WS QHSE S23 G07 ManifoldsFracCement 3313701 05

Well Services QHSE Standard
23 Guideline 07: Manifolds on

Cementing and Fracturing Pump
Units Inspection and Test
Reference: InTouch content ID# 3313701
Version: 1.4
Release Date: 05-Aug-2016
EDMS UID: 1651834232
Produced: 05-Aug-2016 20:50:02

Owner: WS Operations Integrity manager
Private equ ipment,Testing

Services,Safety,standard,23,testing,inspection,treating
IPC,Well
Equipment,Fractu
frac bridle ring,
andcementing,
Inspection units,
of Treating
bridle
Copyright © 2016 Schlumberger, Unpublished Work. All rights reserved.

WS S23 G07:Cement and Frac Manifolds / Legal Information
Legal Information
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WS S23 G07:Cement and Frac Manifolds / Document Control
Document Control
Owner: WS Operations Integrity manager
Reviewer: InTouch
Approver: Joseph Hayes, WS OI manager
Contact Information
Name: WS Operations Integrity manager

LDAP Alias: InTouchSupport.com
Revision History
Version Date Description Prepared by
1.4 05-Aug-2016 Added 3” 2202 and 4” 1502 to Minimum Wing Author: Walter Taylor; TechCom:
Nut Height table John Schneider
1.3 31-Mar-2016 Update owner, approver for OI Transformation Author: John Schneider
1.2 15-Aug-2011 Add 1.5-in 1502 Lm value. Author: John Schneider
1.1 08-Oct-2010 New requirements for Documentation, Banding Author: John Schneider
and Painting
1.01 17-May-2010 Clarify owner, reviewer, and approver Author: John Schneider
1.0 03-Nov-2008 First release as a standalone document from Author: John Schneider
Standard 23
Private
WS S23 G07:Cement and Frac Manifolds / Foreword
Foreword IPC,Well Services,WS,
New releases of this document supersede any other version. The most current
version of the document is in InTouchSupport.
If you have a printed copy, check the "Release Date" against the content in
InTouch to be sure you have the most current version.
Private
1-i WS S23 G07:Cement and Frac Manifolds / Inspection and Test 1-i
1 Inspection and Test

1.1 General information ____________________________________________ 1-1
1.2 Annual inspection requirements _______________________________ 1-2
1.2.1 Visual inspection _____________________________________________ 1-2
1.2.1.1 Fracturing manifolds including frac pump bridles ____________ 1-2
1.2.2 Wall thickness inspection _____________________________________ 1-3
1.2.2.1 Wall thickness testing of horizontal components on frac pump

manifolds ________________________________________________ 1-3
1.2.2.2 Wall thickness inspection of assembled manifolds __________ 1-4
1.2.3 Union inspection on assembled manifolds. _____________________ 1-7
1.2.4 Pressure test _______________________________________________ 1-10
1.2.5 Documentation _____________________________________________ 1-11
1.2.6 Banding ____________________________________________________ 1-11
1.2.7 Painting ____________________________________________________ 1-11
Private
1-1 WS S23 G07:Cement and Frac Manifolds / Inspection and Test 1-1
1 Inspection and Test Services,Safety,sturing,

IPC,Well
equipment,Testing
Equipment,Frac
bridle tandard,23,testing,inspec
andcInspection
ementing, of
units,
Treating
bridle
tion,treating
frac
General information
1.1
Inspection and test occur at the following schedule:
Table 1-1: Inspect and test frequency for discharge manifolds
Unit type Procedure Frequency of the procedure

Fracturing manifolds including Complete disassembly and Per Well Services QHSE Std
frac pump unit manifolds inspection 23, at least annually
Complete disassembly and Every two years

Land cementing units inspection
and portable offshore
pumping units Wall thickness inspection and Annually
pressure test of the complete
assembly
Complete disassembly and Every five years
Permanently installed inspection
offshore cement unit Wall thickness inspection and Annually
integral manifolds pressure test of the complete
assembly
Minimum requirements:
• Each individual component that composes the unit manifold must be

identified with a unique serial number that will remain with the equipment until
it is removed from service.
• Each piece must be inspected and pressure tested as per Table 1-1 unless
otherwise required on a more frequent basis.
• Each individual component must be inspected and thickness tested according
to its applicable guideline.
• Additional thickness testing will be required on horizontal frac-discharge
manifold components, as defined in section 1.2.2.1.
• The results of the inspection and pressure test must be documented. The
documentation (either a paper copy or electronic copy) must be kept on file
at the operating location for one year or until the next inspection.
• Any piece not meeting the requirements of this guideline must be taken out
of service and repaired or destroyed.
Private
1.2 Annual inspection requirements
1.2.1 Visual inspection

If the manifold did not require disassembly for inspection, perform the visual
inspection following these steps.
• Ensure that the components have not been welded for any reason.
• Verify that each component has a band with a serial number; if the band is
missing, perform the necessary research to identify the component’s serial
number.
• Inspect the outside of all components for surface damage such as extensive
corrosion, dents, gouges, or flat spots. Test any points of concern with the
ultrasonic thickness tester.
• Check the area around and under the manifold for signs of leaks that may
indicate a need for individual component inspection.
1.2.1.1 Fracturing manifolds including frac pump bridles

Fixed horizontal components in fracturing manifolds may allow fluid to lay in the
bottom of the component that may cause increased corrosion which can lead to
the formation of microfissures and eventual failure of the component.
• Before disassembling the manifold, mark the 12 o'clock position of all

horizontal components that will allow fluid to lay in the bottom of the
component.
• After disassembling the manifold, thoroughly clean the internal bore at the
male and females ends of each component removing any scale that may
have built up for as deep into the bore as reasonably possible.
• Check the internal bore of corrosion and erosion.
• If there is heavy corrosion at the 6 o'clock position, perform non-destructive
inspections to determine if cracks have initiated. If there is any evidence of
cracks, remove the component from service and destroy it.
• Once the other inspection steps have been completed, reassemble the
manifold, turning any horizontal components that can be rotated to the 3, 6,
or 9 o'clock positions.
Private
1.2.2 Wall thickness inspection
1.2.2.1 Wall thickness testing of horizontal components on frac

pump manifolds
Figure 1-1: Frac pump discharge manifold. Horizontal components, at locations

designated by “*”, are tested at 4 locations around the bore
Locations marked with an asterisk (*) are to be checked per the following
procedure:
1. Scale must be removed to the extent that an ultrasonic thickness tester can
be used at the 12, 3, 6, and 9 o’clock positions.
2. Take readings in all four positions on both the male and the female ends of
the pipe, and compare the results of the four readings on each end.
If there is a difference between any two readings greater than 10% of the
thickest wall, the pipe must be taken out of service. If any readings are below
the minimum wall requirements set out in this standard, the pipe must also
be removed from service.
Private
The minimum wall requirement for 3-in pipe is 0.361 in (9.17mm). The readings
that follow are examples of the type of corrosion that could be experienced.
Position Reading
12 0.414
3 0.417
6 0.370
9 0.401
0.417 – 0.370 = 0 .047-in Wall reduction from highest to lowest reading

0.047 ÷ 0.417 = 11.3% The pipe is to be removed from service.
1.2.2.2 Wall thickness inspection of assembled manifolds

If a cement pump unit has a threaded discharge manifold and any part of the
manifold fails any step in the inspection, the manifold must be replaced with an
integral discharge manifold assembly. Never install or repair threaded discharge
manifolds on existing cement pumpers.
1. Verify that the ultrasonic tester is current on its annual calibration and that it
has been calibrated at least once that day by following the manufacturer’s
procedure.
2. If required for the specific ultrasonic thickness tester, remove paint, grease,
rust and other materials from the area to be tested.
3. Measure the wall thickness at the desired areas designated in Figure 1-2 and
Figure 1-3 and any other areas indicated during the visual inspection.
4. Compare the results of the wall thickness tests to the minimum wall thickness
for the components as shown in Table 1-2 (p. 1-6).
5. Remove from service and destroy any components that show a wall thickness
equal to or less than the minimum wall thickness.
Private
WS Operations Integrity manager\\InTouch content ID# 3313701\1.4\Release Date:05-Aug-2016\EDMS UID: 1651834232\Produced: 05-Aug-2016 20:50:02 1-5 WS S23 G07:Cement and Frac Manifolds / Inspection and Test 1-5
Figure 1-2: Typical truck or float cementer discharge manifold
Private
WS Operations Integrity manager\\InTouch content ID# 3313701\1.4\Release Date:05-Aug-2016\EDMS UID: 1651834232\Produced: 05-Aug-2016 20:50:02 1-6 WS S23 G07:Cement and Frac Manifolds / Inspection and Test 1-6
Figure 1-3: CPS 361 Cement pumper discharge manifold
Table 1-2: Treating Component Wear Limits
FMC 1Minimum SPM Minimum

Type of Component Size Wall Thickness: Wall Thickness:
Inches (mm) Inches (mm
2-in LS15 0.309 (7.85) 0.350 (8.89)
LS15 0.434 (11.02)
0.450 (11.43)
3-in TS15 0.403 (10.24)
Swivel joints TSi 15 0.403 (10.24)
4-in LS10 0.390 (9.91)
4-in TSi 15 0.517 (13.13)
4-in XHTL 0.562 (14.27)
Private
FMC 1Minimum SPM Minimum

Type of Component Size Wall Thickness: Wall Thickness:
Inches (mm) Inches (mm
2-in 1502 0.316 (8.03) 0.330 (8.38)
3-in 1502 0.474 (12.04) 0.480 (12.19)
4-in 1002 0.422 (10.72) 0.390 (9.91)
Segmented male subs on
tees, laterals, and valves 4-in 1502 0.592 (15.04)
4-in (XHTL) 1502 0.648 (16.46)
2-in 1502 0.246 (6.25) 0.220 (5.59)

3-in 1502 0.361 (9.17) 0.320 (8.13)
4-in 1002 0.323 (8.20) 0.290 (5.08)
4-in
Straight joints Modified
(on manifold 0.597 (15.17)
FR15
trailer)
4-in Modified
(on manifold clamp 0.700 (17.78)
trailer) hub
2" (3.0" OD) 1502 0.364 (9.26)
2" (2.75" OD) 1502 0.332 (8.43)
2" (2.5" OD) 1502 0.306 (7.77) 0.23 (5.84)
2" (2.38 OD) 1502 0.246 (6.25)
Integral straight joints 3" (4.12" OD) 1502 0.500 (12.70)
3" (3.75" OD) 1502 0.442 (11.23)
3" (3.50" OD) 1502 0.378 (9.60) 0.37 (9.40)
4" (5.00" OD) 1002 0.386 (9.80) 0.39 (9.91)
4" (5.25" OD) 1502 0.578 (14.68)
Adapters Request the minimum wall thickness from the manufacturer.
1
To be used for other suppliers.
1.2.3 Union inspection on assembled manifolds.

It is necessary to perform the union inspection on any exposed unions such as
the discharge of the cement unit manifold or any unions disassembled to perform
the pressure test.
1. Verify that all go/no-go gauges are current on their calibrations.

2. Thoroughly clean all parts of the union.
Private
3. Clearly identify that the wing is made by FMC or SPM. If not and no
exemption approved by Well Services HQ is in place, remove from service
and destroy the component.
4. If the wing is 2-in and is marked “TEST” instead of “CWP,” remove the wing
and destroy it.
5. Grind the hammer lugs on the wing to match Figure 1-5 (p. 1-9), part B, and
measure L; if any lug matches Figure 1-5, part C, or has L equal to or less
than Lm (see Table 1-3 (p. 1-10)), remove the wing and destroy it.
6. Screw gauge #1 into the wing until it is hand-tight.
7. Backing out gauge #1 while pulling on it, count the number of turns until it
releases from the wing; if gauge #1 turns more than 1 turn before releasing,
remove the wing and destroy it.
8. Slide gauge #2 into the wing; if it enters the wing completely, remove the
wing and destroy it.
9. Dismantle the wing completely.
10. If the wing is an FR design, ensure that the segments and male hub are also
the FR design. Do not use gauges #5 or 6 to inspect FR parts.
11. Using gauge #5, check in three places around the circumference of the male
hub that the hook does not fit; if the hook does fit with the gauge level with the
hub, remove the section of the component with the male hub and destroy it.
12. Slide each of the segments through gauge #5 to ensure that there is no
visible clearance on surfaces A or B; if there is any clearance, destroy the
segment.
Figure 1-4: Inspecting the segment using gauge #5
Private
13. Measure the surface B of all three segments, ensuring that they are the
same height; any differences in heights must be investigated to ensure that
FMC or SPM segments are being used in the respective unions.
14. Screw gauge #3 onto the thread until it is hand-tight.
15. Backing out gauge #3 while pulling on it, count the number of turns until it
releases from the thread; if gauge #3 turns more than 1 turn before releasing,
remove the section of the component with the thread and destroy it.
16. Slide gauge #4 onto the thread; if it slides over the thread to the mark on the
gauge, remove the section of the component with the thread and destroy it.
Figure 1-5: Grinding guide for wing nut lugs
Private
Table 1-3: Minimum Wing Nut Height
Lm
Component Minimum lug height to wing
I.D. in inches
1.5-in 1502 1.6
2-in 1502 1.5
2-in 2002 1.75

3-in 1502 1.75
3-in 2002 2.25
3-in 2202 2.25
4-in 1002 1.75
4-in 1502 2.25
1.2.4 Pressure test

Although manifold components must be pressure tested individually when
disassembled as per the individual component requirements, the manifold must
be pressure tested again after it has been assembled.
For a manifold attached to a pump, the pressure test must be done, as a

minimum, to the rated working pressure of the pump. If more than one pump
is connected to a manifold, as in the case of a double pump cement unit, then
the manifold must be pressure tested to the highest rated working pressure
of the pumps, as a minimum.
If client or regulatory requirements stipulate that the pressure test on an

assembled manifold must be done to the rated working pressure of the
components, disconnect the manifold at the unions closest to the pump, blank off
these unions on the manifold, and perform the pressure test to the rated working
pressure. Reconnect the manifold to the pump and perform the final pressure test
to the pump's rated working pressure to ensure that the these unions are sealing.
Once the manifold has been reassembled, perform the pressure test using the
following procedure.
1. In a pressure test bay or other protected environment, fill with water, and
carefully bleed air from the assembly. Pressure test it to +/-2.5% of its rated
working pressure for, at least 3 minutes.
2. If there are no leaks and the pressure drops off no more than 2.5% of its
rated working pressure within the 3 minutes, the component or assembly
has passed the inspection.
Private
3. If the pressure decreases from the initial test pressure and stabilizes, the
pressure can be increased one time to reach the rated working pressure.
4. If there are visible leaks or the pressure drops off more than 2.5% of its rated
working pressure within the 3 minutes, release the pressure and return the
leaking component or components for repair and retesting.
1.2.5 Documentation
Documentation must conform to the requirements stated in section 23.8.6 of
Standard 23.
Potential Severity: Catastrophic

Potential Loss: Assets, Personnel, Process, Reputation
Hazard Category: Pressure
NEVER weld on treating equipment.
1.2.6 Banding
Identification banding must conform to the requirements stated in section 23.8.7
of Standard 23.
1.2.7 Painting
Paint the treating equipment according to the requirements stated in section
23.8.8 of Standard 23.
Private

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Well Services QHSE Standard

23 Guideline 07: Manifolds on

EDMS UID: 1651834232

Produced: 05-Aug-2016 20:50:02

Private equ ipment,Testing

Copyright © 2016 Schlumberger, Unpublished Work. All rights reserved.

Copyright © 2016 Schlumberger, Unpublished Work. All rights reserved.

electronic or mechanical, in whole or in part, without the express written

Trademarks & Service marks

Schlumberger, the Schlumberger logotype, and other words or symbols used

A complete list of Schlumberger marks may be viewed at the Schlumberger

Approver: Joseph Hayes, WS OI manager

Name: WS Operations Integrity manager

1.2 15-Aug-2011 Add 1.5-in 1502 Lm value. Author: John Schneider

Foreword IPC,Well Services,WS,

InTouch to be sure you have the most current version.

1 Inspection and Test

1.2.2.1 Wall thickness testing of horizontal components on frac pump

1 Inspection and Test Services,Safety,sturing,

Inspection and test occur at the following schedule:

Table 1-1: Inspect and test frequency for discharge manifolds

Unit type Procedure Frequency of the procedure

Complete disassembly and Every two years

• Each individual component that composes the unit manifold must be

1.2 Annual inspection requirements

1.2.1 Visual inspection

inspection following these steps.

1.2.1.1 Fracturing manifolds including frac pump bridles

• Before disassembling the manifold, mark the 12 o'clock position of all

1.2.2 Wall thickness inspection

1.2.2.1 Wall thickness testing of horizontal components on frac

Figure 1-1: Frac pump discharge manifold. Horizontal components, at locations

0.417 – 0.370 = 0 .047-in Wall reduction from highest to lowest reading

1.2.2.2 Wall thickness inspection of assembled manifolds

Figure 1-2: Typical truck or ﬂoat cementer discharge manifold

Figure 1-3: CPS 361 Cement pumper discharge manifold

Table 1-2: Treating Component Wear Limits

FMC 1Minimum SPM Minimum

FMC 1Minimum SPM Minimum

4-in (XHTL) 1502 0.648 (16.46)

2-in 1502 0.246 (6.25) 0.220 (5.59)

1.2.3 Union inspection on assembled manifolds.

1. Verify that all go/no-go gauges are current on their calibrations.

Figure 1-4: Inspecting the segment using gauge #5

Figure 1-5: Grinding guide for wing nut lugs

Table 1-3: Minimum Wing Nut Height

2-in 2002 1.75

1.2.4 Pressure test

For a manifold attached to a pump, the pressure test must be done, as a

If client or regulatory requirements stipulate that the pressure test on an

Potential Severity: Catastrophic

NEVER weld on treating equipment.

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