ABS 168-2010 GUIDE FOR WELL TEST SYSTEMS《试井系统指南》.pdf

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1、 GUIDE FOR WELL TEST SYSTEMS MARCH 2010 Guide to Color Coding Used in Online Version of the Guide The following summarizes the colors corresponding to Rule Changes, Corrigenda items and editorial changes in the Guide files which are available for download. Rule Changes: Corrigenda: CORRIGENDA/EDITOR

2、IALS 1 February 2011 CORRIGENDA/EDITORIALS 10 January 2012 CORRIGENDA/EDITORIALS 1 August 2013 Editorials: Editorial Changes Guide for Well Test Systems GUIDE FOR WELL TEST SYSTEMS MARCH 2010 (Updated August 2013 see next page) American Bureau of Shipping Incorporated by Act of Legislature of the St

3、ate of New York 1862 Copyright 2010 American Bureau of Shipping ABS Plaza 16855 Northchase Drive Houston, TX 77060 USA Updates August 2013 consolidation includes: January 2012 version plus Corrigenda/Editorials January 2012 consolidation includes: February 2011 version plus Corrigenda/Editorials Feb

4、ruary 2011 consolidation includes: March 2010 version plus Corrigenda/Editorials ABSGUIDE FOR WELL TEST SYSTEMS .2010 iii Foreword Foreword This Guide contains the technical requirements and criteria employed by ABS in the review and survey of well test systems that are being considered for Classifi

5、cation and for maintenance of Classification. It is applicable to well test systems that are installed on board vessels and mobile offshore drilling units. Well test systems designed, constructed, and installed in accordance with the requirements of this Guide on an ABS classed vessel or mobile offs

6、hore drilling unit, under ABS review and survey, will be classed and identified in the Record by an appropriate classification notation as defined herein. ABS acknowledges that well test systems are usually installed on board when the vessel or unit is going to be engaged in well testing operations

7、(short-term or extended well testing) and removed when the well testing campaign is finalized. The Guide has been written to account for the different scenarios during the life of the vessel or unit with adequate flexibility to cover the safety aspects during the different phases of operation as wel

8、l as the preparation of the vessel or unit before the well test system is installed onboard. The Guide has an effective date of 1 March 2010. The application of this Guide and referred Rules and Guides is, in general, based on the contract date for construction between the shipbuilder and the prospe

9、ctive Owner (e.g., Rules which became effective on 1 March 2010 are not applicable to a vessel or unit for which the contract for construction was signed on 28 February 2010). At the Owners request and upon agreement by ABS, this Guide may be applied to existing vessels or units or to those projects

10、 for which the contract date of construction has been signed before 1 March 2010. See also 1-1-4/3 of the ABS Rules for Conditions of Classification Offshore Units and Structures (Part 1). iv ABSGUIDE FOR WELL TEST SYSTEMS .2010 Table of Contents GUIDE FOR WELL TEST SYSTEMS CONTENTS SECTION 1 Genera

11、l 1 1 Application 1 3 Scope . 1 5 Definitions . 1 5.1 Well Test Systems . 1 5.3 Permanent Well Test Systems 1 5.5 Temporary Well Test Systems . 1 5.7 Well Test Ready 1 7 Class Notations 1 7.1 Well Test Ready 1 7.3 Temporary Well Test Systems . 1 7.5 Permanent Well Test Systems 2 7.7 Change of Class

12、Notations 2 9 Plans and Data to be Submitted . 2 9.1 Systems . 2 FIGURE 1 Well Test System Classification . 3 SECTION 2 Well Test Ready 4 1 General . 4 3 Deck Structure 4 5 Crude Storage Tank Structure . 4 7 Burner/Flare Boom Structure . 4 9 Components . 4 11 Spill Containment . 4 13 Safety Systems

13、. 5 13.1 Foam Systems for Crude Storage Tanks 5 13.3 Fire Hoses and Nozzles 5 15 Classified Areas 6 15.1 Securing of Hatches, Companionways and Ventilators . 6 15.3 Electrical Equipment within Classified Areas . 6 15.5 Valves and Ball and Socket Hammer Unions 6 15.7 Fired Heaters and Diesel Driven M

14、achinery 6 15.9 Crude Storage Tanks 6 ABSGUIDE FOR WELL TEST SYSTEMS .2010 v SECTION 3 Temporary Well Test Systems 7 1 General . 7 3 Deck Structure 7 5 Crude Storage Tank Structure . 7 7 Burner/Flare Boom Structure . 7 9 Components . 7 9.1 Pressure Retaining Components . 7 9.3 Well Control Component

15、s 8 9.5 Piping Components . 8 9.7 Flexible Hoses . 8 9.9 Pumps . 8 9.11 Electrical Components and Installations 8 11 Spill Containment . 8 13 Hydrocarbon Disposal Facilities . 8 13.1 General 8 13.3 Flares and Burner Booms 8 13.5 Burning of Atomized Crude Oil 8 13.7 Gas Flare Tip Flow Rate 8 15 Safet

16、y Systems . 8 15.1 Monitoring 9 15.3 Flammable Gas Detection . 9 15.5 Hydrogen Sulfide Gas Detection . 9 15.7 Fire Fighting Equipment 9 15.9 Arrangement of Components. 9 15.11 Well Injection Line . 9 17 Classified Areas 9 19 Vessels and Units without WT-TEMP Class Notation 9 19.1 Structures 9 19.3 S

17、afety Systems 9 19.5 Classified Areas . 9 19.7 Mobile Offshore Drilling Units with CDS Notation 9 SECTION 4 Permanent Well Test Systems 10 1 General . 10 3 Deck Structure 10 5 Crude Storage Tank Structure . 10 7 Burner/Flare Boom Structure . 10 7.1 Design Loads . 10 7.3 Allowable Stresses 11 9 Compo

18、nents . 11 9.1 Pressure Retaining Components . 11 9.3 Well Control Components 11 9.5 Piping Components . 11 9.7 Flexible Hoses . 11 9.9 Electrical Components and Installations 11 11 Spill Containment . 11 vi ABSGUIDE FOR WELL TEST SYSTEMS .2010 13 Hydrocarbon Disposal Facilities . 11 13.1 General 11

19、 13.3 Burning of Atomized Crude Oil 11 13.5 Gas Flare Tip Flow Rate 11 15 Safety Systems . 12 17 Classified Areas 12 SECTION 5 Materials for Well Test Systems and Components . 13 1 General . 13 3 Selection of Structural Steels . 13 5 Selection of Well Test Equipment Materials . 13 5.1 Toughness . 13

20、 5.3 Corrosion Hydrogen Sulfide 13 5.5 Corrosion Marine Atmosphere 14 5.7 Stress 14 7 Fabrication Considerations . 14 7.1 Welding . 14 7.3 Forming . 14 9 Primary Product Form 14 9.1 General 14 9.3 Rolled Products . 14 9.5 Forgings 14 9.7 Castings 14 11 Sealing Materials 15 11.1 Elastomeric Sealants

21、. 15 11.3 Ring Joint Gaskets 15 13 Materials and Traceability 15 13.1 Materials 15 13.3 Traceability 15 SECTION 6 Welding and Nondestructive Examination . 16 1 General . 16 3 Specifications . 16 3.1 Welding Procedure Specification . 16 3.3 NDE Procedures 16 5 Welder/Welding Operator Qualification 17

22、 7 Qualification of Nondestructive Technicians 17 9 Post Weld Heat Treatment . 17 11 Nondestructive Examination . 17 11.1 Extent of Examination for Materials and Welds . 17 11.3 Methods and Acceptance Criteria 17 13 Record Retention 18 ABSGUIDE FOR WELL TEST SYSTEMS .2010 vii SECTION 7 Surveys at Ve

23、ndors Plant, During Installation and Commissioning 19 1 General . 19 3 Surveys at Manufacture and During Assembly 19 3.1 Module Fabrication 20 5 Onboard Surveys During Installation 20 5.1 Operation Procedures . 20 5.3 Installation and Testing 20 5.5 Surveys . 20 5.7 Module Hook-up 21 7 Commissioning

24、 Surveys of the Well Test Systems 21 9 Start-up and Commissioning Manual . 22 9.1 Functional Testing Procedures 22 9.3 Start-up Procedure 22 SECTION 8 Surveys After Construction and Maintenance of Class 23 1 General . 23 3 Surveys Onshore and Issuance of Maintenance Release Notes . 23 5 Surveys of W

25、ell Test Systems 23 5.1 Survey Intervals and Maintenance Manuals/Records 23 5.3 Annual Surveys . 24 5.5 Special Periodical Surveys 24 5.7 Continuous Survey Program 24 5.9 Survey Based on Preventative Maintenance Techniques . 25 5.11 Surveys Using Risk-based Techniques . 25 7 Modifications, Damage an

26、d Repairs 25 This Page Intentionally Left Blank ABSGUIDE FOR WELL TEST SYSTEMS .2010 1 Section 1: General SECTION 1 General 1 Application This Guide has been developed to provide requirements for the design, construction, installation and survey of well test systems on board vessels and mobile offsh

27、ore drilling units classed with ABS. The requirements as specified in this Guide are additional to all other relevant requirements of ABS Rules and Guides. 3 Scope This Guide addresses the safety aspects related to well test systems either temporarily or permanently installed on board vessels and mo

28、bile offshore drilling units classed with ABS. The scope of the Guide is limited to surface systems and equipment and does not cover subsea components used during well testing operations. 5 Definitions 5.1 Well Test Systems Well test systems are the facilities installed on vessels or mobile offshore

29、 drilling units (MODUs) for the purpose of evaluating the quality and/or quantity of the well fluid to determine whether the well should be completed for production or plugged and abandoned. Well test systems may include well control equipment, process pressure vessels, piping and electrical compone

30、nts, control systems, burners and gas flares and burner/flare booms. 5.3 Permanent Well Test Systems Well test systems installed on board a vessel or MODU for at least 30 months are considered permanent, notwithstanding if the system is or is not in operation. 5.5 Temporary Well Test Systems Well te

31、st systems installed on board a vessel or MODU for less than 30 months are considered temporary. 5.7 Well Test Ready Vessels or MODUs that have been designed for well test operations, but the well test system has not been installed on board, are considered “well test ready”. 7 Class Notations 7.1 We

32、ll Test Ready Vessels or MODUs designed to be “well test ready” that comply with Section 2 of this Guide will be assigned the notation WT-READY, upon Owners request. 7.3 Temporary Well Test Systems Vessels or MODUs with temporary well test systems that comply with the requirements of Section 3 of th

33、is Guide will be assigned the notation WT-TEMP, upon Owners request. Vessels or MODUs with temporary well test systems installed on board and not assigned with notation WT-TEMP are to comply with the minimum mandatory requirements of Subsection 3/19 of this Guide. In this case, no class notation rel

34、ated to well testing systems will be assigned to the vessel or MODU. Section 1 General 2 ABSGUIDE FOR WELL TEST SYSTEMS .2010 7.5 Permanent Well Test Systems Vessels or MODUs fitted with permanent well test systems that comply with Section 4 of this Guide will be assigned the notation Well Test Serv

35、ice. This notation is mandatory. 7.7 Change of Class Notations The installation or removal of the well test systems on board vessels and MODUs is to be notified to ABS in order to re-assess the compliance with the requirements of this Guide. The class notations will be modified as necessary to refle

36、ct the new status of the vessel or MODU, as shown in Section 1, Figure 1. 9 Plans and Data to be Submitted Plans should generally be submitted electronically to ABS. However, hard copies will also be accepted. 9.1 Systems The detailed, dimensioned drawings listed below are to be submitted and are to

37、 include material specifications, welding specifications and dimensions, and strength calculations, as applicable: Project Specification Process Flow Sheets General Arrangement Plan Equipment Layout Drawings Area Classification Drawings Deck Structural Drawings Burner/Flare Boom Structural Drawings

38、Piping and Instrument Diagrams (P ii) On a deck area of more than 45 m2(484 ft2), there are three or more dry chemical extinguishers whose total capacity of extinguishing agent is not less than: C = 3A kg C = 0.62A lbs where A is the deck area in m2(ft2) iii) The minimum rate of supply of the exting

39、uishing agent is not less than 3 kg/min/m2(0.62 lbs/min/ft2) 13.3 Fire Hoses and Nozzles Firewater stations are to be located on the perimeter of the area designated for installation of the well test system. The stations and their arrangements are to provide at least two jets of water not emanating

40、from the same fire station to reach any part of the well test system that may be exposed to fire. Fire hoses and nozzles are to comply with the requirements of 3-8/5.1.3 of the Facilities Rules. Section 2 Well Test Ready 6 ABSGUIDE FOR WELL TEST SYSTEMS .2010 15 Classified Areas Classified areas rel

41、ated to the installation of well test systems are to be delineated in accordance with the recommended practice of API RP 500 or API RP 505 and the following: 15.1 Securing of Hatches, Companionways and Ventilators Hatches, companionways and ventilators within 3 m (10 ft) of classified areas are to b

42、e secured gas tight for the duration of the test program. 15.3 Electrical Equipment within Classified Areas Fixed electrical equipment within classified areas is to be suitable for the hazard or de-energized. 15.5 Valves and Ball and Socket Hammer Unions Areas around valves and ball and socket hamme

43、r unions are to be designated as Class 1 Division 2 (Zone 2) for a distance of 1 m. (3 ft). 15.7 Fired Heaters and Diesel Driven Machinery Fired heaters and diesel driven machinery are to have air intakes located at least 3 m (10 ft) from any classified area. Exhausts are to be equipped with spark a

44、rresting devices and are to discharge outside classified areas. 15.9 Crude Storage Tanks Delineation of classified areas for vessels and MODUs related to storage tanks for liquids with a flash point not exceeding 60C (140F) is to comply with 4-6-6/1.5 of the Under 90m Rules and Section 4-3-6 of the

45、MODU Rules, respectively. Vessels having crude storage tanks integral with the hull structure need not comply with 4-6-6/1.5 of the Under 90m Rules with regard to the classification of hazardous areas related to crude storage, provided they comply with the following applicable requirements: 15.9.1 O

46、pen Decks Over Crude Storage Tanks Freely ventilated, open and gas tight deck spaces to the full breadth of the ship and 3 m (10 ft) fore and aft of cargo block to a height of 2.4 m (8 ft), or to the height of the production deck, are to be considered Class I, Division 2 areas (Zone 2). 15.9.2 Enclo

47、sed Spaces Adjacent to Crude Storage Tanks Semi-enclosed or enclosed spaces immediately adjacent to crude oil storage tanks are to be considered Class I, Division 1 areas (Zone 1). 15.9.3 Pump Room A continuously ventilated (20 air changes per hour) crude oil pump room is to be considered a Class I,

48、 Division 1 (Zone 1) area, provided the failure of ventilation is alarmed in a manned location. 15.9.4 Cofferdam Spaces which are separated by a single bulkhead from crude oil storage tanks are to be considered Class I, Division 1 (Zone 1) areas. 15.9.5 Crude Storage Tank Vents Areas of unrestricted

49、 ventilation around cargo tank vents are to be considered Class I Division 1 (Zone 1) areas with a spherical radius of 3 m (10 ft), and Class I Division 2 (Zone 2) for an additional 7 m (23 ft). ABSGUIDE FOR WELL TEST SYSTEMS .2010 7 Section 3: Temporary Well Test Systems SECTION 3 Temporary Well Test Systems 1 General Vessels or MODUs fitted with temporary well test systems are to comply with the requirements in this Section when the class notation WT-TEMP has been requested by the Owner. When temporary well test systems are fitted, but the cla