In addition to this SOP, the policies and procedures of each operating company will be strictly observed by Rockwater personnel.

Transcription

1 SOP FB-009 (Revised MAR 2014) STANDARD OPERATING PROCEDURES-FLOWBACK Control of Trapped Pressure Section 1.0 Introduction and Background Rockwater Energy Solutions, Inc. (and all its affiliated and subsidiary companies, hereinafter collectively referred to as Rockwater ) is committed to providing its employees a safe working environment and avoiding injury to our contractors, customers, and neighbors. As part of our overall commitment to safety, Rockwater seeks to prevent acts or conditions that could result in injury and/or illness to any employee, customer, contractor, neighbor, and/or the environment. In an effort to prevent potentially harmful acts or conditions, Rockwater has developed this Standard Operating Procedure (SOP). This SOP will discuss steps to be taken to promote a safe process, as well as a list of potential hazards that should be identified and remediated prior to commencing these activities. This SOP will be reviewed and revised on an ongoing basis to keep pace with best oilfield practices. This SOP will be a part of the training provided to all affected employees when they begin their employment with Rockwater and any time the plan is changed. This SOP will also be reviewed with an employee if his/her responsibilities change under the plan. A written copy of this plan will remain in the regional Safety Office, and will be available for employee review. The Vice-President of Health Safety and Environment, or his agents, may be contacted by any employee if he/she needs additional information about this SOP. This SOP has been developed to assist affected employees with the operational steps that may be used to complete the task safely. It must be noted, however, that the experience and background of a trained flowback operator is essential to the success of any project or task. Nothing contained in this SOP is a substitute for each employee s individual judgment in any given situation. In the event that any employee believes that any task outlined in any SOP cannot be completed safely, then that employee should immediately halt the performance of such task and notify their direct supervisor. In addition to this SOP, the policies and procedures of each operating company will be strictly observed by Rockwater personnel. Section 2.0 Background and Process Steps, Control of Trapped Pressure Due to the inherent nature of flowback operations, pressurized piping and equipment is a daily hazard that must be mitigated. The purpose of this SOP is to outline the steps needed to identify potential sources of trapped pressure and then to mitigate those hazards. NEVER hammer on, apply force to, or manipulate any threaded connection (hammer union or National Pipe Thread [NPT]) while it is under pressure. o Isolate the equipment that will be worked on and bleed off pressure. Ensure that pressure is bled off entirely before work with the connection begins. Open the valve slowly and carefully to commence bleeding off the pressure. Pressure should be vented in a safe manner and directed toward a tank or to atmosphere.

2 o Make sure that no one is in the line of fire as pressure is bled off. Be wary of obstruction at point of bleed-off. Do not walk on or apply unnecessary force to pressurized iron. Hammer unions o Make sure that the unions are properly assembled, as per manufacturer specifications. Note that some mis-matched unions may nest or thread together, but they will have an extremely high probability of failure. o Hammer unions should be properly spaced and aligned. Do not connect hammer unions that are out of alignment (in a bind). Iron should be rigged up in a straight line, and all unions should match up neatly. o Use wood blocks as cribbing when making up hammer union connections. Wood blocks allow necessary clearance for hammer union wing, avoiding damage to containment. This will allow for a solid surface to support iron so that union can be properly tightened. o Prior to use, inspect hammer unions to ensure that they are in good condition. Inspect threads for dings and burrs. Clean and lubricate threads prior to every connection. Clean threads with a wire brush prior to applying lubricant. Inspect and clean wing threads. Inspect wing ears for damage. Damaged wing ears may shed metal shards while hammering, creating a potential hazard. o Wing ears should be ground down to a solid, undamaged surface. Visually inspect wing half segments (dogs) and the retention rings in each wing section. Inspect hammer union seal ring for any sign of wear. Replace if there is any sign of damage or wear The raised lip around the outside of the seal ring should be inserted first into the thread half connection, such that it fits into the groove in the union. o Do not cross-thread hammer unions when making up connections. o Hammer unions should be properly secured. Block up with wood blocks so that lines are resting on a solid surface. Use one of the following types of securement (as required for the operation): Cement blocks

3 o Chains and binders may be used Whip checks Nylon/Kevlar restraints Cable and clamp systems Secure iron such that operational flow will not cause iron to move. For NPT threaded connections, always review the following: o Always make sure that threaded connections are a matched pair, per manufacturer specifications. o Prior to use, inspect threads for signs of visible damage. o Always comply with manufacturers specifications for pressure rating and usage. o Use Teflon thread tape 2-3 wraps around threads Wrapped clockwise if looking at end of threaded piece o Do not cross-thread. o Tighten threaded connection completely. These connections should be tightened with a sledge hammer until they are fully secure. Do not over-tighten Boeing connections and other connections o Always comply with manufacturer specifications. o Properly maintain and lubricate unions. Contributing factors for the failure of pressurized iron include the following: o Vibration and movement. o Connections improperly made Force applied to connection o Damaged iron Washed out or excessively worn Damaged threads o Improper use Any usage outside of manufacturer specifications Pressure up iron gradually. o See SOP regarding pressuring up to manifold Utilize all pertinent safety practices. o Proper energy isolation, per requirements of operation. o Lock out/tag out as needed o Maintain good communication with everyone involved in operation Section 3.0 Potential Hazards Any time that flowback operations are in progress, the following potential hazards must be considered and mitigated: Latent natural gas Wind direction

4 Ignition sources within 100 feet of the wellhead and/or frac tanks Pressure Line of fire/body placement/grease valve placement Hydrogen Sulfide (H 2 S) Stored energy Overhead work or suspended loads Section 4.0 Other Safety Items In addition to the above potential hazards, the following items should be discussed and implemented during the pre-project tailgate safety meeting and JSA process, prior to commencement of onsite activities: All possible flammable gas or liquid sources are to be identified and controlled or remediated. All possible ignition sources are to be identified and controlled or remediated. Environmental controls; o Erosion and Sedimentation (E&S) controls in place? o E&S controls appropriately located? o E&S controls adequate for situation? Ensure that safety equipment and personal protective equipment (PPE) is onsite and available and properly utilized when necessary or otherwise required pursuant to this SOP or the operating company s policies and procedures. Access signs or tape (as required) are available. Non-sparking tools for potential leaks are available. Potential communication issues should be identified and resolved; o Among Rockwater employees. o Between Rockwater and other contractors onsite. Strategies for limiting site access should be discusses and implemented, if possible. Rally points for and routes for emergency evacuations should be identified. o Identify a secondary rally point, along with a secondary evacuation route. Grounding and bonding of tanks and equipment must be completed. Appropriate actions on/around tanks must be discussed. Spill/leak cleanup procedures must be reviewed. Containment requirements must be reviewed. Reporting requirements and procedures must be reviewed. Discuss that the integrity of lines is not guaranteed, and can be negatively impacted by o Pressure; o Vibration; o Torque; or o Binds. Record-keeping and project log requirements should be reviewed. Water for pressure testing, purging requirements and processes must be identified. A minimum of two workers must be present onsite at all times.

5 SOP In-Field Checklist, Control of Trapped Pressure NEVER hammer/apply force/manipulate any threaded connection while under pressure Always isolate equipment off all pressure, open valve slowly Do not walk on or apply unnecessary force to pressurized iron Make sure hammer unions are properly assembled, as per specs Ensure hammer unions are properly spaced/aligned, don t connect hammer unions that are out of alignment Use wood blocks as cribbing when making up hammer union connections Prior to use, inspect hammer unions to ensure that they are in good condition Clean and lubricate threads prior to every connection Inspect and clean wing threads Inspect wing ears for damage Visually inspect wing half segments and retention rings in each wing section Inspect hammer union seal ring for any sign of wear, replace as needed Do not cross-thread hammer unions when making up connections Hammer unions should be properly secured For NPT threaded connections, always review the following: Confirm threaded connections are a matched pair, as per specs Prior to use, inspect threads for signs of visible damage Always comply with manufacturers specs for pressure rating and usage Use Teflon thread tape Do not cross-thread. Tighten threaded connection completely; use sledge hammer until fully secure For Boeing connections (and other connections), always review the following: Always comply with manufacturer specs Properly maintain and lubricate unions Pressure up iron gradually Utilize all pertinent safety practices Proper energy isolation, per requirements of operation. Lock out/tag out as needed Maintain good communication with everyone involved in operation