HUNTING X-Over User manual
X-Over
Tool Manual
Manual
Revision Prepared Checked Approved Date
C P. Kinnaird 09/06/2017
Hunting Energy Services (Well Intervention) Ltd
Revision History
Revision Date Details of Change
A04/06/2014 Issue
B24/06/2015 Reformat
C 09/06/2017 Updated for consistency. Annual Test requirement amended. Storage
requirements added.
Hunting Energy Services (Well Intervention) Ltd
Contents
Hunting Contacts...................................................................................................4
Disclaimer..............................................................................................................5
1.0 Health and Safety ............................................................................................6
1.1 General ....................................................................................................6
1.2 Precautions ..............................................................................................7
1.3 PPE..........................................................................................................7
1.4 Pressure Control......................................................................................7
2.0 Description ......................................................................................................8
3.0 Disassembly and Re-assembly........................................................................9
3.1 Disassembly Instructions ........................................................................9
3.2 Re-assembly Instructions ........................................................................9
4.0 Maintenance ..................................................................................................10
4.1 Routine maintenance.............................................................................10
4.2 Annually................................................................................................11
4.3 5 Year Major Survey.............................................................................11
4.4 Recommended Lubricants/Chemicals: .................................................11
4.5 Equipment Tests....................................................................................12
4.5.1 Annual Maintenance: Function test to Max. Working Pressure (MWP) .........12
4.5.2 5 Year major Survey: Hydrostatic pressure test to Test Pressure (TP)............12
5.0 Recommended Spares/Accessories...............................................................13
5.1 Recommended Spares:..........................................................................13
5.2 Redress options .....................................................................................13
5.3 Accessories:...........................................................................................13
6.0 Troubleshooting and Common Issues...........................................................13
7.0 Storage requirements.....................................................................................14
8.0 Disposal.........................................................................................................14
9.0 Transportation ...............................................................................................14
Annex I – Quick Union Table.............................................................................15
Annex II – Torque Value Chart...........................................................................17
Annex III – API Flanges .....................................................................................19
Annex IV – Specification Sheet..........................................................................21
Annex V – Assembly drawing ............................................................................23
Hunting Energy Services (Well Intervention) Ltd
Hunting Contacts
Hunting Energy Services (Well Intervention) Ltd has offices at several locations around the world. If you
have any problems, queries or require spare parts, please contact a representative located nearest to you.
Alternatively if you have Internet access you can E-mail us or visit our website.
Please quote the Part No and the Serial No in all correspondence as this will help expedite your query.
Internet
Web: www.huntingplc.com
E-mail by Region:
Middle East, North Africa, Caspian:
Asia Pacific:
USA, South America, Mexico:
Canada:
UK, Europe, West Africa, Russia:
well.intervention @hunting-intl.com
United Kingdom
Hunting Energy Services (Well Intervention) Ltd
Badentoy Avenue
Badentoy Industrial Park
Portlethen
Aberdeen
AB12 4YB
Scotland
Tel: + 44 1224 787000
Fax: + 44 1224 787100
United States of America
Hunting Energy Services (Well Intervention) Ltd
1018 Rankin Road
Houston
Texas
77073
Tel: + 1 281 821 5577
Fax: + 1 281 821 6633
Dubai
Hunting Energy Services (Well Intervention) Ltd
Building 23
Oilfield Supply Center
Jebel Ali
P.O. Box 261929
Dubai
UAE
Tel: + 971 4887 6850
Fax: + 971 4887 6849
Singapore
Hunting Energy Services (Well Intervention) Pte Ltd
22 Pioneer Crescent
#05-07 West Park BizCentral
Singapore 628556
Tel: + 65 6863 0668
Fax: + 65 6863 9196
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Hunting Energy Services (Well Intervention) Ltd
Disclaimer
“All rights reserved. No part of this publication may be reproduced in any material form (including
photocopying or storing it in any medium by electronic means or whether or not transiently or
incidentally to some other use of this publication) without written permission of the copyright owner,
except in accordance with the provisions of the copyright, Design and Patents Act 1988 or under the
terms of a licence issued by the Copyright Licensing Agency. Application for the Copyright owner’s
written permission to reproduce any part of this publication should be addressed to Hunting PLC, 5
Hanover Square, London, SW15 5HQ.
Warning: The doing of an unauthorised act in relation to a copyright work may result in both a civil
action for damages and criminal prosecution.
Whilst every effort has been taken to ensure the accuracy of this publication, the editors and authors
accept no responsibility for any inaccuracies or omissions contained herein.”
This Technical Manual covers the general usage and maintenance of this equipment. This equipment
operates under high pressure. As such a great deal of care must be taken to ensure the safety of those
operating this equipment as well of those in its vicinity. It is critical that an adequate maintenance
regime is kept and that personnel fully understand the purpose and the operation of this equipment
before taking it out into the field.
The procedures described herewith are not intended as a replacement to local laws or regulations, nor
your companies’ policies and procedures. If in any doubt contact your local authority, company
superior or a Hunting Energy Services (Well Intervention) representative.
Failure to perform routine maintenance checks could invalidate manufacturer warranty.
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Hunting Energy Services (Well Intervention) Ltd
1.0 Health and Safety
1.1 General
Personnel using this manual to perform maintenance should have basic training in the following
disciplines:
Manual handling
MSDS and COSHH
Use of workshop equipment
Use of hand tools (PUWER)
Other basic courses may be required depending on regulations in the location/region that the
equipment is being used.
Safety is everyone’s responsibility, anyone can stop an operation should they deem an act unsafe no
matter what their position is within an organisation.
By following this document, using hand tools correctly, and following working practices the risk of
injury will be reduced to negligible.
CAUTION
Read service manual before operating
Observe all safety precautions
This system is capable of producing high fluid pressures - appropriate considerations are
required
Check that only qualified personnel are in immediate area around equipment
Suitable PPE must be worn at all times
Do not try to tighten or loosen connections under pressure
Do not weld, file or use metal stamps on the pressure equipment - these can create cracks
which could result in structural damage/failure
Do not over tighten manual/service valves (hand tight only).
Do not attach anything to this equipment unless you are sure of its pressure rating
Watch for trapped pressure. Bleed off fully before breaking down tool
Observe the maximum allowable operating pressure of all system components.
Observe the operating conditions of components.
Never stand under suspended loads or in the lifting area!
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Hunting Energy Services (Well Intervention) Ltd
1.2 Precautions
A competently deemed person must be in attendance when performing maintenance on this
equipment. To be deemed competent the individual should have received training on the subject
followed by being observed performing the tasks to the required standard over a time period.
Personnel competence criteria are defined by the technician’s employer.
Hand tools that have not been maintained can lead to accidents, therefore all equipment must be
inspected before use.
1.3 PPE
Basic personal protective equipment must be worn at all times during the maintenance procedures.
There may be the need to use more specific items when using specialised tools, these rules must be
followed to reduce risk of injury. Basic items deemed by Hunting for maintenance personnel are as
follows:
Safety footwear
Safety glasses
Hand protection
Long sleeved coverall
Some workshop regulations deem that hard hats / bump caps and hearing protection must be worn in
maintenance shops, these will be defined by the policy owner. If working in the field, all of the above
items may need to be worn at all times, once again, this is defined by the company / client’s policies.
1.4 Pressure Control
Working with pressure exposes personnel to one of the greatest risks in our industry hence all
personnel must have received formal training on this subject. Company / Client pressure guidelines
must be adhered to with no deviation from the policies. Personnel performing pressure tests must
observe regulations concerning pressure test bays and operating instructions for pumps. All equipment
must be rated for the pressure being applied and certified.
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Hunting Energy Services (Well Intervention) Ltd
2.0 Description
The X-Over is an adapter which is generally used for connecting two different end connections. The
connections on either end are most commonly of the self-aligning quick union type or flanged.
Threaded connections such as API connections or premium connections are available, but may be
limited by the pressure rating of the threaded connection.
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Hunting Energy Services (Well Intervention) Ltd
3.0 Disassembly and Re-assembly
The procedure for disassembly and re-assembly for a X-over is described fully in this section. It is
important that these procedures are followed for correct operation of this equipment. For the item
numbers listed in the disassembly/re-assembly processes, refer to assembly drawing in Annex V of
this manual. O-rings should be removed as encountered during disassembly.
NOTE: Failure to follow the procedures in this section may result in
equipment failure or damage.
3.1 Disassembly Instructions
Remove Thread Protectors if applicable.
Remove Collar if applicable. (Split Collar shown)
oFor Split Collar – Remove Spirol Pins/Set Screws, back off Hub from Flange and
remove.
Remove handles if applicable.
For X-overs with mid joints separate.
3.2 Re-assembly Instructions
With a suitable solvent, clean and inspect all parts for damage or wear.
Replace or repair any badly worn or damaged parts.
Lubricate all sealing surfaces and install new seals.
Assemble in reverse order of disassembly and torque top and bottom subs if applicable.
Fit new Spirol Pins where used.
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Hunting Energy Services (Well Intervention) Ltd
4.0 Maintenance
We recommend that all pressure containing equipment be subjected to a formal maintenance
schedule, devised to ensure that the equipment is always fit for purpose. If followed correctly this will
minimise downtime and ensure the safety of those who need to work with and around it. Many
companies have established preventive maintenance programs that require re-certification of the
equipment on a quarterly, semi-annual, or annual basis.
Ideally, any X-Over should be stripped, redressed and tested prior to every job, or every quarter as a
minimum. It should be flushed out and all internal surfaces greased after every job. If possible it
should be stored filled with clean oil.
The procedure specified by Hunting is the recommended minimum. This will be superseded by
the policies of individual companies.
4.1 Routine maintenance
Completely disassemble all components and clean thoroughly before inspecting for wear,
corrosion or damage. Pay particular attention to metal/metal seal surfaces on X-Overs.
Seal bores must be inspected thoroughly
Threaded connections must be inspected thoroughly
Elastomers showing any wear should be replaced
Equipment must be fully function tested once reassembled
BEFORE EVERY JOB:
Certification should be checked to confirm equipment compliance with operational needs
Confirm all component pieces are tightened correctly
Pressure test and function as per operational requirements
AFTER EVERY JOB:
Disassemble, clean and inspect all components
Inspect all seals and sealing surfaces, replace as necessary
Check all threaded connections
Reassemble as per the assembly instructions
Pressure test to working pressure
WHEN CHECKING COMPONENTS FOR DAMAGE OR WEAR:
Particular attention should be paid to:
Sealing surfaces
Threads
Lubricate all sealing surfaces and install new seals if required.
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Hunting Energy Services (Well Intervention) Ltd
4.2 Annually
Disassemble and inspect as per the routine maintenance procedure.
Renew all o-rings, inspect sealing surfaces for wear, corrosion or damage.
Rebuild and pressure test to Maximum Working Pressure.
4.3 5 Year Major Survey
Disassemble and inspect as per the routine maintenance procedure.
Dimensional and thickness report.
Magnetic Particle Inspection (MPI) of all parts.
Rebuild using seal kit and any necessary parts.
Hydrostatic body test to Maximum Working Pressure.
Third party certificate of final test and inspection and certificate of conformity.
4.4 Recommended Lubricants/Chemicals:
Grease
Grease anti seize
Lubriplate
WD40
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Hunting Energy Services (Well Intervention) Ltd
4.5 Equipment Tests
Prior to testing disassemble the X-over and clean with a suitable cleaner, then re-assemble with new
O-rings. Ensure that the equipment is placed in a designated safe test area ONLY.
NOTE:
ANY leakage of test fluid detected while the equipment is pressurised is cause for rejection.
Determine the cause of the leak, repair it and re-test.
NEVER attempt to loosen or tighten a connection while pressurised.
NEVER attempt to connect the X-over to equipment incorporating connections other than the
specific quick union/test port. Failure to do so will result in damage to the equipment seal
areas and/or threads.
To prevent personal injury, keep fingers/other extremities AWAY from Acme threads whilst
making up the quick union collar.
4.5.1 Annual Maintenance: Function test to Max. Working Pressure (MWP)
This body test checks that the equipment can withstand the Maximum Working Pressure. To test, take
the following steps: No leaks can be accepted
1. Cap off the bottom with an approved blanking cap. Fill with test fluid and cap off the top with
an approved blanking plug.
2. Bleed off all trapped air.
3. Connect a test pump to a suitable test port.
4. CLEAR the area of all personnel before proceeding
5. Apply maximum working pressure to the X-Over and hold for five minutes. Reduce pressure
to 0-PSI. Re-Pressurise to MWP and hold for fifteen minutes. Reduce pressure to 0-PSI. Re-
pressurise to (300PSI) and hold for five minutes. Reduce pressure to 0-PSI.
6. Disconnect and remove the blanking plug and cap.
4.5.2 5 Year major Survey: Hydrostatic pressure test to Test Pressure (TP)
This body test checks that the equipment can withstand the Design Pressure. To test, take the
following steps. No leaks can be accepted
1. Cap off the bottom with an approved blanking cap. Fill with test fluid and then cap the top
with an approved blanking plug.
2. Bleed off all trapped air.
3. Connect a test pump to a suitable test port
4. CLEAR the area of all personnel before proceeding.
5. Apply maximum test pressure to the X-Over, hold for five minutes and reduce pressure to 0-
PSI. Re-Pressurise to TP, hold for fifteen minutes and reduce pressure to 0-PSI. Re-pressurise
to (300PSI), hold for five minutes and reduce pressure to 0-PSI.
6. Disconnect and remove the blanking plug and cap.
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Hunting Energy Services (Well Intervention) Ltd
5.0 Recommended Spares/Accessories
5.1 Recommended Spares:
For the relevant Redress, O-Ring or Spares Kit Number please refer to the Assembly
Drawing/Specification Sheet in Annex of this manual.
5.2 Redress options
Please contact the Hunting Sales department for O-ring material options to meet your environmental
conditions.
5.3 Accessories:
For accessories that do not have part numbers stated contact the Hunting sales department for details.
Recommended accessories:
Quick Union Test Stump/Cap/Plug
Male thread protector(steel/plastic)
Hand tools associated with the redress process
Non marking Strap Wrench
Grease
Grease anti –seize
6.0 Troubleshooting and Common Issues
Problem Possible Cause Solution
Leak at quick unions O-rings damages Replace elastomers on pin of quick unions
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Hunting Energy Services (Well Intervention) Ltd
7.0 Storage requirements
Draining after testing
All equipment shall be drained and lubricated after testing and prior to storage or shipment.
Rust prevention
Prior to shipment, parts and equipment shall have exposed metallic surfaces protected with a rust
preventative that does not become fluid and run at a temperature of less than 50 °C (125 °F).
Sealing-surface protection
Exposed sealing surfaces shall be protected from mechanical damage for shipping.
Ring Gaskets
Loose ring gaskets shall be boxed or wrapped during shipping and storage.
Age control of non-metallic materials
Indoor storage.
maximum storage temperature not to exceed 49 °C (120 °F).
protected from direct natural light.
stored unstressed.
stored away from contact with liquids.
protected from ozone and radiographic damage.
8.0 Disposal
Hunting does not have a working life limit for its pressure control equipment. Good maintenance and
correct adherence to procedures will increase the longevity of the equipment.
Many companies have a working life policy for pressure control equipment, this will supersede the
above statement.
9.0 Transportation
The Hunting X-Over should be stored:
Fully assembled with Thread Protectors fitted
The hydraulic fittings protected
The components should be stored in the PCE transportation unit on the shaped rack (if available).
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Hunting Energy Services (Well Intervention) Ltd
Annex I – Quick Union Table
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Hunting Energy Services (Well Intervention) Ltd
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Hunting Energy Services (Well Intervention) Ltd
Annex II – Torque Value Chart
Hunti
n
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e
e
rvices (Wel
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Interventio
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Hunting Energy Services (Well Intervention) Ltd
Annex III – API Flanges
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Hunting Energy Services (Well Intervention) Ltd
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