment and request the triplex to be serviced.


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Figure 1: Differential Pressure Gauge

1.1.8) Connect the grounding strap to the tree/wellhead and source trailer.

1.1.9) Verify the suction and source valves are closed. Connect the appropriate hose from

either the source trailer or the day tank as required.

1.1.10) Perform a visual inspection on all hoses, manifolds, connections and gauges.

1.1.11) If a pulsation dampener is installed, verify that that it is isolated from the high

pressure manifold.

1.1.12) Verify PRV setting and calibration date. Current date must be less than 3 years from

the test date and should be set to 4250 psi (See Appendix B).

1.1.13) Review the Over Pressure Protection Discussion and Pressure Crosscheck checklist

(Appendix A).

1.1.14) The high pressure manifold (HPM) is configured with up to three outlets that enable

bleeding and delivery of fluids to the target hose. No modifications to the HPM are to be

conducted in the field.

1.1.15) Each outlet on the manifold will have an inline check valve downstream of the HPM

bleed. An inline check valve will also be installed on the discharge pressure hose as

close to the downstream connection as possible while remaining upstream of the target

valves.

1.2) Pressure Testing / Pump Procedure

1.2.1) Confirm the pump is not engaged.

1.2.2) Open the day tank source valve or the trailer source valve.

Note: Only one source valve may be open at a time. To avoid cavitation, bleed air from the triplex through the HPM bleed prior to engaging the pump.

1.2.3) All triplex pumps are equipped with a pressure relief valve on the high pressure side of

the pump. In Prudhoe Bay the PRV shall be set at 4250 psi. Hydraulic triplex pumps

have a rupture disk located on the HPM set at 7500 psi (See Appendix B).


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1.2.4) If an adjustable trip has been installed it must be tested prior to use (See Figure 2

below).

1.2.4.1) Inform operator, via radio, prior to pressure testing.

1.2.4.2) Block in the pump at the HPM.

1.2.4.3) Set the dial to the desired pressure to trip the pump.

1.2.4.4) Hold down the Press to Set button for 2 seconds or more.

1.2.4.5) The red indicator light will flash, indicating that the setting has been accepted.

1.2.4.6) Slowly engage the pump at a low engine RPM and bring up the pressure to the

trip point.

1.2.4.7) Note the pressure that the pump trips at. Small changes may be necessary to

reach the appropriate setting, repeat steps 1 to 6 as needed.

Note: There MUST be an over pressure protection device (PRV, adjustable trip, etc.) in place for ALL pumping jobs that prevents applied pressure from exceeding the lowest pressure rating of any component. If no adjustable trip is installed, an additional PRV manifold (Figure 3) should be used on the outlet with the appropriate setting to protect all equipment downstream.

Figure 2: Adjustable Trip (2014 Model Only, different setup on the 2015’s)

Figure 3: PRV Manifold


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1.2.5) With a low engine speed, slowly engage the pump to pressure test surface lines.

Disengage the pump when test pressure is achieved. Check all hoses and connections

for leaks. After the pressure test is complete, open the valves to the well / equipment

being tested.

1.2.6) Proceed with the pump operation and continue to monitor the sump, hoses and

connections. If a leak occurs or the sump begins to collect fluid, STOP. Disengage the

pump and discontinue the operation until corrective measures have been taken.

Note: Running the pump with the engine at idle for an extended period of time may not provide adequate lubrication to the power end and could result in bearing damage.

1.2.7) Inform operator, via radio, of the number of valves opened prior to beginning pumping

operation along with duration of pumping operation.

1.2.8) Isolate Triplex Pump From the source and the well between each pumping segment.

Note: When isolating the pump and the source from the well it is critical to prevent the high pressure output side from leaking back into the suction side. After the pump is disengaged, close valves starting at the well and working back to the pump. After closing the triplex outlet needle valve, slowly open the HPM bleed to release the pressure in the manifold. When the manifold pressure is relieved, close the bleed, the suction manifold valve, and lastly the source trailer valve in that order. Reverse the sequence if further pumping is required.

1.2.9) When the pump operation is complete disengage the pump, reduce the engine speed

to a low idle and allow the engine to cool down for 5 to 10 minutes. Isolate the pump

from the well and the fluid source.

1.2.9.1) During summertime operations, shut down the Triplex between pumping

operations to conserve costs accrued on the jobsite.

1.2.10) If discontinuing pumping operations.

1.2.10.1) If possible, bleed residual pressures to the bleed tank rather than the sump.

1.2.11) Verify all high pressure discharge valves are closed. Disconnect and blow down the

hoses to the bleed tank. Verify all suction and source valves are closed. Disconnect and

cap the suction manifold and hose connections.

1.2.12) Inform operator of the number of valves closed and that the pumping operation is

complete via radio.

1.3) Post Well Equipment Release Procedure

Triplex Pumps: Leave the spill containment dikes with the equipment. Prior to departure empty the sump into the day tank and close all the doors.

Note: verify day tank level before emptying sump.

Source Trailers: Verify the tank valve is closed and the source hose is capped. Secure the hose to the trailer and disconnect the grounding strap. Equipment Releases: Once the job is complete, release the equipment to non-mobile dispatch. Communicate any equipment related problems or deficiencies to the dispatchers.


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Appendix A: Over Pressure Protection Discussion Tool & Pressure Crosscheck Forms


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Appendix B: PRV and Rupture Disk Locations

2008 Triplex:


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2014 Triplex:

Rupture Disk (7500 psi)

PRV (4250 psi)


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Performance Measures

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Feed Back and Documentation

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Changes to this procedure must be documented using the LRS MOC process. All changes will be communicated to LRS personnel at weekly safety meetings. Contact the LRS HSE Department if there are any questions about, or feedback for this document.

Revision Log

Revision Date Authority Reviser Revision Details 10/11/2004 Well Testing Manager Well Testing Tech Support Original

09/12/2015 Well Testing Operations

Manager

Well Testing Competency

Supervisor

Revised SOP Following BP standards for Triplex Usage in the

field.

8/13/2017 LRS HSE Summerlin Reformatted and updated document number

Mobile Triplex Pump Operations - Little Red Services

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