High Pressure Iron (HPI) Recertification Guidelines & Procedures

Transcription

1 Page 1 of 5 HPI Shop 6201 Andrews Hwy Odessa, Tx Ph: Fx: Howard Supply Company High Pressure Iron (HPI) Recertification Guidelines & Procedures

2 Page 2 of 5 Purpose The purpose of this document is to represent Howard Supply Company's (HSC) standard operating procedures (SOP) used in inspection, repair, testing, and recertifying high-pressure iron (flow control and stimulation equipment). This SOP is to ensure that all products serviced by HSC meet, or exceed Customer, OEM, and/or Industry Standards/Specifications. Scope - HPI Inspection & Recertification Processes performed by HSC (as a third party), are to ensure that a customer s HPI equipment is free of flaws, damages, defects, or excessive wear that would render the equipment out of conformance and unsafe for use under high pressures and/or it s intended application. Types of inspection performed by HSC, dependent upon Customer Specified Recertification Level: Visual, Ultrasonic Thickness (UT), Hydrostatic Pressure Test (PT) & Magnetic Particle (MPI). Responsibility Technician Qualifications Level 1 - HPI Technician Onsite and/or prior experience & training of processes, measurements (Non-NDE related) and procedures. Duties could include teardown, clean up, dimensional measuring/gauging, visual inspections, service/repairs, re-assembly, blasting, painting, and pressure testing. Level 2 HPI Technician All requirements of Level 1 HPI Technician plus Certificate of Training for Level 1 or 2 NDE (either MPI or UT) Level 3 HPI Technician All requirements of Level 1 HPI Technician plus Certificate of Training for Level 2 NDE (both MPI & UT) * Certificate of Training to be conducted and approved by ASNT Level 3 Certified Personnel

3 Page 3 of 5 Section 1 - Inspection Visual Inspection: (Required for Recertification) A thorough visual inspection will be performed on every piece of High-Pressure Iron (HPI). The visual inspection will include all visible surfaces (internal & external) and all components of the assembly to identify any flaws, damages, defects or excessive wear. Visual Inspections will be performed in all stages of the recertification process: Prior to beginning any work After contaminates (paint, rust, grease, etc.) are removed After disassembly (if applicable) During reassembly (if applicable) Prior to Hydrostatic Pressure Testing (PT) Prior to customer delivery Ultrasonic Thickness Inspection (UT): (Required for Recertification) Ultrasonic Thickness Inspections will be performed on every piece of High Pressure Iron (HPI). The UT process will verify that wall thicknesses meet acceptable minimum specifications, and that no material defects exist. UT readings will be taken at multiple locations, sufficient to ensure product is within compliance. Hydrostatic Pressure Test (PT): (Required for Recertification) Hydrostatic Pressure Testing will be conducted on every piece of High Pressure Iron (HPI), excluding flanges and swages (optional). HPI will be tested to its specified Cold Working Pressure (CWP) rating for a minimum of 3 continuous minutes, or longer if needed to meet customer specifications. Manifold Trailers will undergo PT at CWP for a minimum of five minutes. Magnetic Particle Inspection (MPI): (Optional Performed per Customer Request) Magnetic Particle Inspection is optional, and will only be performed per customer request. MPI is the best option for detecting cracks and other surface indications undetectable by the human eye during visual inspection. Due to the nature of the operation of Manifold Trailers, HSC recommends that MPI be performed on all components that make up the assembly. Inspection Rejections: All High-Pressure Iron (HPI) that fails any of the inspection processes will be documented, marked appropriately and disposed of per customer guidance. HSC can offer permanent deformation of failed HPI and disposal at no additional expense to customer. If failed HPI is to be returned to customer, all existing ID/Certification Bands will be removed (Cut-off) and returned separately to further ensure the iron doesn t mistakenly get returned to service.

4 Page 4 of 5 Section 2 High Pressure Iron Recertification Levels Level 1 HPI Recertification: Level 1 Recertification is a basic level of inspection/recertification, and does not include the complete disassembly of the item. Wing nuts and segments are removed to expose all inspection points (if applicable). Sub ends (male, female and threaded) are cleaned for thorough visual and NDE inspection. UT inspection is performed at various OEM and/or customer specified locations for minimum wall thickness. Nuts are ground to remove and repair irregularities of the wings. Seals and retainer rings are replaced, and properly lubricated. Equipment passing inspection is Hydrostatic Pressure Tested (PT) at Cold Working Pressure (CWP). Equipment is banded with HSC, the unique ID#, date tested, CWP and Customer Name. Equipment failing initial PT can be moved to Level 2 Recertification, per customer request, if the problem appears to be correctable by a complete rebuild. Inspection reports are prepared and provided to the customer in either hard copy or digital format. Level 2 HPI Recertification All the benefits of Level 1 Recertification, plus complete disassembly and rebuild, including all new rebuild kits. HSC recommends Level 2 Recertification whenever possible to ensure the most thorough inspection and preventative maintenance is performed. HSC Level 2 Inspection and Recertification not only ensures operational compliance, but also a higher level of safety assurance and extended life of the equipment. Recertification Service Level 1 Level 2 Remove Wing Nut / Segments X X Clean Sub Ends X X Visual Inspection X X Ultrasonic Testing (UT) X X Grinding Wing Nuts X X Magnetic Particle Inspection (MPI) Optional Optional Disassemble / Re-Kit / Rebuild Lev 2 Only X Hydrostatic Pressure Test Cold Working Pressure (CWP +5%/-0%) X X Banding (HSC, ID#, Date, CWP & Customer Name) X X Paint Optional Optional Inspection Reports X X HSC guarantees product conformity at the time of shipment/delivery to customer. Customer is responsible for supplying proper training in product use to ensure the integrity of product conformance is preserved through proper handling and use. All product(s) that have been modified or damaged through misuse, abuse, accident, neglect, or mishandling should be removed from service immediately and sent through the inspection & recertification process.

5 Page 5 of 5 Section 3 High Pressure Iron Documentation Equipment Quick Reference: (Requirements & Options) Equipment Level 1 Level 2 Visual UT MPI PT Ball Injector Required Optional Required Required Optional Required Bull Plug Required N/A Required Required Optional Required Check Valve Required Optional Required Required Optional Required Cross Required N/A Required Required Optional Required Crossover Required N/A Required Required Optional Required Ell Required N/A Required Required Optional Required Flange Required N/A Required Required Optional N/A Hose Loop Required Optional Required Required Optional Required Lateral Required N/A Required Required Optional Required Plug Manifold Required Optional Required Required Optional Required Plug Valve Required Optional Required Required Optional Required Pressure Relief Valve Required Optional Required Required Optional Required Pup Joint Required N/A Required Required Optional Required Swage Required N/A Required Required Optional N/A Swivel Joint Required Optional Required Required Optional Required Tee Required N/A Required Required Optional Required Wye Required N/A Required Required Optional Required Banding Process: If equipment arrives banded from prior certification, band will remain affixed until such time as the equipment has passed all stages of inspection and is ready to have new recertification band attached. HSC uses uncoated stainless steel bands as a normal practice, however coated-color stainless steel bands are available per customer request to meet customers color coding scheme. No equipment is deemed Safe and/or Approved for operation without a band. (If items physical shape doesn t allow for band to be affixed, Certification Criteria will be Stamped or Stenciled directly onto item). Reporting & Traceability: The following information will be recorded into HSC s online High Pressure Iron Management Database and will be accessible to our customer s: HSC Job# Job Date HSC Location Customer Customer Location Customer Unit# Inspection Results UT Results Inspection Level HSC ID# Item Description CWP Test Pressure *Affixed to each inspection report will be the Hydrostatic Pressure Test Results in Chart Form. Please make sure to initial and date each page and complete the below information. Customer Name: Customer Representative (Print): Customer Representative (Sign):