Production / Frac Tree Valve Integrity Test (SOP)

PRODUCTION / FRAC TREE VALVE INTEGRITY TEST (SOP)

Introduction

Operations which include the integrity of Production and Frac tree valves make up an important part of the oil and gas well operations. By assuming that every valve failure can have operational hazards, safety risk, and well-control issues, The Production/Frac Tree Valve Integrity Test is a systematic process for testing the gate integrity of these valves. Standard Operating Procedure (SOP) for 70% water and 30% glycol mixture and service company pump unit outlining a detailed step-by-step guideline for the execution of the test.

Why is the Procedure Done?

This is to verify valve integrity test of valves of Production or Frac tree to ensure that the valves are intact with no leakage / pressure loss. The test includes charging the system, equalizing valve body pressure and checking for leaks. It can also sometimes require many tries to 'bump up the pressure' in order to generate a valid test.

SOP for Production/Frac Tree Valve Integrity Test — Step by Step

1. Rig-Up (R/U) of Service Company Equipment.

✔Incorporate the service company pump truck and treating lines to the Tubing Kill Valve (TKV).

✔Store treating line pressure at 9,500 psi to ensure the integrity of the system prior to commencement of the valve test.

2. Valve Positioning During Commissioning

✔Check that you have the MLMV closed

✔You need to Open the HMV, CV, IHWV, OHWV, TKV, etc.

3. Bleeding and flushing the tree  

✔Bleed off any existing pressure from the tree via the bleed-off line

✔Flush the tree with a mixture of 70% water and 30% glycol to clean out contaminants.

✔Isolation: Closed Hydraulic Wing Valve (HWV) 'Lo-torque'

4. Displacement of Fluid in the Tree.

✔Fill rest of the tree with water-glycol mixture with needle valve open in the crown cap.

✔When fully displaced, shutter the needle valve on the crown cap to lock in test fluid.

5. HMV Integrity Test

✔Pump the tree up to 7,500 psig with the water-glycol mixture.

✔Close the HMV and slowly bleed the pressure to 7,000 psig through the needle valve in the bleed-off high-pressure hose/line.

✔Watch for the pressure loss to confirm HMV integrity.

✔First reopen the HMV, relieve the pressure, then close the HMV again and retest; repeating this to demonstrate the test was consistent.

Note: As the water volume between the MLMV and HMV is small in HMV from the bottom, it is difficult to test this HMV from the bottom. But workover activity e.g. wireline runs, perforating and pulling the BPV naturally tests the HMV. If a leak does exist, then the indicative of the problem will be pressure build-up at the choke manifold or in the tree.

6. CV Integrity Test

✔And pressure the tree to 7,500 psig.

✔Close the Choke Valve (CV) and slowly Bleed the pressure above the CV to 500 psig.

✔Note the pressure drop indicating CV integrity.

7. IHWV and OHWV Integrity Tests

✔Shut the IHWV with 7,500 psig in the tree.

✔Gradually reduce pressure on the OHWV side until it reaches 500 psig then record your observations.

✔This test verifies the integrity of the IHWV.

✔Repeat the process for the OHWV to double rod is that its integrity.

8. TKV Integrity Test

✔With 7,500 psig in the tree, close the TKV.

✔Gradually bleed pumping line to 500 psig.

✔Verify the TKV integrity by monitoring the pressure drop

9. Reverse TKV Integrity Test

✔Keep TKV closed and pump the pressure up the TKV (up the pumping line) to 7,500 psi against the TKV.

✔Watch pressure in the tree to check the integrity from the other side of the TKV.

10. Bleed-Off and Secure Equipment

✔Slowly bleed pressure from the pumping line and the tree to zero psi

✔Shutdown the HMV for confirming the test procedure.

❗Important Safety Considerations and Best Practices

✔Testing a Frac/Production Tree Valve Integrity Test must follow strict health and safety and best practice to ensure the reliable result:

✔All personnel must wear PPE (Personal Protective Equipment) such as gloves, safety goggles, and flame-resistant clothing.

✔Before testing equipment for pressure monitoring, check calibration.

✔Hold a sybo safety meeting prior the test to get all involved on the same page.

✔Do not depressurize quickly to avoid depressurization scenarios

✔Check valve positions again before pressure (to avoid damage/failure).

Common Problems and How to Fix Them

✔Valve integrity test A few issues that can be encountered. Here are some of the common problems and their fixes:

1. Valve Leakage in Test (Pre-Equilibration)

✔Likely Cause: Not enough pressure or the valves are worn out.

✔Solution: Re-run in a pressure test repeating a lot of times to check for the leakage If leak continues, check and change defective valve seals.

2. Hard to get a pressure test

Potential Reason: Pockets of air are present in the system.

Solution: Again flush with the **water-glycol mixture to remove trapped air.

3. During the Holding Period — A pressure drop

Potential Explanation: Small leaks in the system or equipment failure.

Solution: Check for visible leaks and retest individual valve components to identify the problem.

4. Equipment Malfunction

Possible Cause: → Faulty Pump Unit, Clogged lines.

Fix: Check pump operation, unclogged lines, and retry test.

Conclusion

The Production/Frac Tree Valve Integrity Test SOP delivers a structured and systematic method to ensure the integrity of critical well control valves. Operators can follow this process, so valve gates work properly and prevent leaks, pressure failures, and hazardous operation. Well safety, efficiency, and longevity or service life demands regular valve integrity testing.

Fusing well control with structures of best practices, troubleshooting techniques, and strict safety protocols could reduce operational risks, and maximize the performance of the well control system for companies. Ongoing monitoring and maintenance will also help guarantee that Production and Frac tree valves will remain safe and dependable while in well operations.