HSE Flash Report

All Locations Flash No. 108

SUBJECT: SCOPE: PURPOSE:

Issue Date: 06-24-2009

Reissue of Previous Alert: Re-building Plug Valves Used In Corrosive Service All Halliburton Locations To inform all Halliburton locations of the required replacement parts for re-building LOTORC valves for use in acid service, inform all locations that standard LO-TORC valves cannot be re-built for use in H2S service, and to assign responsibilities to Iron Coordinators for ensuring that contractors use the correct replacement parts when rebuilding valves that will be used in acid service.

This Flash Alert was originally issued as Alert No. 91 in September of 2007. We are reissuing the alert because we have experienced a significant number of similar incidents during the spring of 2009. The recent incidents involved pumping less than 2000 gallons of acid with stem breakage occurring in a very short period of operational time. Please note that the corrosion resistant alloy referenced in the original alert was Monel K-500. We have recently changed to an equivalent product, Incoloy 925. Henceforth we will simply refer to the material used for these plugs as a Corrosion Resistant Alloy (CRA) rather than reference a specific CRA material. The part numbers are still the same for the individual plugs and for the repair kits containing these plugs. The tables below have repair kit part numbers and individual CRA plug part number. A LO-TORC plug valve recently failed and the top stem was ejected while in acid service. The valve had recently been re-built by a contractor. The contractor had not been informed that the valve was intended for acid service so standard heat treated 400 series stainless steel replacement parts were installed. Stainless steel is excellent for service in water, cementing fluids, and most fracturing fluids, but it is susceptible to hydrogen embrittlement and cracking when exposed to acids or H2S.

Alert Contact Information: Lawrence Herndon Alert Legal Approved by: Kelley Green

HSE Flash Report

All Locations Flash No. 108 Issue Date: 06-24-2009
Standard LO-TORC valves can safely be used in acid service, but they must be equipped with a corrosion resistant alloy (CRA) plug (see tables below), have aluminum bronze inserts, and the seals must be made of Viton. New valve assemblies trimmed for acid service can be ordered from Duncan manufacturing (contact Duncan manufacturing customer service for part numbers) or standard valve assemblies can be converted by rebuilding the valve with the correct repair kit from the following table. Use repair kits with "H2S/Corrosive" type of service. The second table lists the part numbers that you will need if you only need to replace the plug.

REPAIR KIT PART NUMBERS

PART NUMBER FULL KIT 100001023 100001024 100015528 100015529 100009313 100001073 100015675 100001017 100015507 100015508 100001086 100015708 100001087 100015709 100001127 100015912 101238029 100001142 100015986 101239693

VALVE SIZE 1" 1" 1" 1" 1.3" 1.3" 1.3" 1.75" 1.75" 1.75" 2.06" 2.06" 2.06" 2.06" 3.12" 3.12" 3.12" 3.06" 3.06" 3.06" 4.06" 3K, 5K, 6K, 10K 5" 10K, 15K

PLUG MAT'L STAINLESS CRA CRA CRA STAINLESS CRA CRA STAINLESS CRA CRA STAINLESS CRA CRA CRA STAINLESS CRA CRA STAINLESS CRA CRA

INSERT MAT'L IRON AL BRZ AL BRZ IRON AL BRZ AL BRZ AL BRZ AL BRZ AL BRZ AL BRZ IRON IRON AL BRZ AL BRZ IRON AL BRZ AL BRZ AL BRZ AL BRZ AL BRZ

SEAL MAT'L NITRILE TEFLON VITON NITRILE NITRILE TEFLON VITON NITRILE NITRILE VITON NITRILE NITRILE TEFLON VITON NITRILE TEFLON VITON NITRILE TEFLON VITON

TYPE OF SERVICE STANDARD H2S H2S /CORROSIVE STANDARD STANDARD H2S H2S /CORROSIVE STANDARD STANDARD H2S /CORROSIVE STANDARD STANDARD H2S H2S /CORROSIVE STANDARD H2S H2S /CORROSIVE STANDARD H2S H2S /CORROSIVE

PART NUMBER SEALS ONLY KIT 100001025 100001026 100015530 100001025 101271653 100001074 100009314 100014084 100014084 100015509 100001089 100001089 100001091 100001090 100001128 101271650 101271648 100015992 101271652 101271651

101503378

STAINLESS

IRON

NITRILE

STANDARD

NONE

101314497

CRA

AL BRZ

NITRILE

STANDARD

NONE

Alert Contact Information: Lawrence Herndon Alert Legal Approved by: Kelley Green

HSE Flash Report

All Locations Flash No. 108 Issue Date: 06-24-2009

Standard Service LO-TORC plug valves are not suitable for H2S service and cannot be field converted to H2S service condition. In addition to having a plug made from a CRA, LO-TORC valves in H2S service also have special valve bodies, adjusting nuts, seals, and end connections (such as wing nuts) suited to H2S service. INDIVIDUAL CRA PLUG PART NUMBERS:

Alert Contact Information: Lawrence Herndon Alert Legal Approved by: Kelley Green

HSE Flash Report

All Locations Flash No. 108
CONTROLS: Iron Coordinators are responsible for coordinating all LO-TORC rebuilding activities with contractors when the valves will be used in acid service. Specifically, Iron Coordinators will: 1. 2. Notify contractors when they are receiving valves intended for acid service. Inform contractors of Halliburtons unique part numbering system for valves originally assembled for acid service so that they can recognize a valve intended for acid service in the event that step one is accidentally skipped. Provide contractors with the specific repair kit part numbers required for the re-build. Inspect re-built valves intended for acid service to ensure that they have the correct internal parts prior to releasing them back into service.

Issue Date: 06-24-2009

3. 4.

Alert Contact Information: Lawrence Herndon Alert Legal Approved by: Kelley Green