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Eni S.p.A. DEPARTMENT ACTIVITY' DEPT. TYPE
TITLE
COMPLETION PROCEDURES MANUAL
DISTRIBUTION LIST
"
INDEX
1. INTRODUCTION 11
1.1 Purpose of the manual 11
1.2 implementation 11
1.3 Updating, Amendment, Control & Derogation 11
2. RESPONSIBILITIES 12
2.1 Well Operations Manager 12
2.2 Well Operations Superintendent 12
2.3 Completion and Workover Engineer 13
2.4 Fluids Specialist 14
2.5 Offshore Installation Manager (OIM) 14
2.6 Well Operations Supervisor 15
2.7 Production Supervisor 16
3. DOCUMENTATION 17
3.1 Preliminary Information 17
3.2 Wellsite Reports 17
3.3 Feed Back Reports 17
3.4 Other Reports 18
3.5 Permit Procedures 18
3.5.1 GUIDANCE FOR PERMITS 18
3.6 Well Handover Procedures 18
3.6.1 WELL HANDOVER CERTIFICATE 19
3.6.2 WELL INTERVENTION HANDOVER CERTIFICATE 20
4. HOLE PREPARATIONS 25
4.1 Preliminary checks 25
4.2 Well Clean Up Procedures 25
4.3 BOP Stack Configuration and testing 26
4.4 Well control 26
4.5 Oil Based Mud Displacement 26
4.5.1 DISPLACEMENT OBJECTIVES 27
4.5.2 LOGISTICAL CONSIDERATIONS 27
4.5.3 DRILLING FLUID PREPARATION 27
4.5.4 SURFACE EQUIPMENT PREPARATION 28
4.5.5 WELL CLEAN UP PILL SEQUENCE 29
4.5.6 PILL FUNCTIONS 29
4.5.7 PIT REQUIREMENTS 29
4.5.8 PUMPING SEQUENCE 30
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5. PERFORATING PROCEDURES 36
5.1 GENERAL 36
5.2 Methods of Perforating 37
5.3 General SAFETY Procedures 38
5.4 WIRELINE CONVEYED PERFORATING 39
5.4.1 CASING GUNS RUN IN OVERBALANCE 39
5.4.2 PERFORATING PROCEDURES FOR THROUGH TUBING CONVEYED GUNS 40
5.5 SAFE SYSTEM 41
5.5.1 GENERAL 41
5.5.2 SAFE SYSTEM DESCRIPTION (SLAPPER ACTIVATED FIRING EXPLOSIVES) 42
5.6 TCP Procedures 42
5.6.1 WELL PREPARATION FOR TCP OPERATIONS 43
5.6.2 ANCILLARY TCP EQUIPMENT 43
5.6.3 FIRING SYSTEMS FOR TCP OPERATIONS 45
5.6.4 GENERAL TCP SAFETY PRECAUTIONS AND RUNNING PROCEDURES 46
5.6.5 FIRING PROCEDURE FOR TUBING INSTALLED PRESSURE ACTIVATED HEAD 47
5.6.6 FIRING PROCEDURE FOR WIRELINE INSTALLED PRESSURE ACTIVATED HEAD
47
5.6.7 FIRING PROCEDURE FOR MECHANICAL IMPACT ACTIVATED HEAD 47
5.6.8 FIRING PROCEDURE FOR ELECTRICALLY ACTIVATED TCP GUNS 48
5.6.9 PROCEDURE FOR TCP ANCHOR RUNNING 49
5.6.10 TCP ANCHOR FIRING HEAD INSTALLATION 50
5.7 Coiled Tubing Gun Deployment 53
5.7.1 SYSTEM FUNCTIONS 53
5.7.1.1 Connector 53
5.7.1.2 BOP Deployment Stack 54
5.7.1.3 Gate Valves 54
5.7.2 GUN DEPLOYMENT 54
5.7.3 JOB PREPARATION 54
5.7.3.1 Running in hole general procedure 55
5.7.4 FIRING SYSTEMS FOR COILED TUBING GUN DEPLOYMENT 58
5.7.4.1 Coiled tubing pressure activated firing head 58
5.7.4.2 Coiled tubing hydraulically activated firing head 58
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7. PACKER INSTALLATION 72
7.1 HOLE Preparation 72
7.2 Wireline Packer setting procedure 72
7.2.1 RUNNING PROCEDURE 73
7.3 Tubing Installed Packer Setting Procedure 74
7.3.1 WORKSTRING RUNNING PROCEDURE 74
7.3.2 COMPLETION STRING RUNNING PROCEDURE 75
8. COMPLETION INSTALLATION 76
8.1 Carbon Steel and Plastic Coated Tubing 76
8.2 Chrome Tubulars 76
8.2.1 TRANSPORTATION 76
8.2.2 TRANSPORT FROM THE MILL 76
8.2.3 ROAD TRANSPORT 77
8.2.4 MARINE TRANSPORT 77
8.2.5 HANDLING AT THE WELLSITE 77
8.2.6 THREAD COMPOUNDS 78
8.2.7 RUNNING CHROME TUBULARS 79
8.2.8 RETRIEVING CHROME TUBULARS 80
8.3 Equipment Pre-installation Procedures 81
8.3.1 MATERIAL REQUISITION LISTS 81
8.3.2 COMPLETION SUB ASSEMBLIES 82
8.3.3 TUBING HANGER 82
8.3.4 LANDING JOINT 82
8.3.5 CONTROL LINE 83
8.3.6 XMAS TREE 83
8.3.7 FLOWLINE 83
8.4 COMPLETION ASSEMBLIES 83
8.4.1 WORKSHOP MAKE-UP AND TEST PROCEDURES 83
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APPENDIX:
1. INTRODUCTION
1.2 IMPLEMENTATION
The guideline and policies specified herein will be applicable to all completion activities.
All engineers engaged in completion activities are expected to make themselves familiar with
the contents of this manual and be responsible for compliance to its policies and procedures.
2. RESPONSIBILITIES
The following job descriptions outline the individual responsibilities and duties of specific key
personnel involved in Completion operations. These are generalised summary of the
individual responsibilities and duties which are specific to completion operations and as such
augment, but do not supersede their current employers approved job descriptions.
Providing reports and analysis on the operated and non-operated activities for
presentation, meetings and reporting to the management and to ensure the
operational feedback reporting system is consistent with Corporate requirements.
Assisting his supervisor in contacts with partners and regulatory bodies providing
the necessary documentation and reports.
Providing the monthly updates on the variance between actual and estimated
expenditures for each job centre for each class of cost, also to liaise with the
Completion/Workover Superintendent, in order to update the expenditure on
each contract.
Ensuring the production and review of the Completion Procedure Manual in order
to comply with company policies and the current legislation.
3. DOCUMENTATION
This section outlines the documentation necessary for conducting efficient completion
operations and reporting of these operations.
The action of transferring the responsibility for a well between area authorities will be
documented and recorded on the Well Handover Certificate or Well Intervention Handover
Certificate. All preparatory work and the status of the well when handed over will be
described in the appropriate Handover Certificate.
A typical example of a Handover Certificate with the information to be recorded is shown in
figure3-1 and figure 3-2.
The completed Handover Certificate must be signed by the responsible persons handing
over and receiving the well. It must be placed in the appropriate well file. Copies are to be
faxed to the Well Operations Superintendent when a new well is handed over.
There are two types of Well Handover Certificates:
Well Handover Certificate
Well Intervention Handover Certificate.
New Wells
Following the successful drilling and completion of a new well, the Operations department
will complete a Well Handover Certificate. Prior to handover of the well to Production, the
well status should be outlined as below:
Xmas tree installed and fully pressure tested
Swab cap installed and pressure tested
SCSSV installed and fully tested
All wireline plugs removed
All obstructions removed, the wellhead and Xmas tree areas are clean and tidy
Written procedure for the venting of annular pressure, if necessary.
Once the Production Supervisor is satisfied that the status of the well is satisfactory, he will
sign the handover certificate in acceptance of the well. Examples of Well Handover
Certificates are shown in figure3-1 and figure 3-2.
Workover Wells
Workover is defined in this instance as any well operation which involves the change-out of
any completion component from the wireline re-entry guide to the Xmas tree.
Following the successful completion of a well which has been worked over, Well Operations
department will complete a Well Handover Certificate. Prior to handover of the well to
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Once the Production Supervisor is satisfied that the status of the well is satisfactory, he will
sign the handover certificate in acceptance of the well.
Prior to handover of the well by Production to Well Services the Production Supervisor will
complete a Well Intervention Handover Certificate and ensure the following procedures are
completed:
1) All chemical injection lines on the flowline will be bled down and isolated.
2) The test and production, or injection, header isolating valves will be closed, and the
flowline bled down to the closed drains and isolated when no liquid or gas is observed
at the sample point. Blind flanges should be installed on the flowline termination.
3) The SCSSV control lines will be bled off ready to be disconnected. All lines from the
wellhead to the remote control panel will also be bled down.
4) If the tree is to be removed all instrumentation and control lines will be removed from
the well.
5) All obstructions (e.g. scaffolding) all instrumentation and control lines will be removed.
Once the Well Operations Supervisor is satisfied that the status of the well is satisfactory he
will sign the Well Intervention Handover Certificate in acceptance of the well.
Following an intervention operation the Well Operations Supervisor will complete a Well
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Handover Certificate. Prior to handover of the well to Production, the well status should be
outlined as below:
Xmas tree installed and fully pressure tested.
Swab cap installed and pressure tested.
SCSSV installed and fully tested.
All wireline plugs removed.
All obstructions removed, the wellhead and Xmas tree areas are clean and tidy
Written procedure for the venting of annular pressure, if necessary.
Once the Production Supervisor is satisfied that the status of the well is satisfactory, he will
sign the Well Intervention Handover Certificate in acceptance of the well. An example of a
Well Intervention Handover Certificate is shown in figure 3-3.
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Flowline Status:
ADJACENT WELLS
Well No SCSSV Plugs Xmas Flowline
Tree
Status Tested Date Status Tested Date Depth Status Status
4. HOLE PREPARATIONS
The procedures in this section described the preparation of the hole and surface facilities for
completion operations.
Note: The casing and liner string may be pressure tested at this point, and an
inflow test on liner laps and shoe tracks performed.
For detailed procedures on Well Control Policy Manual see (STAP-P-1-M-6150).
If a liner lap is a found to be leaking it may be necessary to run a tie back packer into the top
of the liner lap, otherwise it will be necessary to perform a remedial cement squeeze. The
decision on which method to adopt will depend on the location and nature of the leak.
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5) Near the end of the conditioning operation, temporarily shut down the pumps and
stroke each set of pipe rams to clear any debris from the ram cavities except any pipe
rams which are smaller than the workstring. Continue circulation to remove the debris.
6) During this operation, as much of the surface volume of mud should be removed from
the pits to accommodate the completion fluid and the well clean up chemicals. Once
the mud has been back-loaded, surface preparation can be carried out.
Note: Manifolds may contain residual materials that could contaminate the
brine. Therefore all manifolds, pumps, etc. involved in brine delivery will
be thoroughly flushed and dried.
Brine will not be loaded onto a vessel or truck until the Companys responsible person is
satisfied that the brine will arrive at the rig site with the same clarity, density, and solids
content as originally loaded.
Samples of the brine will be taken during the loading operation from the loading tanks and
the vessel's receiving tanks or truck. The volume, density and clarity of the fluid after
loading must be identical to the fluid from the suppliers tanks.
Prior to transferring the brine to the installation from the tanks all hoses, connections, dump
valves, etc. will be checked for leaks.
The volume and density of the brine will be monitored as it is transferred from the
vessel/truck. Any discrepancies in density and volume will be recorded.
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2) Disadvantages
They are limited normally to temperatures <280 F.
They are only effective in low permeability formations where seepage losses are
low to moderate (<1.5 - 2bbl/min).
Notes:
1) The above formulation will give a final weight of 10.5ppg assuming that a 10ppg NaCl
brine is used as the base.
2) If a higher density is required, the formulation will require modification by the addition
of FL-7 Plus and Watersal A. The specific formulation will be determined by the Fluids
Engineer on the rig. However, typical formulations are as follows (see table below).
3) Mixing order of products should be listed.
4) A small amount of defoamer is required (0.2gal/bbl) to minimise foaming.
The system's simplified cleanup reduces rig time during completion and workover
operations. While other fluids require costly processes for removal, removal is simply
accomplished by flowing the well.
The system utilises very pure calcium carbonate with a broad particle size distribution to
effectively bridge the pore openings of the formation. The bridging agent and polymer
chemistry form a thin filter cake to protect the pay zone from damage caused by fluid
invasion. The filter cake is effectively removed by low break-out pressures, leaving no
significant residual material to inhibit the well's production.
Before using a calcium carbonate pill, any potential damaging effects from the calcium
carbonate needs to be assessed as any particles trapped in pore spaces can only be
removed by an HCl acid treatment.
5. PERFORATING PROCEDURES
5.1 GENERAL
Two methods are currently used to perforate wells: wireline conveyed guns and tubing
conveyed guns (Refer to the Completion Design Manual STAP-P-1-M-7100). In the drive to
obtain maximum perforating efficiency, tubing conveyed perforating is the preferred method
for most completion operations as the zones to be tested can be perforated underbalanced
in one run with large size charges, if possible. However, under some circumstances wireline
conveyed guns may still be preferred. The procedures for both methods are described in the
following sections.
The type of explosive to be used will depend mainly on the bottom hole temperature and the
length of time the guns are likely to be on bottom before firing. Refer again to the
perforating section in the Completion Design Manual (STAP-P-1-M-7100) and to suppliers
technical specification sheets.
The BOPs and the rig manifolds should have undergone a recent full programme of
pressure testing.
At the safety meeting, the perforating operation should be discussed in fine detail. Apart
from outlining the sequence of operations and contingency plans, all present should be
clearly aware of the extent to which their own area of responsibilities may affect, and be
affected by, the special requirements of a perforating operation.
The perforating engineer should have a diagram of the well, clearly indicating the interval(s)
to be perforated, the fluids present, the pressures/temperatures expected and the depths,
diameters and angles of any changes in the well geometry. There must be no doubt about
the method of referencing the top shot and the settings of the tools (e.g. shear pin settings,
timer delays, etc.). These must be discussed with the Completions Supervisor and fully
understood.
No crane lifts should be made over loaded perforating guns or over the logging cable.
Only essential personnel will be permitted in the vicinity of loaded guns, especially at the
loading area, catwalk, drill floor and spider deck. All personnel, except the perforating
engineer, should be clear of these areas while the guns are being armed.
Diving activities are not permitted during the perforating operation.
Electrical Activation
In addition, whenever the gun firing sequence is initiated by electrically operated detonators,
the following will apply:
Weather forecasts (two independent sources) must confirm there will be no
likelihood of electrical storms for the duration of the perforating operation.
Offshore, the perforating engineer should remain on the drill floor at all times
when TCP guns are in the hole still above ground level.
The perforating engineer must verify there are no stray voltages (greater than
0.25 V) between the rig and the casing or riser.
Radio silence must be in force before connecting the firing head and until the
guns are 100m below rotary table, unless the Schlumberger SAFE firing system
or similar is used (Refer to section 5.5).
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The firing head detonator must not be installed until the Completion Supervisor
confirms to the Perforating Engineer that the rig is on radio silence.
On recovery of the guns, regardless of any indications that the guns have fired,
radio silence must be reinstated prior to the guns being retrieved above 100
metres below the sea bed. This period will end only after the detonator sub-
system has been removed and the perforating engineer has confirmed to the
Completion Supervisor that the guns have been made safe.
No electric/MIG welding is permitted during the perforating operation.
Cathodic protection should be shut down and isolated during the period of
radio silence.
No diving is to be allowed during perforating.
No crane lifts should be made over the wire during perforating, if applicable.
No boats should be alongside during perforating.
No helicopter landings should be allowed during radio silence.
All non-essential personnel should be excluded from the areas affected,
including the gun loading area, the catwalk, the drill floor and the moonpool,
around the riser below the drill floor.
Common to all perforating operations, a safety meeting should be held before the operation
commences. This is important because perforating will impose restrictions on other rig
operations, such as radio silence, diving and use of the cranes. These procedures are to be
used as a guideline. They should be used only in conjunction with other company
procedures for these operations.
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Through-Tubing Guns
Through-tubing guns are small diameter guns run through the test string. They can be used
to perforate underbalanced, and hence eliminate the risk of damaging the formation with
wellbore fluids immediately after perforating. Also, and especially in production situations,
they can be run and fired with the well nippled up and intrinsically safe. The gun size which
can be run is limited by the tubing size.
On recovery of the guns, regardless of any indications that the guns have fired, radio
silence must be in force before the guns are pulled back past 100 metres below ground
level and until the cable head is removed.
2) The logging engineer should be given a diagram of the well showing the depths of all
restrictions or changes in diameter.
3) Wireline should be rigged up as per the procedure in the General Wireline Procedures
Manual (STAP-P-1-M-7110).
4) If perforating inside casing ensure the length of the gun assembly is less than the
distance between the blind rams and the grease head.
5) The distance between the top shot and the GR/CCL should be measured. It may
sometime no be necessary to run a record the depth by GR or CCL if depth can be
correlated to a sump packer or bridge plug.
6) The logging engineer must not connect the cable head until the Well Operations
Supervisor, or his designated representative, has confirmed that radio silence is
instated.
7) There is no restriction on running speed but care must be taken at any restrictions and
when applying the brake.
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8) The Logging Engineer must inform the Drilling and Completion Supervisor, or his
designated representative, when the guns are deeper than 100 metres below ground
level.
9) Tie on depth to the CBL/VDL/GR/CCL log. Record a short section of film across the
interval to be perforated showing at least five casing collars and the pup joint at the top
of the reservoir section. The well should be perforated from the bottom upwards.
10) When the gun is on depth and ready to be fired, the logging engineer must inform the
Well Operations Supervisor, or his designated representative, and the driller, who
should observe the well for losses or gains when the gun is fired.
11) Pull out at less than 5,000 ft/hour to avoid swabbing.
2) The logging engineer should be given a diagram of the well and test string showing the
depths of all restrictions or changes in diameter and he should check that he has
sufficient weights for the maximum anticipated wellhead pressure.
3) Rig up wireline for a full bore drift run. Run in the hole and drift the tubing.
Note: On offshore rigs, prior to arming the guns, the Offshore Installation
Manager will ensure that conditions for safe operations exist. He should
then inform base, standby vessels, supply boats and any relevant
persons that the rig is passing into radio silence.
4) The wireline should be rigged up with the lubricator system, grease flow tubes,
hydraulic stuffing box, tool trap, ball check valve and line wiper. Once radio silence
has been obtained, rig up the perforating guns into the lubricator and pressure test.
5) Monitor the pressure in the annulus.
6) Ensure the surface tree master and swab valves are open and run in the hole with the
perforating gun tool string.
7) Correlate the GR/CCL to the original GR log. Record a short section of film across the
interval to be perforated showing at least five casing collars and the pup joint at the top
of the reservoir zone. Do not run down into the perforations on subsequent runs.
8) Position the string at the desired perforating interval and fire the guns.
9) Observe and record WHSIP to confirm the guns have fired.
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10) Pull out of the hole with the perforating string, taking care when passing through
restrictions.
11) Repeat steps until the total required interval has been perforated. Do not flow the well
while pulling the guns back through the tubing to surface.
12) Stop when the guns are at 100 metres below ground level until the Completions
Supervisor, or his designated representative, confirms that there is radio silence.
13) The gun should be inspected at surface to check that all charges have detonated.
Care should be taken as pressure can be trapped by debris behind the gun ports. A
film record should be made of the job and the explosion register should be updated.
14) Open the well to flow and continue as per the Completion Programme.
5.5.1 General
There are two types of detonators in general use today:
a) The Electric Detonator or Blasting Cap (which is classed as an Electro Explosive
Device).
b) The Percussion Detonator or Percussion Cap.
Both of these systems contain primary high explosives which are initiated by an electric
current heating a filament wire in the case of the blasting cap and a direct mechanical shock
in the case of percussion cap. The blasting cap can also be initiated by shock as it contains
primary high explosives.
In order to store and handle these detonators, special safety precautions must be taken.
These precautions include, in the case of electro explosive devices, the elimination of stray
electric potential differences while arming guns at surface and when returning to surface
after perforating.
Stray electric potential differences can originate from:
RF Radiation
Impressed Current Cathodic Protection
Electric Welding
Electric Generators and Motors
Lighting Storms.
The SAFE system was developed to preclude the loss of radio communication and other
vital equipment during perforating operations.
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TCP perforating is now the most common method of perforating today as it has many
advantages over wireline conveyed perforating. These advantages include:
The guns can be made up and run in the hole on the completion string or on an
independent anchor system.
The packer is set and the string fully tested and completed before guns are to be
fired.
The well can be perforated underbalanced to increase the perforating efficiency
for completion.
Various methods of detonation can be utilised depending on well conditions.
Long perforation intervals can be fired in a singe run.
Accurate placement and efficient detonation in high deviation wells with selective
zonal perforations can be achieved.
Guns and charge size can be maximised for optimum perforating efficiency.
Guns can be loaded to perforate specific target intervals.
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Perforating systems are available which allow several different intervals to be independently
perforated and tested during one trip in the hole.
Ensure that the casing/liner has been gauged and junk basket/junk sub trip has been made
prior to running the TCP guns.
Note: If the guns are to be dropped into the sump, it is essential that the depth
of the rat hole is sufficient to swallow the guns.
Clean Casing
This helps prevent problems with packer setting. A bit and scraper run to clean up the casing
and condition the hole is essential, followed by a gauge ring run before TCP gun installation
(Refer to section 4.10). This provides a good clean area for the packer to set and seal off in,
hold high differentials and withstand the shock of the gun detonation.
Clean Tubing
This is also a vital factor that assists in a trouble free firing operation. Tubing should always
be calibrated before being run. This prevents any pipe scale, mud cake or general debris
from falling down to settle out and create a barrier around and over any firing head or
stinger. This is critical if bar drop methods or wireline conveyed firing heads are used.
Any preventative methods employed in the area of scale/dope are strongly recommended.
Clean Fluids
These are important in any perforating operation. By keeping the downhole fluid
environment as clean as possible, less problems will be encountered later in the operation.
As stated above, solids settling out can cause problems/delay/cost, so an emphasis where
possible on clean, filtered well fluids is essential. Perforation tunnel and near wellbore
damage are also a consideration (Refer to the Drilling Fluids Operations Manual (STAP-P-1-
M-6160) for recommended fluids policies, recipes and cost considerations.
BOP Tests
It must be taken into consideration that perforating/testing and killing operations may require
a considerable time; therefore the next scheduled BOP test may be rescheduled to take this
into account.
Bullnose
Allow the test string to enter top liner easily. It may also be ported to allow pressure
communication with a pressure activated firing head on the bottom of the guns.
Circulating Sub
This sub is optionally run above the mechanically activated firing head. It is a ported sub
which allows circulation and beneath the ports is a brass or glass disc preventing debris from
dropping onto the mechanical firing head. The drop bar must pierce the disc before passing
on to the firing head. The ported sub acts as a perforated anchor after the guns have fired.
Spacer Tubing
Spacer tubing is inserted between the gun drop sub and the top of the guns. The distance
between the gun drop sub and the top perforation should be at least 50ft if production
logging is to be performed.
Shock Absorber
This is an optional tool which may be run to protect downhole equipment from the shock of
gun detonation. This is important when, in particular, downhole gauges are run below the
packer. Both radial and longitudinal force shock absorbers are available.
Radioactive Sub
A radioactive tag in a sub should be installed in the string within the proximity of the packer.
This sub is used as a marker when performing the GR/CCL correlation for depth control. If
the formation has little GR character, radioactive collars can also be included in the casing
string for definitive depth control. If chrome tubulars are being used consideration must be
given to the non magnetic properties of the pipe with regard to the CCL.
TCP String
If using a test string to conduct a shoot and pull procedure, the full range of string
components such as packer, test tubing, tester valve, circulating valves, etc. need to be
employed as per the Company Well Test Procedures Manual (STAP-P-1-M-7130).
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Shot Detection
Shot detection equipment comprises acoustic detectors (hydrophones), vibration detectors
(accelerometers) and the normal surface pressure gauges. Using a combination of the data
detected by these sensors it is usually possible to confirm gun detonation.
Mechanical Impact
The TCP guns are detonated by the mechanical impact of a firing bar, which for safety must
be run on wireline. (This system is colloquially known as the drop bar system.) Since the
system can be affected by debris in the tubing, the completion fluid must be kept clean. The
system is preferred as a back up instead of the primary firing mechanism because of the
need to use wireline.
Electrically Activated
With this system, the guns are fired with an electrically-initiated detonator which must be run
on a logging cable. Therefore the pressure control system must be rigged up. Since an
inductive or wet electrical connection must be made at the firing head, the system is also
susceptible to debris. This system is rarely used on well tests as the firing heads for this
system are wireline retrievable, hence the guns can be run unarmed and, in the case of a
misfire, the firing head can be recovered on wireline to determine the cause of the misfire.
The guns are run in the hole without the firing head. Then, when ready to arm the guns, the
head is run to depth on slickline and latched on to the firing stem or stinger. This system
provides its own back-up because if the firing head does not work, it can be retrieved and a
replacement be run.
Retrievable firing heads are available with mechanical, hydraulic or electric triggering.
Running procedure
1) The elevators should be changed out to match the special lift sub and the correct slips
for the gun size must be used together with a dog clamp. The perforating engineer will
provide a list of the correct torque for each component of his equipment.
2) After clearing the area of non-essential personnel, pick up the guns on a tugger with
the special lift sub. The guns are made up just as tubing singles but avoid mechanical
shock because the internal carriers can be displaced.
3) Check the booster positions and 'O' rings before making up guns. The firing head
delay will have previously been set according to the test programme and agreed by the
Perforating Engineer.
4) Before connecting the firing head, clear the drill floor and cellar deck areas of all non-
essential personnel.
5) A spacer sub must be installed so that the top shot is well below the rig floor when the
gun is armed. Do not pull the gun back above the drill floor once the firing heads are
installed.
6) Run the rest of the test string but take special care that no debris shall fall down on top
of the firing head. If tubing is in poor condition, ensure it is cleaned and calibrated to
remove all loose rust and scale.
7) The string must be run without jarring to avoid premature detonation because most
firing heads use shear pins.
8) Run the string to set the guns approximately on depth.
9) Rig up the main logging cable and run a gamma ray logging tool down to the
correlation depth. Tie on depth to the reference log and record sufficient film to show
both radioactive pip markers and any zones of gamma ray character on the log.
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10) The required spacing out should be calculated according to the section 8.
11) Set the packer and land the completion string. If there is any doubt about the space
out, re-run the gamma ray tool to ensure that the guns are set on depth.
12) Install the surface equipment (Xmas tree or flowhead) and pressure test as per the
well programme.
13) Circulate the cushion into place and line up the well to flow.
7) Run in at reasonable speed to detonate firing head. The slickline operator should note
the depth and time.
8) If there are definitive signs of the guns firing, continue pulling out. If there are no
indications of detonation, check the tag depth of the firing head to check for debris. If
there is debris, attempt to jar through it. If there is no debris, observe the well for
30min, after which if there is no change, jar down twice again before pulling out.
9) Pull the tool back into the lubricator. Close the tree upper master valve and bleed off
pressure through the flowline.
Close the swab valve and recover and inspect the firing bar impression nose. If
there is an impression, it is very likely that the guns have fired. But if there is no
impression of the firing head then the string is blocked by debris. If there is a
back up firing system, it should be employed. Otherwise reverse circulate or
attempt to bail the well.
Pick Up Procedure
Refer to Figure 5-1 TCP Anchor System.
1) The guns should be pre-loaded and spaced, and laid out in numerical order on the
pipe rack. The bottom gun (#1) should be next to the catwalk and the top gun, hanger
and firing system furthest away.
2) The 20ft section gun will be lifted up the V-door by the platform crane, using slings
double wrapped. Alternatively, if lift subs are attached to the guns, single joint
elevators and an air winch may be used.
3) Do not lift by means of the thread protectors.
Note: Never move a gun section that does not have protection on each
connection.
Note: The dog collar must always be made up prior to unlatching the elevators.
(As the gun assemblies have no external set up)
Radioactive sources are present within the gun. These pip tag positions
have been labelled on the outside of the carrier and no contact should be
made at these markings by the rig crew. (Radiation levels will be
monitored by an Instruments Engineer)
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4) Make up the anchor assembly complete with setting tool and a 27/8 ins EUE pup joint.
5) Make up a 30ft joint of 27/8in EUE tubing, crossover and RA marker sub. Check gun
assembly weight.
6) In order to prevent surging or mechanical shock when running or pulling armed guns,
running speeds should be restricted, particularly through downhole restrictions.
7) The guns should be handled carefully at all times to avoid shock, and time taken to
make connections etc. Slips should be set gently. In bad weather, use tag lines when
lifting. Try to keep the lift subs clean. Do not set a gun down on an unprotected pin.
Running Procedure
1) Rig up slickline lubricator and pressure test against swab valve. Care must be
exercised to not exceed the minimum shear pin rating of the firing head.
2) Run in with firing head, sinker bars and spang jars.
3) Continue slowly going in the hole and stop 30ft above the receptor.
4) Pull up and record pulling weight.
5) Continue to run in hole and locate receptor and jar down gently to latch confirm latch
by over pulling 300-500lbs above pulling weight.
6) Jar down to release firing head. Recover toolstring to surface.
7) Before commencing the pressuring up operation, the shot detection chart recorder
should be set and running.
8) Tubing pressure can now be applied to fire the guns. Pressure the tubing steadily up
to the predetermined level to shear the pins (upper limit), hold for 1 min, then bleed off
swiftly to the required tubing pressure (for correct underbalance).
Note: Once the pins have sheared, the hydraulic time delay begins and the guns
will fire when the delay is complete.
9) If no shot is detected, wait 11/2 times the estimated delay. Slowly increase the tubing
pressure until the pressure below the packer is just above formation pressure. Shut in
the well and monitor for fluid leak-off. If there is no leak-off into the formation, increase
tubing pressure to the tubing test pressure or leak-off pressure, whichever is lower.
Hold briefly and bleed off swiftly to the required underbalance pressure and continue to
1
monitor for firing. If no shot is detected after 1 /2 times estimated delay, resort to
secondary firing system.
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5.7.1.1 CONNECTOR
Gun Connector is the ballistic link between the gun sections in the Lubricator.
Connector consists of a sealed ballistic transfer system and in a mechanical connector
activated by an external manipulation.
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General procedures
The following generic check list is an example of what should be used to ensure the safe
deployment of the guns into the well.
Check list shall be developed between Company and Coiled Tubing contractor to ensure
that objectives such as safety and best practices are met.
1) A pre-job safety meeting should be held prior to commencing the rig up operation (ref.
on herein par.5.4.2)
2) The tool string should be checked and the distance from the Casing Collar Locator
(CCL) to top of guns accurately measured.
3) Pressure tests shall be carried out on surface equipment as per Contractors
procedures and all tests shall to be recorded on chart recorder and signed by
Contractors operator and Company Supervisor.
4) BOP and BOP Deployment stack must be functionally tested with the Connector
system installed.
5) Guns sections should be loaded as per programme and the Connectors installed on
their terminations.
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6) All pressure operated firing system and associated tools should be verified and ensure
that are compatible with each other.
7) Hydraulic calculations must be checked and approved by Company Supervisor prior to
make up the gun string.
8) Each gun sections with the Connector installed should be individually measured and
numbered; all measurements should be cross checked by the Company Supervisor.
9) Contractors Supervisor must make a drawing of the bottom hole assembly showing
the relative position of all tools in the well bore.
10) Verify presence and compatibility of all the pick-up subs and lifting equipment.
All the gun sections and the safety spacer are made up following the steps a to l.
NOTE: The wireless CCL technology enables coiled tubing operations to benefit
from real time surface read out with the accuracy of an electric line,
p) Remake the Lubricator connection and conduct the required pressure testing.
q) Run in hole few hundred feet, start pumping to confirm that the depth correlation tool
(CCL) is functioning and data acquisition is available from the tool.
r) When CCL is confirmed operational, RIH the BHA to the TD and correlate with the
existing logs. (for Coiled Tubing running procedure ref. par.13.5)
s) Displace completion fluid by circulating through the BHAs proper port a volume to be
confirmed by Company Supervisor, to give the required under-balance.
t) If required make the final correlation log as per Company procedure.
u) When depth as been correlated, apply injector break and proceed with the steps to
activate the firing system. (par. hereinafter)
v) Observe well for indications of gun firing.
Warning:
Flowing the well at surface has to be avoided to prevent CT and BHA to became stuck in
wellbore by the presence of perforators debris in the CT/Tubing annulus.
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Other electronic type firing head use Electromagnetic Telemetry waves sent through a
power amplifier through the earth to a downhole receiver which decodes the signal and
activates a controller assembly to release the safety mechanism allowing the firing pin to
detonate the gun.
The following generic check list is an example of what should be used to ensure the safe
deployment of the guns out of the well.
Check list shall be developed between Company and Coiled Tubing contractor to ensure
that objectives such as safety and best practices are met.
a) Start to POOH maintaining balanced pressure in the annulus and inside CT and
continue to monitor and record the two pressures.
b) Pull back BHA into Stripper to zero-depth reference
c) Run back to position the Connector across the No-Go Rams into Deployment Stack.
Record CT weight.
d) Record Static Tubing Head Pressure (STHP), close SCSSV and if required displace
well fluid from Lubricator and surface wellhead.
4) Ensure that the following slickline tools are available and on site:
Overshot designed to catch the fishing neck
11/4 ins OD bailer
11/4 ins lead impression block
Chisel point bailer bottom for the 11/4 ins bailer.
5) Make sure that the length of the lubricator is adequate to accommodate the toolstring
and the length of the detonating bar if recovered.
6) Confirm the distance from the firing head to the ports in the tubing string. This should
be sufficient to allow both the toolstring and detonating bar to remain below the ports.
7) Rig up slickline and prepare the toolstring with an overshot to catch the detonating bar.
8) When running in hole, confirm the fluid level in the well. Record this depth.
9) Shot detection equipment will be used and it should be monitored during all fishing
operations and attempts to fire the guns.
10) When the detonating bar is located, spud down as hard as possible. Do not pick up
straight away. If the bar moves, chase it to the firing head as quickly as possible. This
will ensure that the slickline tool will not be above the entry ports (should the guns fire)
and be blown up the well. Repeat this process three times.
11) If the guns do not fire fish the detonating bar and pull out of the hole.
1/4
12) Rig up with 1 ins bailer and Chisel Point bailer bottom. The bailer should be
dressed to a sharp point.
13) Run in the hole and jar down as hard as possible on the firing pin. Again ensure that
the toolstring does not get pulled above the entry ports. Pull out of the hole and
inspect the leading edge of the chisel point. Damage will indicate whether or not
something hard (firing pin or foreign object) is being struck.
14) Carefully observe for any material recovered in the bailer, it may indicate what is
preventing the detonating bar from reaching the firing pin. Fine black powdery
deposits are an indication that the guns have fired and will be associated with a smell
of burnt cordite. Hydrocarbons may also be present.
15) Repeat bailing operations until it is certain that the bailer is striking the firing pin.
16) If it becomes obvious that the bailer is striking something other than the firing pin, run a
lead impression block.
17) Check the fluid level in the well during every wireline run. Monitor carefully for
losses/gains.
18) When it has been determined that the firing pin has been struck, and the guns have
not fired, pull out of the hole with the drop bar.
19) In the event that a retrievable head has been used, this should be retrieved at this
point and inspected.
If it has not fired, run another firing head on slickline and repeat the procedure.
If the head has fired, rig down wireline.
20) Top up the well with fluid, and if not already done so, rig up circulating lines from the
cement unit to the production string. Attempt to pump into the formation to confirm
that the guns have not fired. The leak-off pressure should be taken into consideration.
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21) Unseat the packer and circulate the well contents to kill fluid. Circulate and condition
the brine. Prepare to pull the completion and retrieve the guns.
22) Once the firing head has been retrieved the guns are safe, and can be pulled from the
well.
23) If it proves impossible to retrieve the detonating bar, the string and guns will have to be
pulled. This is potentially very hazardous. Refer to base and seek the advice of the
TCP gun manufacturer and senior Company personnel. No further action should be
taken without written instructions endorsed by all parties concerned.
1) If no indication of the guns firing is observed, twice the duration of the time delay
should be allowed before repeating.
2) If the guns will not fire at the design pressure, increase the pressure (in increments of
500 or 1,000psi) and re-apply, allowing twice the time delay before repeating.
3) Monitor any fluid gains or losses.
4) Monitor the shot detection equipment. In the event that it is established that the guns
will not fire, the TCP representative on location will evaluate the situation in conjunction
with the Company representative. Both Company and the TCP contractor bases will be
consulted. A detailed procedure will be prepared based on the current status of the
operation, prior to any further action.
There are two gravel pack applications, one for open hole completions and the other for
inside cased hole. This section contains the common procedures for both open hole and
internal gravel packing.
For perforating gun applications and gun design options, refer to the Company Completion
Design Manual (STAP-P-1-M-7100).
Open Hole
Step 1
Calculate the total annular volume outside the screen to the planned height of the sand:
Total Annular Volume = Screen/Hole Annulus + Blank Pipe/Hole Annulus + 40-60ft
volume surplus
If the planned sand height was up into the casing, this reduced volume would need to be
considered.
Step 2
Calculate the volume of sand in the rat hole, if applicable:
Hole volume below screens.
Step 3
Calculate total sand required:
Add the calculated volumes from steps 1 and 2.
Internal
Step 1
Calculate the annular volume outside the screen to the planned height of the sand:
Screen/Casing Annulus + Blank Pipe/Casing Annulus + 40-60ft volume surplus
Step 2
Calculate the volume of sand in the rat hole, if applicable:
Hole Volume below screens
Step 3
Calculate the volume required for the perforations:
3
Length of Perforations x Volume factor (usually 1ft /ft)
Calculate total sand required:
Add the calculated volumes from steps 1, 2 and 3.
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Note: All fluids pumped downhole during the completion phase must be filtered
prior to use.
3) Run in hole with casing scrapers and a short open ended tailpipe on workstring.
Thoroughly scrape the casing through all intervals to be perforated and all packer
setting depths (Refer to section 4.2).
4) Displace the wellbore fluid with the filtered completion fluid. Circulate with filtered
completion fluid till returns are clean according to the well programme.
5) Rig up electric line. Make gauge ring and junk basket run to TD. Pull out of the hole
with the gauge ring and junk basket, if necessary.
6) Verify screen gauge and gravel delivered is correct according to the well programme.
Note: Apply thread compound sparingly to the pin ends of the connections
only.
11) Run in the hole slowly with the completion assembly (90sec per 90ft stand). Set down
into, and pick up gently out of, the slips.
12) Record the pick-up and slack-off weights when reaching the packer setting depth.
13) Once the assembly is positioned on depth, rig up the gravel infuser pumping
equipment, manifold and lines. Test to 5,000psi.
14) Establish circulation, record circulating pressure and drop the packer setting ball.
Allow time for ball to gravitate to the ball seat in the crossover tool, roughly
5min/1,000ft.
15) Set the packer by slowly pressuring up the workstring according to the steps and
pressures stated in the well programme.
16) Verify slip anchoring of the packer by alternately setting down and picking up 10,000-
15,000lbs weight.
17) Slack off to the neutral position and test the packer by pressuring the casing to
1,000psi for 5min.
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18) Since 1,000psi annular pressure releases the crossover tool from the packer, the
crossover tool may now be snapped out of the packer. Alternatively, the crossover tool
may be released from the packer by turning 15 rotations to the right at the packer
depth holding a slight upstrain.
19) Raise the crossover tool to the reverse circulating position. Apply the appropriate
workstring pressure to shear the ball seat in the crossover tool. Break circulation in the
reverse direction at 3bpm and record the pump pressure.
20) Pickle the workstring by circulating the pickling agent to the end of the workstring.
Reverse circulate 1.5 workstring volumes of filtered completion fluid until returns are
clean.
21) Lower the crossover tool and set down 10,000lbs on the packer. This is the squeeze
position; mark the pipe at the rotary table level. Establish injection pressures at 3, 2, 1,
and 0.5bpm. Do not exceed the formation fracture pressure.
22) Raise the crossover tool to neutral weight plus an additional 2ft. This is the circulating
position;
1
mark the pipe at the rotary table level. Establish circulating pressures at 3, 2,
1, and /2 bpm. Monitor the return rate with a flowmeter to determine the leak-off rate
to the zone. If full returns are observed, partially close the annular BOP to hold back-
pressure and induce leak-off. Do not exceed the formation fracture pressure.
23) Raise the crossover tool to the reverse circulating position. Infuse gravel pack sand
into completion fluid at the desired mix ratio and pump a circulating rate of 3bpm. 1 A
pump rate of 3bpm must be maintained to achieve a fluid velocity of 500ft/min in 3 /2
workstring.
24) When the sand is 5-10bbls above the packer, lower the crossover tool into the
circulating position. Continue displacing the gravel with filtered completion brine until
an initial pressure increase is observed due to gravel covering the screens. While
pumping, allow the pressure to build to 1,500-2,500psi over the initial circulating
pressure at a1 given rate. Maintain this sandout pressure while slowing the pump rate
to 2, 1, and /2 bpm. Allow the pressure to bleed off to the formation. Calculate the
gravel height above the screen top using the linear flow equation.
25) Do not re-stress the pack. Close the annular BOP and apply 500psi to the annulus.
Raise the crossover tool to the reversing position. Reverse out excess gravel plus two
workstring volumes. Divert the gravel returns to the slurry dehydration tank and
determine the volume of gravel reversed out. The volume of gravel placed can then be
calculated by subtracting the volume reversed out and the screen/open hole, blank
pipe/open hole and blank pipe/casing annular volumes from the total volume of gravel
pumped.
26) To test the gravel pack, lower the crossover tool into the circulating position and
attempt to circulate at the same rate and pressure achieved earlier. If sandout
pressure cannot be achieved, mix and pump another batch of gravel. Reverse out
excess gravel. Repeat this step until final sandout occurs.
27) Pull out of the hole with the service toolstring.
28) Revert to the completion procedures in the completion programme.
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Note: Use a Tubing Conveyed Perforating system with the highest possible shot
density (typically 12spf), with Gravel Pack or Big Hole charges.
Note: This operation should be performed with the underbalance stated in the
well programme (normally 500-1,000psi depending on the formation
strength.
5) Verify the proper positioning of the perforating guns by tagging the sump packer and
space out the string at the correct depth.
6) Set the packer.
7) Rig up the control head and surface lines (if on a floater this will be done before step 6
above).
8) Detonate the perforating guns by appropriate procedure.
9) Flow the well to sufficiently remove all debris from the perforations.
10) Reverse circulate two workstring volumes with filtered completion fluid to stabilise the
well. Continue circulating and filtering until returns are clean.
11) Monitor the well to determine if it has stabilised. Record any fluid losses or gains. If
necessary to control fluid loss, spot a fluid loss control pill.
12) Unseat the packer and reciprocate the string to fully release the packer and repeat one
more complete circulation.
13) Pull out of the hole with the TCP assembly, monitoring for fluid losses.
14) If there is evidence of formation sand in the returns, pick up and run a scraper with a
tailpipe to enter and wash down to the sump packer.
15) Pick up and assemble the gravel pack assembly in the rotary table as follows, from
bottom up, running at a slow speed to prevent damage to the packing element and to
prevent prematurely setting the packer.
Snap Latch Seal Assembly
Sand screens
Blank pipe
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16) Run flush joint washpipe inside, and to the bottom of, the screen through the blank
pipe. The assembly consisting of the following items is then picked up and made up
onto the screen assembly.
Knock Out Isolation Valve
Shear Out Safety Joint
Crossover Sub
Gravel Pack Extension with Sliding Sleeve
Gravel Pack Packer.
17) The gravel pack service toolstring assembly is then made up to the previous assembly:
Shifting Tool
Gravel Pack Crossover Tool
Hydraulic Setting Tool.
Note: Apply thread compound sparingly to the pin ends of the connections
only.
18) Run in hole slowly with the completion assembly (90sec per 90ft stand). Set down into,
and pick up gently out of, the slips.
19) Record the pick-up and slack-off weights when reaching the packer setting depth.
20) Record pick-up and slack-off weights one stand above the sump packer. Tag the
sump packer and set down sufficient weight to force the latch of the snap latch to
engage the packer. If desired, the latch may be snapped out of the packer with pull to
verify correct operation.
21) Once the assembly is positioned on depth, rig up the gravel infuser pumping
equipment, manifold and lines. Test to 5,000psi. Establish circulation, record
circulating pressure and drop the packer setting ball. Allow time for ball to gravitate to
the ball seat in the crossover tool, roughly 5min/1,000ft.
22) Set the packer by slowly pressuring up the workstring according to the steps and
pressures stated in the well programme.
23) Verify slip anchoring of the packer by alternately setting down and picking up 10,000-
15,000lbs weight.
24) Slack off to the neutral position and test the packer by pressuring the casing to
1,000psi for 5min.
25) Since 1,000psi annular pressure releases the crossover tool from the packer, the
crossover tool may now be snapped out of the packer. Alternatively, the crossover tool
may be released from the packer by turning 15 rotations to the right at the packer
depth with a slight upstrain.
26) Raise the crossover tool to the reverse circulating position. Apply the appropriate
workstring pressure to shear the ball seat in the crossover tool. Break circulation in the
reverse direction at 3bpm and record the pump pressure.
27) Pickle the workstring by circulating the pickling agent to the end of the workstring.
Reverse circulate 1.5 workstring volumes of filtered completion fluid until returns are
clean.
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28) Lower the crossover tool and set down 10,000lbs on the packer. This is the squeeze
position; mark the pipe at the rotary table level. Establish injection pressures at 3, 2, 1,
and 0.5bpm. Do not exceed the formation fracture pressure.
29) Raise the crossover tool to neutral weight plus an additional 2ft. This is the circulating
position;
1
mark the pipe at the rotary table level. Establish circulating pressures at 3, 2,
1, and /2bpm. Monitor the return rates with a flowmeter to determine the leak-off rate
to the zone. If full returns are observed, partially close the annular BOP to hold back-
pressure and induce leak-off. Do not exceed the formation fracture pressure.
30) Raise the crossover tool to the reverse circulating position. Infuse gravel pack sand
into completion fluid at the desired mix ratio and at a circulating rate of 3bpm. A pump
1
rate of 3bpm must be maintained to achieve a fluid velocity of 500ft/min in 3 /2
workstring.
31) When the sand is 5-10bbls above the packer, lower the crossover tool into the
circulating position. Continue displacing the gravel with filtered completion brine until
an initial pressure increase is observed due to gravel covering the screens. While
pumping, allow the pressure to build to 1,500-2,500psi over the initial circulating
pressure at1
a given rate. Maintain this sandout pressure while slowing the pump rate to
2, 1, and /2bpm. Allow the pressure to bleed off to the formation. Calculate the gravel
height above the screen top using the linear flow equation.
32) Do not re-stress the pack. Close the annular BOP and apply 500psi to the annulus.
Raise the crossover tool to the reversing position. Reverse out excess gravel plus two
workstring volumes. Divert the gravel returns to the slurry dehydration tank and
determine the volume of gravel reversed out. The volume of gravel placed behind the
casing can then be calculated by subtracting the volume reversed out and the
screen/casing and blank pipe/casing annular volumes from the total volume of gravel
pumped.
33) To test the gravel pack, lower the crossover tool into circulating position and attempt to
circulate at the same rate and pressure achieved earlier. If sandout pressure cannot
be achieved, mix and pump another batch of gravel. Reverse out any excess gravel.
Repeat this step until final sandout occurs. Pull out of the hole with the service
toolstring.
34) Revert to the completion procedures in the completion programme.
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Service
Seal Unit
With X-Over
Open
Automatic
J-Latch
Shear Pins
Tying Seal
Unit to Packer
Production
Permanent- Seal Unit
Retrievable
Packer
Swivel
Saftey
Joint
Gravel Pack
Sand Screen
Service
Seal Unit
With X-Over
Open
Automatic
J-Latch
Shear Pins
Tying Seal
Unit to Packer
Production
Permanent- Seal Unit
Retrievable
Packer
Swivel
Saftey
Joint
Gravel Pack
Sand Screen
7. PACKER INSTALLATION
In some completion programmes, packers may be set on electric wireline, such as when
installing reference packers for gravel packs or using a packer as a plug. Normally it is
preferred to install a production packer on the completion tubing string in order to obtain
single trip installation saving unwarranted wireline trips and, hence, reduce cost. Refer to
the Completion Design Manual (STAP-P-1-M-7100) for various packer completion designs
and installation methods.
An advantage of setting a packer on wireline is its quick and simple and accurate setting.
This ensures that the packer is not set across a casing coupling or can be used as a
reference for TCP gun depth correlation. A disadvantage, other than trip cost saving, is that
the packer is not pressure tested until the tubing string is installed.
Packers to be set in highly deviated wells may be installed on a workstring where wireline
would not reach. The packers set on a workstring can be set mechanically or hydraulically by
applying pressure to the workstring.
Selective completions may have a number of tubing retrievable type packers installed in a
single trip which are set in sequence.
Company policies for the use of retrievable and permanent packers are fully outlined in the
Companys Completion Design Manual (STAP-P-1-M-7100).
Both tubing and wireline set packer installation procedures are described in this section.
Note: Do not tag the packer after setting, as the adapter kit may become stuck
in the packer, resulting in a fishing job.
19) Pull the tool back to surface carefully, ensuring that all radio silence procedures are
followed.
20) When the toolstring is back at surface, inspect the adapter kit and setting tool to verify
the proper setting of the packer, handling carefully in case there has been a misfire.
21) Release any pressure from the setting tool and rig down.
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8. COMPLETION INSTALLATION
The procedures in this section describe the procedures for equipment pre-installation
checking and completion installation.
8.2.1 Transportation
Handling, transportation, and temporary storage of tubular goods will comply with Section 3
of API RP 5C1.
Note: Where possible, the pipe should be racked at a 20o incline to ensure
proper drainage of water, with the box end being raised to prevent
accumulation of water in the threads.
9) As each row is laid out the thread protectors will be removed and cleaned and the
threads cleaned and inspected by an approved thread inspector, i.e.:
Clean the threads using a steam jet.
Do not use oil based solvents and wire brushes.
Dry the threads with compressed air.
Apply a thin coating of Molycote to the clean threads.
10) If driftable open ended protectors are provided then they will be installed (after
cleaning as above), and the tubing drifted with the appropriate size drift.
11) If closed end protectors are provided then they will be installed after drifting the tubing.
12) The tubing will be drifted from end to end using a nylock drift to API/ISO spec. The drift
dimensions will be as per (API RP 5A5):
7" 29 lbs/ft 6.059" (153.9 mm)
51/2 " 17 lbs/ft 4.767" (121.1 mm)
1
4 /2" 12.6 lbs/ft 3.833" (97.3 mm).
13) The diameter of the drifts will be checked regularly during the drifting operation.
14) Extreme care should be taken at pin and box sealing areas.
15) If a joint is rejected for any reason, i.e. fails to drift, or if the threads are damaged, the
joint will identified with red paint. It will then be repackaged and sent back onshore. A
report detailing the reason for rejection will be sent to the Workover Superintendent in
the Company office.
16) The tubing will be measured from the end of the coupling to the pin threads by the
designated Company Representative and the entire length corrected for make up loss.
For shouldered connections measure the length from box end to the shoulder on the
pin.
17) Record the joint number as per stencilled description. The measurements will be
recorded on the tubing tally form.
18) Make up loss details should be sourced from manufacturers technical data sheets.
Note: A thread compound described as API Modified does not necessarily have
a friction factor of 1.
1) Avoid contamination of the thread compound by water, rain, snow, etc. whilst it is being
applied.
2) Do not use thread compounds which have been contaminated by any kind of
extraneous matter, i.e. sand, dirt, water, solvent, drilling fluid, etc. It is recommended
to use a new can of compound and new brushes for application.
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Note: When using a brush, it is easy to over apply the joint with thread dope.
By applying thread compound to the pin end only the amount extruded
into the tubing as the connection is made up will be minimal, thus
minimising any build up on wireline tools, and contamination of the
formation.
7) For VAM connections the minimum quantity of dope required is given by the following
relationship:
Minimum weight (grams) = 10 x pipe OD (ins)
i.e. 51/2 pipe requires 55 grams or 2 ounces.
8) Store thread compounds in a clean, warm, dry environment away from direct sunlight.
Upturn the compound containers periodically while in storage to prevent solids
separating out.
9) A thread inspector must inspect all threads.
5) Pick up lines to the single joint elevators will be arranged to allow the joint to be
stabbed to hang vertically over the hole, so that no undue pull will be exerted on one
side during make up.
6) The tubulars will be transferred to the catwalk with thread protectors installed. Nylon
slings wrapped around the joints will be used for lifting purposes.
Note: On no account will metal slings be used when handling chrome tubulars.
All new tubulars will be supplied with Econowrap LE.
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7) Use single joint pick up elevators for handling tubulars onto the drill floor.
8) Tubing slips will be dressed with low stress dies.
9) Care will be taken when setting pipe in the slips to prevent shock loading and impact
damage.
10) After removing the thread protector the threads will be cleaned and inspected (if not
already done on the pipe deck).
Note: Do not use a wire brush for cleaning chrome thread forms.
11) Any joints with damaged threads will be laid out, and clearly identified.
12) Apply API Modified thread compound with a friction factor of 1, using an automatic pipe
dope applicator (Refer to section 8.2.6)
13) A non-metallic (i.e. plastic) stabbing guide will be used to guide the pin correctly into
the box.
14) The joint will be lowered slowly into the stabbing guide to allow the man on the
stabbing board, and the man on the rig floor to guide the pin into the stabbing guide.
Throughout the stabbing operation the pipe should be kept as vertical as possible.
15) If the stabbing operation was unsuccessful both pin and box threads will be inspected
for damage. If the box was damaged consideration will be given to replacing it. If the
pin was damaged the joint will be laid out.
16) After successfully stabbing the pipe the first four or five turns of the make up will be
done by hand using a nylon strap wrench.
17) The last turns will be made using a torque turn unit with a graphical torque turn
analyser to confirm the correct make up value.
18) The make up speed should be between 3 to 10rpm. Final make up should be at 5
RPM.
19) The running speed will be limited to a maximum of 14 joints per hour.
8) Once the thread has been broken the connection will be backed off using a strap
wrench.
9) The threads will be cleaned using a high pressure jet of fresh water, or a quick
evaporating petroleum solvent (chlorine free), and then dried. High pressure cleaning
equipment must be used in accordance with platform procedures.
10) After inspection of the threads storage, compound will be applied and clean thread
protectors installed.
Note: If LSA scale is present, closed end protectors will be installed and the
joints clearly identified as being LSA contaminated. The designated
responsible person will check all tubing joints for LSA scale
contamination and will ensure that the correct action, documentation,
manifesting and notifications are adhered to for shipment of all LSA scale
contaminated tubulars.
11) The tubulars will be transferred from the rig floor using nylon slings wrapped around
the joints.
Note: On no account will metal slings be used or hooks inserted into the pin
and box ends.
Note: If possible, the crane will be used to lift the joints from the rig floor to the
transport boxes.
12) Each joint will be clearly marked, and an 'as pulled' tally prepared by the Well
Operations Supervisor.
13) Before placing the tubulars in their transport frames they will be flushed with fresh
water.
14) Any joints with damaged threads will be clearly identified and laid out for back-loading
in a separate transport frame.
15) A detailed report will be prepared by the Well Operations Supervisor on the condition
of the recovered tubulars. This report shall contain details of thread damage,
corrosion, scale build up, position in well of damaged tubulars, etc., and will be
forwarded to the Completions and Workover Superintendent in the Company office.
8.3.7 Flowline
Check with the Production Supervisor that the flowline is on site and that it is the correct
length (the amount of curvature applied to coflexip flowlines is critical) and that it is ready to
be connected to the Xmas Tree.
Also confirm that the tree choke valve is present on site.
8) Check the composition of the completion fluid at regular intervals, and maintain the
required levels in the tubing and annulus.
9) If running chemical injection or downhole gauge systems, attach an across-coupling
and mid joint protectors (one each per joint) to secure the lines to the tubing. Do not
over-tighten to allow movement for stretch induced by temperature changes. Pay
particular attention to the lines when lowering the slips.
10) When changing tubing sizes, count all the remaining previous tubing left on the pipe
rack. Make sure that this agrees with the running list. If there is a problem do not
proceed until it has been resolved.
11) Continue running the completion to depth where the SCSSV is to be installed.
Pressure test the tubing string to the pressure given in the well programme.
12) Make up the SCSSV. Install the control line and pressure test to the pressure stated in
the well programme for 15min. Bleed off the pressure to WP and maintain this
pressure whilst running in the hole. Secure control lines with the across-coupling and
mid joint protectors.
13) When running tubulars with control lines attached, take care to ensure that the string is
properly centralised to prevent stripping off the protectors.
14) When pressure testing equipment, build up pressure slowly. Pressure should be built
up in a series of stages to the required maximum. Maintain pressure for the required
time and record on a suitable chart recorder.
15) After the final space out, drift the complete string using an appropriate drift.
11) Check the completion running list; make sure that all remaining equipment left on deck
agrees with the running list.
12) Rig up slickline and set a standing valve in the tubing nipple. Pressure test the tubing
integrity to the pressure stated in the well programme. The SCSSV control line
pressure must be increased to the appropriate pressure when conducting this test (test
pressure + valve opening pressure + margin), refer to the following sections on SCSSV
installations. Retrieve the standing valve.
13) Set a standing valve in the packer tailpipe nipple.
14) Check that the packer is at the correct setting depth. Slowly pressure up the tubing to
the specified differential pressure according to the programme. The shear screws
locking the packer setting mechanism will shear with the applied tubing pressure
differential, then the setting cycle of the slip mechanism will be complete, and the pack
off element fully set. Hold the setting pressure for 10min.
15) After setting the packer, pressure up to pressure test the entire completion string. Hold
the pressure until a 15min straight line is recorded on the recorder. Records of this
test are to be retained in the well files.
16) Run in hole with slickline and retrieve the standing valve.
17) Pressure up the well through the production string to pressure test the packer from
below. This test should be according to the programme (or the same as the casing
test pressure), observe the pressure is stable for 15min.
18) Pick up to shear out the tubing movement device, if applicable. This should be
observed at surface.
19) Set down and slack off string weight, land and set the surface hanger as per the
manufacturers instructions. This operation may sometimes be carried out prior to
setting the packer.
20) Pressure test the annulus according to the programme; observe the pressure is stable
for 15min.
21) If the well has been perforated, set a wireline plug in the tubing string and the plug in
the tubing hanger profile.
An alternative procedure for testing the packer without having to remove the tailpipe plug, is
to utilise a ported slick joint in the landing string on which the pipe rams or annular can be
closed. The packer is then pressure tested by applying 500psi to the annulus. This saves
installation time.
6) Lock and monitor the pressure in on the reel keeping the valve open as it is run in the
hole preventing pressure locking, allowing the string to self fill and checking for control
line leaks.
7) Attach an across-coupling protector at the first connection and ensure the control line
is flat against the tubing and is in tension.
8) Run in the hole on tubing applying the protectors at every connection and mid joint,
keeping tension on the control line. Never rotate the tubing with control line in the
hole.
9) When the spacing out procedure has been completed, wrap the control line around the
pup joint below the hanger to provide contingency if the line is damaged during make
up and landing.
10) Bleed the pressure off the control line, cut it and connect it to the hanger control line
port.
11) Attach the remaining control line from the reel to the exit port in the hanger and
pressure test the line according to the completion programme.
12) Reduce the pressure to the required calculated operating pressure.
13) Land off the completion, install barriers, perform all hydraulic tests and close the valve
prior to rigging down the BOPs.
14) Remove the control line.
15) Install the Xmas tree, pressure test and function test.
16) Cycle the SCSSV, checking the returns are per specification ensuring the valve is fully
opening and closing.
17) Continue with the Completion Programme.
10) Bleed the pressure off the control line, cut it and connect it to the hanger control line
port.
11) Attach the remaining control line from the reel to the exit port in the hanger and
pressure test the line according to the completion programme.
12) Reduce the pressure to the required calculated operating pressure.
13) Land off the completion, install barriers, perform all hydraulic tests and close the valve
prior to rigging down the BOPs.
14) Remove the control line.
15) Install the Xmas tree, pressure test and function test.
16) Continue with the Completion Programme, pulling the dummy valve and installing the
SCSSV according to the procedures in the General Wireline Procedures Manual
(STAP-P-1-M-7110).
If direct acting SSSVs (storm chokes) are being used, they will be calibrated and then
installed also according to the procedures in the General Wireline Procedures Manual
(STAP-P-1-M-7110).
An option to steps 5 through 8 is to install a check valve on the SCSSV control line port and
open the valve locking in the pressure. This then allows tripping in the hole to space out
without the control line in the hole.
On top of the last casing spool it is mounted the Tubing Spool which, rated for the maximum
well pressure and made of the proper class of material, has the function of suspending the
completion, providing a load shoulder for the Tubing Hanger.
It is composed of a lower connection, one or two side outlets and a top connection with an
internal Tubing Hanger bowl.
As well as the Casing Head Spool, the two studded outlets (normally 2 nominal) allows the
annulus control and monitoring; in particular one outlet is usually provided with a flanged
Gate Valve; the other outlet with a companion flange and a monitoring pressure gauge
The tubing spool seals around the production casing either with the Annulus Packing
assembly or with a metal pack-off when this is required.
A secondary seal recess is provided in the lower flange to accommodate the production
casing secondary seal unit, normally elastomeric type. Secondary metal seal can be
foreseen in HP/HT wells.
The top flange is usually equipped with Lock Down Screws to hold the Tubing Hanger down
under light loads or to energise the Annulus Packing.
Completion is suspended inside the Tubing Head Spool by means of the Tubing Hanger.
The Tubing Hanger seals inside the Tubing Head Spool either with an elastomer pack-off
assembly or with a metal pack-off when this is required.
Tubing Hanger also shall be anchored inside the Tubing Head Spool to avoid that, during
production it can be lifted off by the tubing string elongating for temperature increase; this is
usually accomplished by tie-down screws which radial acts on a conical shaped ring which at
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Tubing Hanger top preparation is designed to fit different Tubing Head Adapter (Seal
Flange) bottom bowl shapes:
in its simplest version it can have a solid neck which intrudes inside the Tubing
Head Adapter ( Bonnet) where O rings segregates circumferential galleries for
Safety Valve/s Control Line/s hydraulic control fluid.
transfer carriers throughout the hanger body which seals inside the Tubing Head
Adapter body can be provided. These transfer carriers can be provided with
elastomeric O rings or with metal seals (crash rings usually manufactured with a
softer plastic stainless steel).
in other cases, Control Lines continuous type, have separate outlets through the
Tubing Head Adapter or Tubing Head Spools body ; so their is granted by
passages through the Tubing Hanger body . Block Terminations arrangements
are provided on Control Line exit.
Tubing Hanger internal profile always foresees either for a seat for the Back Pressure Valve
or for a wireline plug. Both devices have the scope of plugging the production bore before
removing the X-mas tree and nippling up the BOPs.
The advantage of the wireline plug against the use of the BPV, is the possibility to run or
retrieve it under pressure using normal wireline pressure equipment, while the retrieval of
BPV under pressure requires the use of special tools.
Is the equipment which adapts and seals the Tubing Hanger to the lowermost Christmas
Tree bottom connection.
Tubing Head Adapter bottom bowl shall accommodate the elastomeric or metal seal pack
off to seal on Tubing Hanger neck and appropriate Test / Vent Ports should be provided for
test all the sealing elements.
It also provides access to the casing tubing annulus through side outlets.
Control Line exits are foreseen on Tubing Head Adapter body when Tubing Hanger with
Control Line Transfer Mandrel is used.
In Continuous Control Line configuration, Control Line exits can be provided on Tubing Head
Adapter or through the Tubing Head Spool body.
If the individual valves and fittings are bolted together the Tree is referred as Composite
Tree.
However, if the Tree consists of a solid steel forging with the valves and fittings machined
into it, is called Solid Block Tree. Solid block Tree, being more compact, offer space-saving
advantages, therefore, are particularly suitable for off-shore production platforms or cluster
lay out land wells.
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NOTE: On off-shore locations one master valve and at same time the wing valve
will be fitted with a hydraulic or pneumatic Actuator and serves as an
automatic surface safety valve. The uppermost valve called Swab Valve,
sometimes Lubricator or Top Valve, is used primary for well access by
wire line or other intervention techniques.
Valves used on X-mas Tree are almost invariably the Gate type Valve, providing full bore
access to the well.
Gate Valves for Xmas Tree are of different configuration mainly with respect:
Valves for application at working pressure above 5000 psi can be provided with balanced
stem, because this eliminates the hydrostatic thrust on the stem itself and eases the
operations.
Figure 8-1 Slab Gate Valve Figure 8-2 Expanding Gate Valve
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Actuators for Surface Safety Valves can be Hydraulic or Pneumatic type according to the
safety system design and power supply available.
Both type of actuators can be easily replaced on the field without removing the Valve from
the line.
Hydraulic actuators use hydraulic fluid (control fluid) as external source to move a piston
counterbalanced by a spring which, when hydraulic power would be removed will cause the
gate valve to fail safe close; properly sized coil springs provide a reliable return stroke to
close.
The new design of actuators usually allows easy conversion in the field of manual gate
valves to automatic.
Sound engineering practices in selecting an actuator should look at the exposure of seals to
the environment and to the correct coating of surfaces contacted by saline offshore
atmosphere.
Also considerations should be placed on the volume of hydraulic fluid needed to operate the
actuator. Big volumes means long closure times due to the return line friction losses
especially offshore where control cabin are usually far from the wellhead area.
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8.6.7 CHOKE
Choke is a device fitted downstream of the Wing Valve to restrict, control and regulate the
well flow.
Figure 8-6 Positive Choke Valve Figure 8-7 Adjustable Choke Valve
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At this stage the Xmas tree should be API pressure tested to the required pressure against
the hanger plug in the tubing hanger. This test should be carried out in two stages:
1) With the flow and kill wing valves closed and the choke open.
2) With the valve downstream of the choke and kill wing valve closed, and the flow wing
valve and choke open.
When all tests are complete, the hanger plug should be removed from the tubing hanger and
the tubing plug retrieved by wireline.
The results of all SCSSV tests will be forwarded to the Completion and Workover
Superintendent, and a copy retained in the onsite production well file.
As nearly all gas lift designs use Side Pocket Mandrels (SPM) for gas lift valve installation,
the procedures in this section are concentrated on this basis and ignore earlier less effective
methods (Refer to
figure 9-1).
The gas lift method and applications are thoroughly described in the Completion design
Manual (STAP-P-1-M-7100).
Tubing
Pressure
Latch
Packing
Casing
Pressure
Packing
Retrievable Mandrel
(pressure valve shown)
Record and monitor all production and gas injection data including pressures to enable
comparison of the well performance versus the design. If production is not as expected,
conduct a fault finding exercise.
The gas lift design can be optimised by making adjustments to the injection rates, pressures
or changing the operating valve settings (by changing out the existing valve). Complex
software programmes are available to optimise gas lift production.
9.3 TROUBLESHOOTING
Gas lift installations are designed to unload and operate with a minimum amount of manual
control. Constant observation of the wells performance is necessary to maintain maximum
production. These observations include well tests, casing-tubing pressures, gas input
volumes, flowing pressure-temperature surveys, acoustical surveys, static bottomhole
pressures and producing characteristics.
Should an installation fail to function satisfactorily, it should be analysed carefully before
changing gas lift valves. Most problems can be determined while the well is still gas lifting.
Many problems can be corrected or minimised at the surface by changing the surface
parameters. Should it be necessary to pull valves, the new installation should be based on
the analysis of the previous installations.
Well test data, flowing parameters are most commonly tools used for gas lift analysis. A two
pen pressure recorder should be used every time a well is unloaded.
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This section contains generic procedures for downhole pump installations, namely ESP, Rod
Pumps and Hydraulic Pumps.
10.1.1 Handling
The downhole components, motor, pump, protector, and intake are usually shipped in a
metal shipping box for protection. The shipping boxes are painted red on the end that
should be placed towards the wellhead when the equipment is delivered to the wellsite. The
shipping boxes should be lifted with a spreader chain or bridled with a sling at each end.
Severe equipment damage can result from dropping, dragging, or bouncing the boxes. The
shipping boxes should never be lifted by the centre of the box only.
The cable reel should be lifted by using an axle and a spreader bar. If a fork lift is used, the
forks should be long enough to support both reel rims when the reel is picked up from an
end. The ends of the cable should be covered or sealed to protect them from the elements.
Transformers and switchboards are provided with lifting hooks. To avoid damage, the
recommended practice is to lift with a spreader bar to maintain a vertical position. Variable-
speed drives are normally skid-mounted with fork lift slots and lifting eyes. Some VSD
models are manufactured with pull bars.
Additional information on ESP handling and installation procedures is available in API
Recommended Practices for Electric Submersible Pump Installation.
10.1.2 Installation
There are five phases to every ESP installation. These are:
Well preparation
Site layout
Equipment preparation
Assembly and installation
Start up of the equipment.
4
3
2
4 1
4 3
3 2 4
2 1
3
1 2
1
Well Preparation
1) Prior to beginning installation of the ESP equipment, the well must be cleared of any
tubing, rods, packers, etc., that would prevent the downhole equipment from reaching
target depth.
2) The casing flange and wellhead should be examined for burrs and sharp edges. This
is very important in small-diameter casing because cable damage can be caused by
burrs and sharp edges catching cable bands.
3) A gauge ring should be run in (particularly in 4.5 casing) to below the setting depth of
the downhole equipment. If gauging indicates tight spots, a scraper or reamer run
should be conducted to remove the obstruction (scale, paraffin, burrs, or partially
collapsed casing). This will ensure adequate clearance for the ESP downhole
equipment as it is run into the well.
4) The BOP, if used, should be checked for adequate clearance as well as burrs and
sharp edges. Cut-out profiled rams are available for most tubing and cable sizes. They
should be installed in the BOP for well control in the event of a kick during equipment
installation.
Site Layout
1) The pulling rig should be centred over the well as close as possible. The guide
wheel/cable sheave should be secured safely to the rig mast no higher than 30 to 45ft
above the wellhead. The guide wheel should be at least 54 in diameter.
2) The cable reel or spooling truck should be positioned about 100ft from the wellhead in
direct line of sight of the rig operator or driller. One person should be responsible for
the cable operation. The responsibilities of this person are to ensure that there is
minimum tension on the cable (the cable should be run at the same speed as the
tubing), that the cable is kept clear of the power tongs during tubing makeup or break,
and that no one stands in front of the cable reel/spooler.
3) The cable junction box must be located at least 15ft from the wellhead. The
switchboard must be located a minimum of 50ft from the wellhead and 35ft min from
the junction box. The junction box normally is located 2 to 4ft above ground level to
ensure there is adequate air circulation and easy access. The junction box must never
be located inside a building.
Equipment Preparation
The ESP manufacturers field representative must thoroughly check all equipment before
installation.
During installation his responsibility is to supervise the pulling and/or running of the
downhole equipment. All equipment delivered to the wellsite is checked to determine that all
components necessary to complete the installation have arrived and are not damaged. The
ESP manufacturers field representative will perform the following checks and procedures.
1) Remove the shipping box covers and record all component serial numbers from name
plates
2) Check the casing, wellhead and pack-off materials.
3) Check the switchboard for proper fuses, potential transformer set-up, and current
transformer ratios.
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4) Check all couplings for shaft diameter and spline match. Check that the shaft is
centred correctly (as impact can cause misalignment).
5) Check the flat cable length, size, and pothead type.
6) Check power transformers for correct primary and secondary voltage rating.
7) Confirm that the pump design setting depth and capacity match the well conditions and
the specification in the Completion Programme.
8) Check the power cable and flat cable with instruments and a high voltage megger.
10.1.4 Troubleshooting
This section outlines recommendations to identify typical ESP problems and provide
solutions. The sole method that a failure can be analysed and its cause determined, is by
data collection. When problems occur, obtaining as much data as possible is essential.
Data Collection
Information that should be routinely compiled on each ESP installation includes:
Production data (such as water, oil, and gas rates)
Run life in days
Number of unit start ups and stoppages
Dynamic and static fluid levels
Pump setting depth
Perforation depths.
When an ESP well is first placed on production, data should be collected daily for the first
week, weekly for the first month, and a minimum of monthly after the first month. Production
data during the first month are very important because they will indicate whether the pump is
performing as designed. If a downhole pressure instrument is installed, operating BHP is
equally if not more important.
The major source of information when troubleshooting an ESP installation is the recording
ammeter. The recording ammeter is a circular strip-chart accessory mounted in the
switchboard that records the amperage drawn by the ESP motor. A number of changes in
operating conditions can be diagnosed by interpreting ammeter records. The following
addresses ammeter chart reading and typical problem situations.
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Normal Operation
A normal chart is smooth, with amperage at, or near to the motor specification amperage
requirement. Actual operation may be, either, slightly above or below the specification
amperage, however, as long as the curve is symmetric and consistent over a period of time,
operation is considered normal.
Normal Start-up
The start-up spike is caused by the inrush surge as the pump comes up to operating speed.
The subsequent amperage requirement is high but trending towards the normal level. This
is principally a result of the fluid level being drawn down to the design TDH, resulting in a
high but declining amperage requirement. Using the modern variable speed units this
problem has been overcome.
Power Fluctuations
Operating ESP amperage will vary inversely with voltage. If system voltage fluctuates, the
ESP amperage will fluctuate inversely to maintain a constant load. The most common cause
of this type of fluctuation is a periodic heavy load on the primary power system. This load
usually occurs when starting up another ESP or other large electric motor.
Simultaneous start-up of several motors should be avoided to minimise the impact on the
primary power system.
Ammeter spikes also can occur during a thunderstorm that is accompanied by lightning
strikes.
Gas Locking
Gas locking occurs as fluid level approaches the pump intake and intake pressure is lower
than the bubble-point. There are three possible remedies for gas locking:
Install a gas intake and/or a motor shroud
Lower the setting depth of the pump (but not lower than the perforation unless
the motor is shrouded)
Reduce the production rate of the pump by using a surface choke (but ensure
that the production rate remains within the recommended range for that pump).
It is entirely feasible that none of these solutions are satisfactory, then the pump should be
replaced with a pump that does not decrease the fluid level or reduce intake pressure below
the bubble-point.
Another possible solution is to add a variable speed drive (VSD) to the existing system. The
VSD controls the speed of the pump, which in turn controls the pump capacity. Thus the
pump output can be fine-tuned to protect against pump-off and gas lock while contributing to
improved pump life.
If the problem is confirmed to be due to reservoir conditions, then a stimulation operation
may be considered to reinstate the original PI and therefore allow operation of the current
ESP design.
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Fluid Pump-Off
Fluid pump-off occurs typically when an ESP is too large in relation to the inflow capacity of
the well. The remedial actions are much the same as those listed for a gas lock and, in
addition, a well simulation treatment may increase the wells productivity closer to a match
with the pump.
In general, cycling an ESP will have an adverse effect on optimal run life. As a temporary
measure, the amount of time delay before automatic restart can be increased if the
switchboard is equipped with a Redalert Motor Controller. This may allow the fluid volume to
build up to prevent a high frequency of shutdown occurrence. Nevertheless, the pump and
well are not compatible and the pump size should be checked on the next change-out or the
well worked over to improve productivity.
Overload Shutdown
A pump will automatically shut down when it reaches an overload condition. When an
overload condition shutdown does occur the unit must not be restarted until the cause of the
overload has been identified and corrected. Some motor controller overload-detection
circuits contain a built-in time delay, ranging from 1 to 5 secs at 500% of the set point to 2 to
30 secs at 200% of the set point. However, they will not automatically restart the unit on an
overload condition. A restart attempt in an overload condition can destroy the downhole
equipment if the cause of the overload is not identified and corrected first.
The most common causes of overload conditions are:
Fluid pump-off
Increased fluid specific gravity
Sand production
Emulsion formation
Scale
Electric power supply problems
Worn equipment
Lightning damage
Many of the problems outlined above have been reduced due to the use of VSD.
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Tubing
Sucker Rods
Working Barrel
Plunger
Travelling Valve
Working
Barrel
(Heavy Wall)
Standing Valve
Shoe
The design and installation procedures for subsea wells are significantly different from land
and platform wells. Although the downhole completion equipment is generally the same, the
subsea wellhead and subsea Xmas tree systems are totally different and are also
manufacturer specific.
Similarly, well interventions methods from floating vessels are much more complex requiring
specialised well intervention or workover systems.
In todays technology, there are two main types of subsea Xmas tree and intervention
systems termed Conventional and Horizontal.
The conventional subsea completion system utilises a Xmas tree with valving configurations
similar to dual surface Xmas trees, to which a dedicated well intervention riser, run from the
vessel, can be attached. After latching to the subsea Xmas tree and testing the integrity of
the system, well servicing operations such as wireline and coiled tubing can be safely
conducted through the riser into the wellbore. This riser system is also utilised for the
installation and retrieval of the subsea tree.
This design, however, has some drawbacks in that the dedicated riser systems are
extremely costly to purchase and maintain, especially for fields with only a few wells over
which to share the costs. Nowadays, some standardisation has been adopted between
manufacturers and riser systems which are adaptable to various manufacturers subsea
trees are offered on a rental basis, however their availability at critical times may not always
be guaranteed. Further to this, in order to re-complete or workover a well, the conventional
system requires the subsea tree to be recovered and a marine riser system deployed to be
able to pull the completion string.
A less costly alternative to the conventional subsea tree system, is the Horizontal
(sometimes refereed to as Spool) system. This only requires the use a conventional drilling
marine BOP riser system for re-completion or workover. Tie-back strings and tooling back to
surface are deployed through the riser to enable access to the tubing bores. The horizontal
system design uses a casing head spool through which casing and the completion string can
be installed (with the tree production valves equivalent to two master valves on the horizontal
flowline bore). This enables re-completion or workover operations to be conducted without
having to pull the subsea tree and without having to purchase a dedicated riser system. The
drawback of these systems is the complexity of the re-entry tools used inside the marine
riser for wellbore re-entry (dual subsea tree, tubing running tool, etc.).
An alternative guidewire running tool for use in deep water, combines a camera and guide
frame deployed on drillpipe which is steered by fluid jets. Pumping down the drillpipe steers
the tool via the jetting nozzles, and the camera allows the observation of the positioning and
orientation of the collet connector above the guide post. One draw back of this tool is the
ability to run only one guideline connector at a time.
The tool should be checked to ensure that it has not been damaged and is intact.
Check that the connectors fit the tool.
Check the nozzles operate correctly.
Attach the camera umbilical and ensure the camera is operational.
3) When preparation of the tubing hanger is complete, leave the tubing hanger in the
tubing hanger stand or remove the hanger from the stand and lay back down in its
shipping box. Protect the tubing hanger from mechanical and weather damage.
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Some systems have the THRT and THOJ as separate tools, whilst other systems have a
single run/set and orientation tool.
For setting up of the orientation of the THRT/THOJ refer to the Manufacturers Operations
Manual.
Pre-deployment testing may be performed, either on the rig deck or drill floor, and involves
stack-up of the THRT on the tubing hanger and utilises the test stands. Tests, according to
the manufacturers operating procedures manual, will be required to verify the integrity of the
system. These will cover the following aspects:
Cleanliness of the hydraulic systems meets with the specification, especially the
sub-surface safety valve line, usually to NAS 1638 class 6 or better.
Operation of all of the THRT functions.
Pressure integrity and operation of all hydraulic lines from the panel to the tubing
hanger.
The following tests are required to test the integrity of the system. Afterwards the THRT and
tubing hanger assembly will remain as one unit stored on the rig floor, connected to the utility
umbilical, if possible. A second or back-up system must be available for testing. The testing
procedure can be modified as long as the overall testing requirements are satisfied:
1) Check the tubing hanger in its shipping box (Refer to previous section).
2) Install the tubing hanger in the tubing hanger stand over a suitable hole in the deck.
3) Position the THRT tool stand.
4) Install the THRT in its stand and test.
5) Interface test and flush the THRT with the tubing hanger in the stand.
6) Check and position the tubing hanger body seal.
7) Check the THOJ and flush through the tool.
8) Move the THRT and stand up to the rig floor.
9) Move the THOJ to the rig floor with the handling tool and make up to THRT.
10) Return the complete assembly to the deck and test.
11) Before running the tubing, return the complete tool to the rig floor.
12) Run through the rotary and make up to enough joints of tubing or 5 DP to stand the
assembly back in the derrick.
13) Hook up the utility umbilical.
14) Stand back in the derrick.
15) Test the function lines.
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These activities are described in more detail in the following sections. Refer to the specific
manufacturers Operation and Maintenance Manual for additional instructions.
It should be noted that pressure tests conducted through flexible hoses will be subject to
some pressure decay caused by umbilical expansion. For this reason, acceptable pressure
decay should be established during chart recorded tests.
All site received inspections and ECR punch list items relating to this equipment must have
been satisfactorily addressed before proceeding.
THRT Preparation
1) Locate the THRT stand adjacent to the tubing hanger stand on the rig deck and within
hot-line range of the control panel.
2) Perform THRT preparation according to the Manufacturers Operating Manual.
3) Perform LATCH/UNLATCH and LOCK/UNLOCK tests.
4) Check the orientation key function and that the correct key is selected to ensure
correct orientation of the hanger.
5) Install the running tool back onto the stand.
THOJ Preparation
1) Check end connections and seals when horizontally located on the deck. Check that
there is no evidence of orientation sleeve and slot damage. Check the orientation
sleeve securement pins and field welds for damage or distortion. Check the downhole
pressure transducer connectors.
2) Fit the flushing tool to the bottom end of the joint, hook up the utility or test umbilical to
the top and circulate/flush as necessary to achieve the required hydraulic cleanliness.
3) Disconnect the utility or test umbilical and cover/protect any quick couplers.
4) Fit the handling tool to the top end of the joint.
WARNING: Do not bend the umbilical beyond its minimum specified bend radius.
WARNING: Do not bend the umbilical beyond its minimum specified bend radius.
7) Ensure the umbilical clamps are a tight fit. Ensure that the installed clamp dimensions
are within the BOP diameter.
8) Umbilical tails must be plaited as necessary to take up any excess length and to
provide protection.
9) Protect hoses as much as possible by tying back to the riser pipes.
10) Fit a hose protector if provided.
11) While handling the sheave and paying out the umbilical, stand the assembly back in
the derrick and secure to protect from unnecessary damage.
12) When stood back, the final pressure and function tests of the lines from the panel to
running tool can be performed in order to save time later.
13) The THOJ/THRT assembly is now ready for use.
Note: Some subsea tree designs have extension subs that can be shimmed
and/or slide within seal pockets to adjust for any incorrect stack up
heights of the casing hanger or tubing hanger assemblies. Typically this
adjustment is limited to a maximum of 1 to 2ins.
Mechanical probes, sleeves, lead impression blocks are all used in various tool designs with
some being diver assist.
The tools probes or shear sleeves must be set and pinned according the
Manufacturers Operating Manual.
Care should be exercised so as not to accidentally clash with other equipment
and inadvertently move the probes or sleeves thus giving a false
indication/impression.
If diver assists, the diver must be fully versed in the tool operation.
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Preparation of this equipment, up to the end of the main and utility umbilicals, is addressed
in the following sections.
After each of the above items is loaded onto the rig, a Site Received Test should have been
performed. Thereafter, the equipment will be stacked, function and pressure tested on deck
to verify equipment performance prior to running.
Assuming that all the necessary equipment is available, SRTs are complete and ECR Punch
Lists are acceptable, pre-deployment testing should commence as defined below.
Pre-test activities should be performed on deck and conducted according to a plan provided
in the well programme.
1) Place the XT on the XT test base and the tree cap on the LRP test base ensuring that
the connectors are fully unlocked prior to interface and correctly locked following
interface. Connector indicator pins should be observed to be correctly positioned.
2) Flush the control lines to the specified cleanliness standard.
XT
XT XT = XT
BASE BASE
TCRT
TCRT CAP
CAP + LRP BASE = LRP BASE
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3) Test the XT/XT base interface, i.e. AX/VX gasket, production, annulus and flowline
bores.
4) Integrate the XT and tree cap ensuring that the connectors are fully unlocked prior to
interface and correctly locked following interface. Connector indicator pins should be
observed to be correctly positioned.
5) Test production, annulus bores and peripheral area.
TCRT
TCRT CAP
XT + CAP = XT
XT BASE XT BASE
TCRT TCRT
CAP CAP SCM
SCM
XT + = XT
XT BASE XT BASE
7) Function and test via the Portable Electronic Simulator Unit (PESU):
8) DHPTT and sensor readings
9) Platform PCS commands and shutdown sequences
10) Hydro-test both sides of actuated valves.
11) If the LRP and TRT control fluids are acceptably clean, stack p as shown and test the
interface ensuring that the connectors are fully unlocked prior to interface and correctly
locked following interface. Connector indicator pins should be observed to be correctly
positioned.
12) Flush all lines. Hook up to Workover Control System (WOCS) and perform:
Pressure test of bores and AX/VX cavities
Pressure test of control lines at TRT/LRP interface
Hydro-test both sides of LRP valves.
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13) Integrate the LRP on the XT assembly ensuring that the connectors are fully unlocked
prior to interface and correctly locked following interface. Connector indicator pins
should be observed to be correctly positioned.
TCRT TRT
CAP SCM LRP SCM
- TCRT + TRT =
XT CAP LRP XT
XT BASE XT BASE
Note: This step may be omitted if the tree is known to be clean through
previous flushing. Hydraulic cleanliness must be verified by sampling 3
lines at random within each assembly. All three samples must all meet
hydraulic cleanliness criteria.
The combined XT and cap will be flushed together later. This activity
should be conducted with the assistance of a tree schematic which will
show all the lines on the tree.
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5) Hotline open the ASV and AMV and drift the tree production bore valves. Close the
valves after drifting. Valve indicator pins where fitted should be observed for correct
action and travel.
6) Pressure test the XT/test stump interfaces through the test skid lines.
7) If required, hook up the DHPTT simulator to the electrical lines emerging from the
base of the tubing hanger simulator and check.
8) Fill the tree and test stump with water to aid later testing when the cap is installed on
the tree by using hotlines to open all necessary valves. Valve indicator pins where
fitted should be observed for correct action and travel.
9) Bleed air from test stump connections as necessary.
10) Prepare the tree cap on the maintenance stand for interface with the LRP/Tree cap
test and flushing skid.
Note: Tree cap flushing may be omitted if the cap is known to be clean from
previous flushing. Hydraulic cleanliness must be verified by sampling
any 3 lines at random. All three samples must meet with hydraulic
cleanliness criteria.
11) Place the cap on the cap test and flush stand and pressure test the production and
annulus bores ensuring that the connectors are fully unlocked prior to interface and
correctly locked following interface. Connector indicator pins should be observed to be
correctly positioned.
12) Prepare the cap for TCRT interface according to the Manufacturers Operating Manual.
13) Prepare the TCRT according to the Manufacturers Manual.
14) Install the test sub into the top of the TCRT and torque up tight on the drill floor.
15) Install a 15ft pup joint above the sub.
16) Use hotlines or the TCRT umbilical to function and pressure test the tool.
Integrate Tree/Tree Cap with Surface Control Module (SCM) and Test Stump
1) Ensure the SCM has been fully inspected and tested upon the SCM test and flushing
skid according to the relevant procedures.
2) Pick up the SCM, check all the connections, and without the use of the SCM running
tool, land on the XT mobile mounting base (MMB) ensuring that the connectors are
fully unlocked prior to interface and correctly locked following interface. Connector
indicator pins should be observed to be correctly positioned. This is a very critical
activity and extreme care must be taken to avoid damage.
3) Lock the SCM to the MMB by setting weight on the locking bar.
Note: The seals and gaskets will be rechecked later before stacking the
LRP/TRT onto the tree.
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7) Pick up the LRP using slings or the tree handling tool and land over the LRP/Tree cap
test skid. Use hotlines to lock the LRP to the skid ensuring that the connectors are
fully unlocked prior to interface and correctly locked following interface. Connector
indicator pins should be observed to be correctly positioned.
8) Perform a brief pressure gauge test of the LRP/Test skid hub interface to obtain
confidence in the interface sealing.
9) Flush the control lines through the skid until the required cleanliness is achieved.
10) When hydraulic line cleanliness is satisfactory, remove the tree handling tool.
11) Ensure that the WOCS is fully flushed and tested, then connect the main umbilical to
the TRT.
WARNING: Do not bend the umbilical beyond its minimum bend radius.
12) Pick up the TRT and carefully set over the LRP ensuring that the connectors are fully
unlocked prior to interface and correctly locked following interface. Connector indicator
pins should be observed to be correctly positioned.
13) Test the LRP and TRT connector control lines.
14) Flush the combined LRP/TRT as a unit.
15) Test and chart record the TRT AX/VX test.
16) Test the LRP AX/VX gasket.
17) Test all the functions per the Operating Manual.
18) Open all the LRP valves and fill the LRP with water. Valve indicator pins where fitted
should be observed for correct action and travel.
19) Pressure test and chart record either side of the LRP valves. Vent all pressure after
the tests and check that all LRP valves are closed. Valve indicator pins where fitted
should be observed for correct action and travel.
20) Pressure test the SCSSV1 line.
21) At the LRP/tree cap test stump, perform a hydro-test.
The LRP/TRT/WOCS system is now tested as a unit and is ready to be integrated with the
tree (Refer to Section 8 for details on WOCS).
Note: Throughout all tests check that return flows generally match and that
there is no visible return line leakage. Because of line expansion and
effects from adjacent lines in the umbilical, inconsistent supply and
return flows can occasionally be experienced.
Valve Function
IUMV OPEN
IWV OPEN
AMV OPEN
AWV OPEN
XOV OPEN
When pressure has stabilised, zero the LCP and return flow meters and monitor. Also
check visually for leaks. Close valves after the test. Valve indicator pins where fitted
should be observed for correct action and travel.
10) Pressure test the SCSSV1 line from above and below.
11) Check line continuity, then close the tree AX/VX test line isolation valve.
12) Pressure test the tree connector AX/VX line.
13) Pressure test below the tree AX/VX isolation valve. After the test, open the tree AX/VX
test isolation valve to prove HPP to test base continuity.
9) Attaching the umbilical to the strings, run in the hole on drillpipe/tubing stands.
10) Run in the hole and on the compensator, gently tag the hanger in the wellhead
recording the exact depth that the weight drops off and marking the pipe at the rotary
table.
11) Repeat the procedure ensuring the depth remains the same.
12) Pull up until the tool is 10ft above the orientation key/slot (for whichever type of system
is being used. Hydraulically activate the orientation key and slowly lower the handling
string observing for orientation of the string. If the string does not turn, apply a chain
tong and check that it is correctly engaged in the slot. Check the depth is the same as
found in step 10 above. Repeat the procedure if it is felt there may be any uncertainty.
13) If necessary to check the ram sealing ability on the THOJ, close the rams, install the
safety valves on the landing strings and test down the kill line to the appropriate
pressure, usually 1,500psi. Painting the THOJ white will give confirmation that the tool
has been correctly positioned within the stack.
14) Bleed off the test pressure, open the rams and pull the landing string, strap the pipe if
necessary.
15) Observe the paint on the THOJ and for signs on the dummy hanger that it was
properly positioned.
16) Close the blind rams and disconnect the dummy hanger. Pick up the allocated TH and
pack off into the rotary table and attach the THRT/THOJ to the hanger.
17) Check that the TH seals have not been damaged and install the protection cap. Stand
the complete assembly back in the derrick.
18) Rig down the dual elevators and rig up the single completion handling equipment.
19) Ensure the completion sub-assemblies have been laid out in correct running order and
appropriately numbered.
20) Refer to completion installation procedures in section 8.
21) Run the string to the hanger installation point and, according to the completion design
and procedures in the well programme, conduct the spacing out operations or install
the hanger/THRT assembly. Terminate and connect up the control line and electrical
cable.
22) Pressure test the SCSSSV control line on the control panel. Check electrical continuity.
23) Conduct the final tubing pressure test and any other necessary tests according to the
Operating Manual.
24) Run the completion string to depth on the hanger landing strings, locking pressure in
all the correct functions.
25) When 10ft above the hang off point, activate the orientation mechanism and lower the
hanger until soft landing into the wellhead.
26) Check the depth marks on the landing string confirming proper depth location. Check
with chain tongs that the orientation slot is engaged. Repeat the procedure only if
absolutely necessary as damage to the control line or cable may be caused by cycling
in and out of the hole.
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27) Ensuring all the completion string weight has been hung off, proceed with the hanger
setting and testing procedures as per the manufacturers Operating Procedures
Manual which will test:
Production string
Annulus string
Above the hanger
Below the hanger
All control or injection lines
DHPTT cable.
28) Rig up wireline and plug the well for BOP removal according to the well programme.
29) Unlatch the running tool from the hanger and retrieve the landing string to surface.
30) If applicable, run the TH orientation or verification tool.
After each of the items has been received onboard, a Site Received Test should first be
performed. It is then to be tested to confirm operation before use.
The pre-deployment test procedures for both systems are detailed in the following sections.
Antenna
'A'
ESD
Eni S.p.A.
Radio Antenna
Link 'B'
E&P Division
SXT ESD
S P E O
Panel
Battery
Elecrtical Supply Safe Area
HPP LCP
RCP
Air Supply
Remote ESD
Panel
Hydraulic Hydraulic
Power Power
Control
SXT
Lines
STAP-P-1-M-7120
Control Control
Lines Lines
IDENTIFICATION CODE
SCM
THOJ TCRT
LRP RT
OF
REVISION
XT XT THRT
269
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Note: During the following tasks the subsea ESD accumulator should re-charge
after each ESD test; but allow 5min between tests to provide sufficient
time for re-charging.
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Record that, the operating time until the last valve closes according to the time
specified in the manual and within tolerance.
b) Verify that the next set of valves close:
PWV
AWV
XOV
PSV
ASV
Methanol Injection Valve
Scale inhibitor Injection Valve.
Record that, the operating time until the last valve closes according to the time
specified in the manual and within tolerance.
c) Verify that the next set of valves close:
PUMV
AMV
Record that, the operating time until the last valve closes according to the time
specified in the manual and within tolerance.
e) Verify that the SCSSV1 line depressurises at the correct time after the workover
ESD button was pressed on the LCP.
f) Unlock the workover ESD push-button at the LCP.
g) Operate the workover ESD, reset push-button on the LCP after the ESD
sequence is completed.
h) Verify that the workover ESD lamps at the LCP, RCP, and RESDP switch off.
3) Enable the RCP at the LCP and re-open all the actuated valves as per step 1 above at
the RCP. Verify at the LCP gauges, SCSSV1 test base gauge and by visual
inspection. Also check that the ESD supply is fully charged.
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5) Disable the RCP at the LCP. Re-open all the actuated valves as per step 1 overleaf at
the LCP. Verify at the LCP gauges, SCSSV1 test base gauge and by visual
inspection. Also check that the ESD supply is fully charged.
6) Depress the workover ESD push-button at the remote ESD panel.
a) Valve closure should be identical to that monitored in step 2 overleaf.
b) Unlock the workover ESD push-button at the remote ESD panel.
c) Operate the workover ESD reset push-button on the LCP, after the ESD
sequence is completed.
d) Verify that the workover ESD lamps at the LCP, RCP, and RESDP are switched
off.
Check Sensors
1) Configure the PESU as a surface unit with the suppliers protocol. Send a BREAK
STATE REQUEST COMMAND to SEM A. Verify that all valves and indicators are
shown as OK.
2) Send an ANALOGUE DATA REQUEST COMMAND to SEM A. Verify that all
transmitters are indicated as (tick).
3) Verify that readings for Annulus Pressure and Production Pressure are correct.
Ensure that the bores are vented at the block elbows by opening the wing valves,
hence ensuring pressure is not locked in.
Injection Pressure
(Ambient pressure) = __________ barg
PESU reading = __________ mA
350
Converted PESU reading = x (PESU reading diff. from 4.00)
16
(Acceptance criterion is +/- 2.2 bar) = ___________ barg
Annulus Pressure
(Ambient pressure) = __________ barg
Take the opportunity to check the tree valve position indicators during these tests.
1) Check the displayed readings of LP supply and return volumes by sending an
ANALOG DATA REQUEST COMMAND. If the readings are not zero, transmit
commands to RESET the readings. Record that the readings have been reset in the
table.
2) Transmit a VALVE COMMAND to open the Production Tree valve specified in the
table.
3) Send a FUNCTION/STATUS REQUEST COMMAND to SEM A and check that the tree
gate valve is indicated in the OPEN position.
4) Obtain the displayed readings of LP supply and return volumes by sending an
ANALOG DATA REQUEST COMMAND and record readings in the table.
5) Check on the XT that the valve actuator has moved to the energised position. In the
case of the simulated SCSSV1 valve, check on the gauge on the hook-up line coming
from the tree test stump that the line has been energised.
6) Transmit RESET FLOW COUNTER COMMANDS to reset the LP supply and return
volumes.
7) Transmit a VALVE COMMAND to close the production tree valve.
8) Send a FUNCTION/STATUS REQUEST COMMAND to SEM A and check that the tree
gate valve is now indicated in the CLOSED position.
9) Obtain the displayed readings of LP supply and return volumes by sending an
ANALOG DATA REQUEST COMMAND and record readings in Table 11-a.
10) Check on the XT that the valve actuator has moved to the de-energised position. In the
case of the simulated SCSSV1 valve, check the needle valve/gauge on the tree test
base.
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1) Set the PESU to operate SEM B. Transmit a VALVE COMMAND to open the PUMV
valve.
2) Send a FUNCTION/STATUS REQUEST COMMAND to SEM B and check that the
PUMV valve is indicated in the OPEN position.
3) Check on the tree that the PUMV valve actuator has moved to the energised position.
4) Transmit a VALVE COMMAND to open the SCSSV1 valve.
5) Send a FUNCTION/STATUS REQUEST COMMAND to SEM B and check that the
SCSSV1 valve is indicated in the OPEN position.
6) Check the gauge on the tree test base that the SCSSV1 line has been energised.
7) Transmit a VALVE COMMAND to open the PWV valve.
8) Send a FUNCTION/STATUS REQUEST COMMAND to SEM B and check that the
PWV valve is now indicated in the OPEN position.
9) Check on the tree that the PWV valve actuator has moved to the energised position.
10) Transmit a VALVE COMMAND to close the open PWV valve.
11) Send a FUNCTION/STATUS REQUEST COMMAND to SEM B and check that the
PWV valve is now indicated in the CLOSED position.
12) Check on the tree that the PWV valve actuator has moved to the de-energised
position.
13) Transmit a VALVE COMMAND to close the open PUMV valve.
14) Send a FUNCTION/STATUS REQUEST COMMAND to SEM B and check that the
PUMV valve is now indicated in the CLOSED position.
15) Check on the Tree that the PUMV valve actuator has moved to the de-energised
position.
16) Transmit a VALVE COMMAND to close the open SCSSV1 valve.
17) Send a FUNCTION/STATUS REQUEST COMMAND to SEM B and check that the
SCSSV1 valve is now indicated in the CLOSED position.
18) Check the gauge on the tree test base that the line has been de-energised.
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5) Confirm that the valves on the tree follow the same sequence. Send an FSR to verify.
5) Confirm that the valves on the tree follow the same sequence. Send an FSR to verify.
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3) Verify SCM valve functions using SEM A. As the LRP is installed to the top of the tree,
the tree valves will not function when operated through the SCM and PESU, however,
valve supply lines will be pressurised up to the tree receiver plate and the SCM will
give a 'pressurised' status for that line.
Check valve functions in the following order:
IUMV
SCSSV1
IWV
AMV
AWV
XOV.
Test No. 2 IUMV From Above, ISV & XOV From Below
Open valves: IWV, ILMV
Monitor at: (Lines according to the Operating Manual)
Pressurise from: (Lines according to the Operating Manual)
Hold and continue with Test 2A
Test No. 2a ILMV From Above
Open valves: As Test No. 2, then open IUMV, close ILMV
Monitor at: (Lines according to the Operating Manual)
Pressurise from: (Line according to the Operating Manual)
Test No. 3 IWV, AWV and XOV From Above
Open valves: AWV, IUMV, ILMV
Monitor at: (Lines according to the Operating Manual)
Pressurise from: (Lines according to the Operating Manual)
Test No. 4 IUMV and AMV From Below
Open valves: AWV, XOV, ILMV
Monitor at: (Lines according to the Operating Manual)
Pressurise from: (Lines according to the Operating Manual)
Test No. 5 IWV, ASV and AWV From Below
Open valves: IUMV, ILMV, AMV
Monitor at: (Lines according to the Operating Manual)
Pressurise from: (Lines according to the Operating Manual)
Note: The readings will not be representative as the tree cap is not fitted.
Return Flowmeter
Reading
Return Flowmeter
Reading
Return Flowmeter
Reading
Return Flowmeter
Reading
Following the successful completing of a well, it will normally have been left with the
completion fluid left in both the tubing and annulus. To enable the well to produce under
natural flow conditions (i.e. non artificial lift) the overbalance pressure exerted by the
completion fluid must be removed, sometimes referred to as unloading. The well may be
brought onstream direct into the production facility but is often tested with a well test
package to be cleaned up prior to placing it on production (this is normal practice for subsea
completions where the production of the well straight into the subsea flowline system without
cleaning up may plug and perhaps damage the facilities).
If losses have occurred during the drilling and completion phases, the hydrostatic pressure in
the tubing needs to be reduced to such an extent that the replenishing losses flowing back
into the wellbore does not kill the well again. It is normal practice to circulate an
underbalanced fluid into the tubing using a circulating device or coiled tubing service, which
will provide sufficient underbalance to enable the well to flow under the conditions stated.
The fluid used is usually selected to provide as large drawdown as possible at low cost.
Under some circumstances, an underbalance can be achieved by simply bullheading a
lighter fluid into the tubing relying on produced gas to maintain the underbalance during
flowback. This is a cost effective method if bullheading is acceptable for a particular
formation.
The fluids normally used may be water, base oil, diesel or nitrogen. Nitrogen can be
circulated by deploying the coiled tubing and continuously gas lifting the well until natural
flow is established. It may also be installed like the other fluids by pumping it into the tubing
taking returns through a circulating device and out of the annulus. The depth to which the
underbalance fluid is circulated depends upon the drawdown which can be achieved.
Continuous gas lifting a well is preferred if there has been large losses otherwise the
circulation process may have to be repeated more than once causing higher costs, this
needs to be evaluated.
The procedures for circulation are given in this section. The procedures for nitrogen lifting
are given in section 14 and coiled tubing procedures in section 13.
4) Pressure test the wireline lubricator to a minimum of 1,000psi above the maximum
anticipated wellhead pressure or to WP.
5) Install the circulating device opening or shifting tool. If using a SPM, install the SPM
dummy valve pulling tool.
6) Run in the hole and open the circulating device. There should be no differential
pressure across the device as there is completion fluid on both sides.
7) Confirm the circulation path is open by pumping up on the tubing and observing
pressure on the annulus.
8) Pull out of the hole. With some particular SSDs, it is sometimes possible to run two
tools in one run to open and close the sleeve in one trip (positioning it below the SSD
during circulation).
9) If a SPM is being used, run and install a circulating valve in the pocket and pull out of
the hole.
10) With the return system from the annulus open, begin to pump the underbalance into
the tubing monitoring the volume pumped and the volume of returns from the annulus.
11) Continue pumping until the calculated amount of fluid has been pumped. Check that
the surface U tube pressure is correct for the volume of underbalance fluid pumped
according to calculation and hold this pressure on the pump.
12) Run in the hole and close the circulating device. In the case of a SPM, reinstall the
dummy valve. Confirm closure by pressuring up on the annulus and observing no
pressure on the tubing or any significant volume is pumped.
13) Pull out of the hole.
14) Rig up, run in the hole and pull the packer tailpipe plug or standing valve, if used.
15) Rig down wireline and the pump lines.
16) Ensure the production flowline is lined up to flow to the production facilities and that the
production operators are informed that the well will produce back through their
facilities.
17) Open the production wing valve.
18) Gradually open the production choke to flow the well.
19) Monitor the wellhead pressure, slowly opening the choke as it is assured that the well
is successfully unloading.
20) Continue until the well has stable flowing conditions at a reasonably high rate
(reservoir engineering will provide the flow parameters).
5) Ensure the production flowline is lined up to flow to the production facilities and that the
production operators are informed that the well will produce back through their
facilities.
6) Open the production wing valve.
7) Gradually open the production choke to flow the well.
8) Monitor the wellhead pressure, slowly opening the choke as it is assured that the well
is successfully unloading.
9) Continue until the well has stable flowing conditions at a reasonably high rate
(reservoir engineering will provide the flow parameters).
13.1 PREPARATION
Coiled tubing (C/T) operations will not be allowed to commence without an approved work
programme.
The Completions and Workover Superintendent will confirm that the well to be worked on is
available and accessible. Should the rig be required, then he will confirm its availability and
the manning requirements.
A pre-job meeting should be held well in advance of the actual operation. The purpose of
this meeting is to:
Discuss the programme of operations.
Establish channels of communication and define responsibilities.
Discuss any special requirements or circumstances that may arise, e.g.
procedures in the case of emergency, adverse weather conditions, ID of string
components versus tool OD, escape of hazardous treatment fluids, etc.
Additional topics will be discussed as required and may include working in
confined spaces, working with pressurised equipment, handling of heavy
equipment, etc.
Make sure a completion diagram of the well is available. This should include the location of
casing, tubing shoe, packers, perforations, etc., as well as KOP and maximum angle of
deviation. A brief written outline of previous relevant well operations should be given to the
coiled tubing supervisor.
The Completions and Workover Superintendent will ensure that all relevant equipment and
materials for the job are on site in a timely manner.
Before rigging up coiled tubing, a safety meeting will be held with all relevant
personnel. The topics to be covered will include, but are not be limited to:
a) Working with pressurised equipment
b) Handling of heavy equipment
c) Use of hazardous chemicals
d) Safe working areas
e) Emergency procedures
f) Protective clothing
g) etc.
Communication with the operator in the C/T control cabin, the drill floor/skid deck
and the control room will be maintained throughout the operation.
All personnel should be aware of the Emergency Procedures for C/T operations.
13.2.1 Tubing
The coiled tubing should be treated like a pressure vessel. While operating or pressure
testing it will contain several cubic meters of gas, fluid, or energised fluid. Unlike a pressure
vessel however, it undergoes considerable stress during running and also suffers from both
internal and external corrosion. Therefore, ensure that the reel carries a full and up-to-date
operational history, which should include the following information:
The cycle history of the whole reel length (one cycle being a run in followed by
the run out).
The treatment history, i.e. what fluids have passed through the reel.
The well conditions. What fluids and gases were in the well being treated, e.g.
H2S, Acid.
The condition of welds or joins in the reel, i.e. are they original, are X-rays
available of the welds, etc.
The records showing when the last non-destructive test of the full reel length was
performed.
4) After de-pressuring the Xmas tree and riser but before the BOP is broken out, the
swab valve must be closed. This is to prevent any possible hazardous condition
arising due to the inadvertent opening of a wing valve, or flow from a leaking master
valve.
Note: All permits will be issued in accordance with the Permit to Work System.
Note: Permits may not be valid for 12 hours on crew change days.
Note: The C/T unit will be function tested on the deck prior to it being made up
in the well.
Note: It is Company policy to run a remote hydraulic control shear seal BOP at
the bottom of the riser immediately above the tree.
9) When picking up the injector head, use tugger lines to keep the assembly vertical.
Tugger lines must not be attached to the injector body, as this will interfere with the
weight indicator readings.
10) Fill the reel with water. The reel should be flushed with water and pigged with a no-go
prior to running packers and other sensitive tools to gauge reel volume, ensure that
there are no restrictions to the ID of the coil and to purge any debris form the tubing.
Make-up and fit the end connector and test sub. Test reel to full test pressure and
perform pull test before stabbing on to BOP.
11) Attach the C/T BHA, and stab the injector onto the BOP.
12) The assembly will be pressure tested with the BHA across the BOP.
Injector Head
Hydraulic Hose
Stripper/Stuffing
Box
Quad BOP's
STAP-P-1-M-7120
Lubricator/Riser
IDENTIFICATION CODE
Wellhead
165
OF
REVISION
269
S P E O IDENTIFICATION CODE PAG 166 OF 269
Eni S.p.A.
E&P Division REVISION
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When removing a fixed dead column of fluid from a well, as when creating a nitrogen
cushion prior to DST or TCP, follow the main procedure, except that the well will not flow and
dry gas should be produced at surface.
The procedures in this section are guidelines only, specific operational programmes will be
issued by the Company.
Safety
A safety meeting will be held with all relevant personnel prior to any job. The meeting will
address the hazards inherent with handling liquid nitrogen (Refer to section 14.2). The
meeting will also address the actions to be taken in the event of an emergency.
Procedures
1) Rig up and test the coiled tubing (Refer to section 13.4)
2) The nitrogen tanks, converter and pumping unit should be positioned close to the
tubing reel in order to minimise the length of pressurised lines.
3) Reduce the test separator pressure according to the coiled tubing contractors
procedures, and line up the well to the test separator.
4) Allow any gas cap on the well to vent off through the test separator.
5) Confirm that the tree and SCSSV controls have been isolated from the main control
system.
6) Equalise pressure across the swab valve then open.
7) Run in the well carefully, stopping to establish nitrogen injection at a low rate,
increasing the rate slowly as the coiled tubing is further run in.
If the well begins to slug nitrogen, reduce the injection rate
Shut down the nitrogen unit at the first indication of any rapid build up in wellhead
pressure.
8) Once the tubing has reached the predetermined depth, stop running in and continue
pumping nitrogen until nearly all the nitrogen is pumped, or the well is flowing strongly.
Note: Pull the tubing out of the well before the nitrogen supply is completely
exhausted. This is to ensure that the pressure differential across the
tubing wall does not exceed 1,000psi.
9) Rig down and hand the well over to the Production Department.
10) The following data will be recorded throughout the nitrogen lift operation:
Wellhead flowing pressure
Nitrogen injection pressure
Nitrogen injection rate
Wellhead flowing temperature
Separator level
Separator pressure
Separator temperature.
11) Fluid samples will be taken from the flow line sample point by the Well Operations
Supervisor.
S P E O IDENTIFICATION CODE PAG 169 OF 269
Eni S.p.A.
E&P Division REVISION
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Scale removal can be achieved by circulating acid across the area requiring treatment.
Note: Much of the acid may remain unspent and that this may have an effect on
surface flowlines and production equipment. Specific formulations may
be recommended by the contractor to remove sulphate scale, and scale
containing hydrocarbons.
Matrix acidisation of the formation can take the form of a small acid wash injected from the
coiled tubing directly to the zone requiring treatment, or for larger treatments, with the coiled
tubing being used to circulate the acid to fill the tubing prior to direct high rate injection from
surface. If leaving the coiled tubing in the well ensure that it is sufficiently inhibited and that
the internal pressure of the C/T remains equal to or above the external pressure.
Well bore clean-ups are performed to remove scale, debris and waxes from the perforation
tunnels. They are not intended to penetrate the formation, which could lead to additional
damage. The treatment is applied by jetting the treatment fluid into the perforations while
slowly cycling the nozzle across the perforations. The treatment is performed with the well
balanced or slightly underbalanced to prevent treatment fluid penetration.
Safety
Prior to rigging up the acid equipment a safety meeting will be held with all relevant
personnel (Refer to section 15.5.2). The meeting will address the hazards inherent with
handling acids, particularly under pressure. The meeting will also address the actions to be
taken in the event of an emergency.
S P E O IDENTIFICATION CODE PAG 170 OF 269
Eni S.p.A.
E&P Division REVISION
STAP-P-1-M-7120 0 1
Procedure
The following details the basic procedures to be followed when performing acid treatments
through coiled tubing:
1) Rig up and test coiled tubing (Refer to section 13.4).
2) Suggested BHA is, from the bottom up:
Jetting nozzle
2 dart type check valves
6ft straight bar
Tubing connector.
3) Confirm that the tree and SCSSV controls have been isolated from the main control
system.
4) Pig the reel to determine accurate reel volume.
5) Equalise pressure across the swab valve then open.
6) Run in the well carefully, circulating at minimum rate. Perform regular pull tests/checks
at 1,000 ft intervals.
7) Once the area to be treated has been reached, pump treated injection quality seawater
in order to establish the circulating pressure.
8) If an acid wash or solvent treatment is to be performed then:
Circulate the coiled tubing to treatment fluid
Jet the area to be treated while reciprocating the coiled tubing slowly
Circulate the tubing to injection quality seawater
Pull out of the hole.
Inhibition
It is essential that a sufficient quantity of inhibitor is used in the acid system. If a mutual
solvent is being used, the inhibitor content must be doubled due to the detrimental effect that
the solvent has on inhibitor efficiency.
A slug (5-10bbl), with 5% inhibitor in injection quality seawater, should be circulated ahead of
the acid treatment. This will give protection to both the inside and outside of the tubing.
S P E O IDENTIFICATION CODE PAG 171 OF 269
Eni S.p.A.
E&P Division REVISION
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Safety
Prior to rigging up the coiled tubing and circulating equipment a safety meeting will be held
with all relevant personnel. The meeting will address the hazards of handling chemicals and
use of pressurised equipment. The meeting will also address the actions to be taken in the
event of an emergency.
Procedure
1) Ensure that the well is lined up to take returns to the test separator.
5) The required gel system should be prepared in a mixing tank and transferred to a
holding tank containing agitators once it is fully hydrated.
6) Confirm that the Xmas Tree and SCSSV controls have been isolated from the main
control system.
7) Equalise pressure across the swab valve then open it.
8) Begin running in carefully with the well producing at a reduced rate. Keep the tubing
string filled full of treated sea water by circulating at the minimum rate. Carry out
regular pull tests/checks at 1,000ft intervals.
9) Once the string is below the SCSSV, increase the production rate to its normal level.
10) Break circulation when well above the last recorded hold up depth and establish a
minimum circulation rate while pumping gel.
S P E O IDENTIFICATION CODE PAG 172 OF 269
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E&P Division REVISION
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Note: Monitor the pump pressure, wellhead pressure and coiled tubing string
weight continuously throughout the operation. If there are any
indications of problems, pull back above the last hold up depth
immediately and evaluate the situation.
11) Run in slowly to the top of the fill, stopping to note the hanging weight. Slow down
when the weight begins to drop off the tubing and flag pipe at surface as a reference.
The tubing must be kept in tension at all times.
12) After penetrating 20ft, pick-up to the tubing shoe then run back in to repeat the
process in stages of 20ft, pumping continuously.
13) Having reached the required depth, continue to pump gel while reciprocating the tubing
back to the tubing shoe twice. Carefully monitor fluctuations in pick-up weights. If an
increase is seen, wash back until weight corresponds with the initial running weight.
14) Pull up above the perforations and displace the tubing to treated seawater.
15) Pull out with the well flowing to ensure that all sand moving up as the tubing is
removed.
16) Rig down and hand control of the well back to Production.
17) Sand wash the test separator and record the volume of sand removed.
S P E O IDENTIFICATION CODE PAG 173 OF 269
Eni S.p.A.
E&P Division REVISION
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The use of nitrogen is potentially hazardous and many precautions need to be taken to
obtain a successful safe operation.
14.1 PREPARATION
1) No nitrogen operations will be allowed to commence without an approved work
programme.
2) The Completions and Workover Superintendent will confirm that the well to be treated
is available and accessible. Should the rig be required then he will confirm its
availability and the manning requirements.
3) A pre-job meeting should be held well in advance of the actual operation. The purpose
of this meeting is to:
Discuss the programme of operations.
Establish channels of communication, and define responsibilities.
To discuss any special requirements or circumstances that may arise, e.g.
procedures in the case of emergency, adverse weather conditions, safety data
sheets, escape of gaseous or liquid nitrogen or energised fluids, etc.
Additional topics will be discussed as required, and may include working in
confined spaces, working with energised fluid, extreme low temperatures,
handling of heavy equipment etc.
4) A brief written outline of previous relevant well treatments should be given to the
stimulation supervisor, or nitrogen operator.
Good communications between the nitrogen operator, rig floor, wellhead area
and coiled tubing or stimulation operator where applicable must be maintained
throughout the operation.
All personnel should be aware of the Emergency Procedures for C/T operations.
All work areas will be chained or roped off, and warning signs placed at access
routes. The exact requirements will be specified on the work permits.
Fire hoses will be available in the areas where liquid nitrogen is to be used. The
hoses will be fully charged, so that they can be used immediately should a spill
occur.
The nitrogen tanks and nitrogen converter/pump will be positioned as close to
the well as possible to minimise the length of pressurised lines.
Gaseous nitrogen will escape from nitrogen tanks continuously as the tank is
warmed. Do not stand in the immediate vicinity of escaping nitrogen and do not
attempt to plug or block the escaping gas.
Nitrogen is not toxic (it represents about 80% of the air we breathe), but if
released in a confined area it will displace some of the oxygen present leading to
an oxygen poor atmosphere and possibly asphyxiation of people present. (The
effect is like putting a plastic bag over ones head.) Do not enter or work in a
confined area where nitrogen is escaping.
Liquid nitrogen is very cold being a cryogenic fluid. It will freeze flesh on contact
almost instantly, especially if the surface is water wet. The freezing effect is
anaesthetic and may not be immediately noticed. The flesh or eye once frozen is
effectively destroyed. The affected area will be treated as a serious burn.
Lines carrying liquid nitrogen are also very cold and should only be handled with
dry insulated gloves.
On contact with steel, liquid nitrogen causes embrittlement and shrinkage of the
surface leading to fracture generation. Thus if nitrogen is spill on a steel deck, it
will quite rapidly freeze and crack the deck, allowing the liquid to spill to the next
level. Apply a fine spray of water to the spill immediately. As in a liquid fire, do
not apply a fierce jet to the liquid as this will disperse it to other areas. The fine
spray will lay down an insulating layer of ice on the deck and help evaporate the
liquid nitrogen.
Note: The pressure testing will be witnessed by the Well Operations Supervisor.
Pressure tests will be monitored for 15 mins on a chart recorder. The chart will
be labelled and stored for reference.
The PRV is to be isolated during pressure test.
A nitrogen pumping schedule will be prepared in advance by the service company. If during
the nitrogen operation there are any significant variations from this schedule the job will be
shut down and the cause investigated. If necessary, the operation will be adjusted and
restarted.
14.5.1 Pressures
Nitrogen pump pressures should be determined before the start of a job. This is
of particular importance with gas lifting. If the job is not correctly designed the
combined coiled tubing friction pressure and negative hydrostatic effect can lead
to high surface pump pressure which may exceed the maximum allowable coiled
tubing pressure.
The maximum working pressure of wellheads and production equipment should
also be considered when designing nitrogen operations. High pressure gas
pockets may return to surface.
Note: Safety of personnel is paramount, and the above actions should only be
followed if it is considered safe to do so. Therefore, if there is ANY doubt,
ALL personnel will report to their muster stations IMMEDIATELY.
15.1 INTRODUCTION
All wells are susceptible to formation damage to some degree, from relatively minor loss of
productivity to complete plugging of specific zones. The purpose of this chapter is to help the
technicians involved in the well operations to take the correct decisions when chemicals
selection is required while developing the intervention on the wells.
Plugging Associated with Solids. Plugging by solids occurs on the formation face, in the
perforation, or in the formation. Solids may be weighting materials, clays, viscosity builders,
fluid loss-control materials, lost-circulation materials, drilled solids, cement particles,
perforating charge debris, rust and mill scale, pipe dope, un-dissolved salt, gravel pack or
frac sand fines, precipitated scales, paraffin or asphaltene.
Solids Precipitation. Solids may also be precipitated within the formation. For example, scale
often precipitates due to mixing of incompatible waters; asphaltene or paraffin may be
precipitated due to changing equilibrium conditions.
2) Water may tend to wet the rock increasing water saturation and reducing relative
permeability to oil or gas. Filtrate invasion is normally termed water blockage. The
extent of oil productivity reduction depends on the degree of water saturation and the
radius of the affected area.
3) Liquid filtrate may determine a viscous emulsion with the virgin reservoir oil; stable
emulsions appear to be associated with partially oil-wet systems. Viscosity effects also
include formation plugging by a high-viscosity treating fluid which, for some reason,
does not "break" and does not return to the well bore under the available differential
pressure.
S P E O IDENTIFICATION CODE PAG 182 OF 269
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E&P Division REVISION
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In a radial flow system, any reduction in permeability around the well bore results in serious
reduction of productivity or injectivity. In a linear flow situation, some plugging of the face of
the fracture can be tolerated due to the large area represented by the faces of the fracture.
However, plugging of the fracture itself results in serious reduction in productivity or
injectivity.
15.2.2.1 INTRODUCTION.
Scale is deposited in formation matrix and fractures, well bore, down hole pumps, tubing,
casing, flow lines. The direct cause of scaling is frequently pressure drop, temperature
change, mixing of two incompatible waters, or exceeding the solubility product. Scale
sometimes limits or blocks oil and gas production.
Wells exibit appreciable reduced productivity or injectivity and often require a large number
of costly remedial jobs.
The most common oil field scale deposits are calcium carbonate (CaC03), gypsum (CaS04
2H20), barium sulphate (BaSO4) and sodium chloride (NaCI). A less common deposit is
strontium sulphate (SrS04).
Scale deposited slowly may be very hard and dense, and may be difficult to remove with acid
or other chemicals.
S P E O IDENTIFICATION CODE PAG 184 OF 269
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Scale precipitation also varies with calcium ion concentration (common ion effectsuch as
from CaCI2), alkalinity of water (concentration of bicarbonate ion), temperature, total salt
concentration contact time, and degree of agitation:
Careful examination of completion, testing and workover reports is helpful to identify the type
of formation damage.
S P E O IDENTIFICATION CODE PAG 187 OF 269
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E&P Division REVISION
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Rock Wettability.
Wettability is a descriptive term used to indicate whether a rock or metal surface has the
capacity to be preferentially coated with a film of oil or a film of water.
Surfactants may adsorb at the interface between the liquid and rock or metal surface and
may change the electrical charge on the rock or metal, thereby altering the wettability.
Although the surface of a solid can have varying degrees of wettability under normal
reservoir conditions, the following conditions usually exist:
Sand and clay are water-wet and have a negative surface charge.
Limestone and dolomite are water-wet and have a positive surface charge in the
pH range of 0 to 8.
Mechanics of Emulsions
Emulsions can occur between two immiscible liquids and may be stable depending on
effects that occur at the interface. Energy is required to create the emulsion, and stabilisers
must collect at the interface between the liquids to keep the emulsion from breaking.
The most significant stabilisers of emulsions are:
1) Fine particles of clay or other materials.
2) Asphaltene.
3) Surfactants.
Surfactants have the ability to break an emulsion by acting on the stabilising materials in
such a way as to remove them from the interfacial film surrounding an emulsion droplet.
S P E O IDENTIFICATION CODE PAG 188 OF 269
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Water Blocks.
When large quantities of water are lost to a partially oil-wet formation, the return of original
oil or gas productivity may be slow, especially in partially pressure-depleted reservoirs. This
problem is caused by a temporary reduction in relative permeability near the well bore to oil
or gas. It is usually self-correcting but may persist for months or years.
Water blocking can usually be prevented by adding to all injected well fluids about 0.1 to
0.2% by volume of surfactant selected to lower surface and interfacial tension. The
surfactant should also water-wet the formation and prevent emulsions.
Cleanup of a water-blocked well can be accelerated by injecting into the formation a solution
of 1% to 3% by volume of a selected surfactant in clean water or oil. The surfactant should
lower surface and interfacial tension and leave the formation in a water-wet condition.
Removing damage requires many times the volume of surfactant required to prevent
damage.
S P E O IDENTIFICATION CODE PAG 189 OF 269
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If laboratory tests show potential damage caused by fluid circulation or injection into a well,
surfactants should be selected through laboratory tests to prevent damage.
If a surfactant is needed, tests must be run to determine the best surfactant for the job.
Many commercial surfactants appear to lose much of their surface activity above
50,000 ppm salt. To overcome this difficulty, it is sometimes desirable to pump a
preflush of solvent or relatively low salinity water, such as 1% KCI, ahead of the
surfactant treatment. The use of a solvent preflush may also reduce water production,
immediately following treatment. However, a solvent preflush should not be used in dry gas
wells.
If the damage problem is oil-wetting, this may be alleviated by injecting a strong water-
wetting surfactant into the formation.
Prior to the surfactant treatment, it may be necessary to clean the tubing, well bore,
and perforations of rust, scale, paraffin, asphaltene, sand, silt, and other debris.
Fluid Placement.
The surfactant treatment should be planned to insure injection into all permeable zones that
are open to the well bore. In long zones, isolation techniques should be employed to insure
that the treated interval does not exceed approximately 50 feet.
After squeezing surfactant into the formation, below frac pressure, the well should be shut in
for about 24 hours to insure proper surfactant operation response.
Temperature
The speed of any chemical reaction is directly affected by temperature. For instance acid
will react three times faster at 300oF than at 150oF.
Increasing temperature will cause a reduction in viscosity, which will have a role in reaction
kinetics.
Increase in temperature will also lead to more severe corrosion of the well bore tubulars.
Acid Concentration
The greater the strength of hydrochloric acid the longer it will take to react to completion.
However the initial reaction rates are faster. The increase ion by-products resulting from the
stronger acids acts as a retarder to the acid as its strength reduces. For example:
25% HCl reacts faster than 10% HCl in a limestone. But when the strength of
the 25% acid is reduced to 10% its reaction rate is less than that of a 10% acid
concentration.
For temperature from 75F to 250F, 30% HCl will take approximately three
times longer to react than 15% HCl.
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Velocity
In general increasing velocity will reduce the time it takes for acid to react. This may be
offset by the increase in penetration rate.
Surface Area
The greater the surface area exposed to acid the faster the acid will react, so limiting the
depth of penetration of the acid. However in anisotropic formations (e.g. limestone) the acid
may tend to 'wormhole', and so penetrate to a greater depth than might be thought.
Formation Composition
The chemical and physical composition of the formation will have an effect on the reaction
rate, the greater the volume of calcium carbonate the faster the reaction.
The main types of acid used in sandstone acidising are hydrochloric acid (HCl), and
hydrofluoric acid (HF). Organic acids, such as acetic acid and formic acid, can also be used
in conjunction with HF and HCl.
HCl will not dissolve sand or clays. It will dissolve any carbonates present in the formation
(e.g. from LCM material, or scale build up). It will also partially dehydrate any water swollen
clays that may be present. When hydrated bentonite is in contact with HCl an ion exchange
occurs. This results in the sodium bentonite being altered to hydrogen bentonite. This can
result in up to 80% loss of water, and shrinkage of the clay particles.
HF does have the ability to dissolve silica (sand) or silicates such as clay, shale, silt and
feldspar. As bentonite is a silicate it can be dissolved by HF acid. Formations with damage
due to clay migration, or bentonite from drilling mud can be treated with HF.
HF is usually pumped as an HCl-HF acid mixture, with the HF being liberated by the reaction
of HCl on ammonium bifluoride. Excess HCl is used as it tends to increase the solubility of
some of the secondary reaction products, and also has a significant effect on the rate of the
reaction.
Matrix acidizing is applied primarily to remove skin damage caused by drilling, completion,
workover or well-killing fluids, and by precipitation of deposits from produced water. Due to
the extremely large surface area contacted by acid in a matrix treatment.
Removal of severe plugging in sandstone, limestone, or dolomite can result in a very large
increase in well productivity. If there is no skin damage, a matrix treatment in limestone or
dolomite could stimulate natural production no more than one and one half times.
One of the problems in matrix acidizing is that fracture pressure is not always known.
Because breakdown or fracture pressure may decrease with a decrease in reservoir
pressure, it is frequently necessary to run "breakdown" tests to determine fracture pressure
of a specific zone or reservoir.
Fracture acidizing is an alternative to hydraulic fracturing and propping in carbonate
reservoirs.
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Un-dissolved fines can significantly reduce fracture flow capacity if not removed with spent
acid. Suspending agents, usually surfactants or polymers, will materially aid in the removal of
these fines.
Fracture acidizing has not, normally application in sandstone wells. "Breakdown" of a
sandstone well with acid at fracture pressures may break down natural vertical permeability
barriers to adjacent unwanted zones.
"Breaking-down" with acid may also tend to open channels between the cement and the
formation, even though formation fracturing pressure is never reached.
Formic acid (HCOOH) is a weakly-ionised, slow reacting organic acid. It has somewhat
similar properties to acetic acid. However, formic acid is more difficult to inhibit against
corrosion at higher temperatures and does not have the widespread acceptance and use of
acetic acid.
Hydrofluoric acid (HF) used in oil, gas, or service wells is normally 3% HF acid plus 12%
HCI. It is employed exclusively in sandstone matrix acidizing to dissolve formation clays or
clays which have migrated into the formation.
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Sulfamic acid (HSO3NH2), a granular-powdered material, reacts about as fast as HCl. The
primary advantage of sulfamic acid is that it can be hauled to the location as a dry powder
and then mixed with water. Unless sulfamic acid is modified, it will not dissolve iron oxides or
other iron scales. Because of its molecular weight, the amount of calcium carbonate
dissolved by one pound of sulfamic acid is only about one-third that dissolved by an equal
weight of HCI. Acidizing with sulfamic acid is usually much more expensive than with HCI.
Sulfamic acid is not recommended for temperatures above 180F because it hydrolyses to
form sulphuric acid (H2SO4). When H2SO4 reacts with limestone or CaCO3 scale, Calcium
sulphate (CaSO4) can be precipitated.
A summary of commonly used acids and their reactions is presented in Figure 15-1.
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Friction Reducers
These are added to reduce the frictional pressure drop while displacing acid into the well.
They are particularly important when coiled tubing is being used, as the frictional pressure
drop can be considerable. They are added in concentrations varying from 1 to 4lb/1,000
gals in order to achieve a reduction in friction pressure of 65-80%. Normally they are natural
or synthetic polymers, such as guar, cellulose, etc.
Diverting Agents
To ensure that the total interval of interest is to be properly stimulated it will be necessary to
limit the amount of acid penetrating any zones of high permeability and/or low pressure.
This is done by adding a diverting agent to the treatment.
Diverting agents available are both mechanical and chemical in nature.
Mechanical means, such as ball sealers of high specific gravity are pumped at sufficient
velocity to plug off the perforations. Then, they drop off and fall into the sump when
pumping stops.
Chemical diverting agents bind together to form an impermeable skin across the
perforations, or within the formation. They must be soluble in hydrocarbons or water to allow
clean-up on back flushing.
Surfactants
Surfactants lower the surface tension of the acid solutions. They assist acid penetration into
microscopic pores in tight formations, or in removing scale or cement particles from sand
faces. They aid acid penetration of oil films present in the pores, or formation surfaces so
improving contact. They also aid back flushing and return of spent acid during clean up by
decreasing the resistance of the formation to acid flow.
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Retarders
Retarders are used to decrease the reaction rate to achieve increased penetration away
from the wellbore. This is done by using chemicals which deposit a film over the rock after
initial acid contact or through increased viscosity by using natural or artificial gums to thicken
the acid.
Demulsifiers
Demulsifiers are used to reduce the tendency of the acid to form an emulsion with oil within
the formation. This is particularly important, as the formation of an emulsion may block the
pores completely.
Suspending Agents
Most carbonate formations contain insoluble which can cause blocking in formation pores or
fractures if fines released by acid are allowed to settle and bridge.
Suspending agents are usually polymers or surfactants.
Clean-up after fracture acidizing can be accelerated by using a suspending agent.
Sequestering agents
Act on complex ions of iron and other metallic salts to inhibit precipitation as hydrochloric
acid spends. During acidizing, if ferric hydroxide is not prevented from precipitating, this
insoluble iron compound may be re-deposited near the well-bore and cause permanent
plugging. Citric acid acts as a cheating agent and is particularly useful when higher iron
concentrations are present.
Tubular goods are often coated with iron corrosion products which are soluble in HCI. If iron
is in the oxidised condition, it will precipitate when HCI extinguishes in the formation and
cause plugging of the rock pores. Other sources of iron that could cause plugging in
producing, water-flood, and disposal wells are iron sulphide and iron carbonate (Siderite).
Acid concentrations used in a well treatment are dependent on the amount of iron that may
be dissolved and on the formation temperature. HCI concentration may be increased from
the normal 15% to as high as 25% where higher concentrations of iron oxide scales are in
the well system. A normal acetic acid concentration of 10% is suggested for most
applications.
Lactic acid is also an effective sequestering agent but is not usually recommended where
the temperature is higher than 200F.
All sequestered acid solutions require a corrosion inhibitor to minimise acid reaction on
tubular goods. Adequate protection to 450F can be obtained with the correct inhibitor.
Well conditions should be thoroughly analysed to determine the most effective sequestered
acid solution. Iron precipitation can be prevented for as long as fifteen days.
Anti-Sludge Agents.
Some crude, particularly heavy asphaltic crude, form an insoluble sludge when contacted
with acid. The primary ingredients of a sludge are usually asphaltene; sludge may also
contain resins and paraffin waxes, high-molecular weight hydrocarbons, and formation fines
or clays.
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The addition of certain surfactants can prevent the formation of sludge by keeping colloidal
material dispersed. Sludge is more of a problem with high strength acids.
Corrosion inhibitors
Temporarily slow down the reaction of acid on metal. Corrosion inhibition time varies with
temperature, acid concentration, type of steel, and inhibitor concentration.
Both organic and inorganic corrosion inhibitors have application in acidizing. Some organic
inhibitors are effective up to the 300F range. Extenders have been developed to increase
the effective range to 400F. Inorganic arsenic inhibitor can be used up to at least 450F.
However, the use of arsenic in oil well treatments has been banned in many areas because
even small percentages of arsenic acts as a poison to refinery catalysts.
Alcohol
Normally methyl or isopropyl alcohol in concentrations of 5% to 30% by volume of acid, may
be mixed with acid to lower surface tension. The use of alcohol in acid may accelerate the
rate of well clean-up, particularly in dry gas wells.
Retardation of Acid
To achieve deeper penetration in fracture acidizing, it is often desirable to retard
acid reaction rate. This can be done by emulsifying, gelling, or chemically
retarding the acid. Also, HCI can be retarded by adding CaCl2, CO2,. Another
approach is to use naturally retarded acetic or formic acid.
Emulsification is the most used technique in fracture acidizing to retard reaction
rate of HCl in limestone and dolomite within the temperature range of 80F to
300F. Emulsified acid usually produces the longest spending time of any
retarded acid. It may also serve as a diverting agent between stages of
conventional acid.
Gelled acid provides minor retardation in the temperature range from 80F to
200F Gels usually have high viscosity and low friction loss and provide some
fluid loss reduction. Their primary application is as a diverting agent.
Chemically-Retarded Acid-Retardation of HCI is obtained by the addition of a
unique surfactant to the acid which causes oil-wet and water-wet spots. Oil,
injected ahead of/or with the acid, adheres to the oil-wet spots and reduces acid
reaction on the oil-wet areas of the fracture faces.
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In actual practice, acidizing is usually divided into two categories based on pressure. Acid
jobs performed below fracture pressure are called matrix acidizing and are usually aimed at
damage removal. Fracture acidizing are usually performed to open new linear flow channels
to the well bore.
1) For some limestone and dolomite, higher fracture flow capacity is obtained.
2) Acetic acid sequesters iron and prevents formation of ferric hydroxide, an insoluble
precipitate.
3) It reduces slugging and emulsification with spent acid.
4) It provides a higher acid strength with a lower grade of corrosion than an equivalent
strength of HCI.
5) Acetic acid with HCI maintains a low pH, thus minimising swelling of clays.
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Foamed Acidizing
Foam is becoming widely used for acid fracturing low permeability liquid-sensitive carbonate
formations, especially gas wells. Foams employed are a dispersion of gas, normally
nitrogen, in acid with a small amount of surfactant foaming agent. Most jobs have been
made with HCI; however, HCI and organic acid combinations have been employed.
Apparent advantages of foamed acid over conventional acid fracturing are:
The low fluid loss inherent in foamed acidizing makes more acid available for
etching longer fractures.
There is less formation damage and wells clean up quicker.
The relatively high apparent viscosity of foamed acid results in wider fractures
and increases acid spending time because of lower area/volume ratio during
acidizing. Higher viscosity improves pumpability.
The built-in gas assist of 65 to 85% nitrogen in the spent acid provides rapid
cleanup, particularly in low pressure reservoirs.
High strength HCI is any concentration of HCI from about 20% to 35%.
The advantages of using high strength acid are:
Dolomite and some very dense limestone require high strength acid for
dissolution. Twenty-eight percent to 33% HCI is usually employed for these types
of formation.
In fracture acidizing, higher strength acid provides longer spending time,
resulting in longer etched fractures.
More CO2 is released per gallon of acid and less CO2 is dissolved in spent high
strength acid, thus providing more CO2 gas to assist in fracture clean-out after
the acid spends.
Sludge and emulsion plugging is considerably more severe with high strength
acid. Many damage problems with both high and low strength acid fracturing are
overcome by over-flushing with a volume of water equal to the volume of acid
used in the treatment.
A matrix type treatment with injection below fracture pressure should be used.
In planning an HF acid treatment to remove clay damage, the primary factors to be
considered are the depth of damage and the weight percent of clay naturally occurring in the
formation plus the weight of clay that has been forced into the formation pores near the well
bore from drilling or workover fluids.
It may be assumed that reaction of live HF acid on clay is essentially instantaneous.
To achieve stimulation, the treatment should be designed to meet these requirements:
Dissolve clays and mud solids near the well bore.
Prevent the precipitation of insoluble in the formation.
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Clay Stabilisation
As noted previously, an HF acid treatment is normally preceded by a volume of HCI to
dissolve carbonates. However, the action of HCI in the formation can dislodge clays and
other fines. If all of these released fines are not dissolved by HF acid, they may migrate
toward the well bore when the well is put back to production. Bridging at flow restrictions in
the pores of the sand can occur and cause production declines in a relatively short time. The
addition of certain cationic organic polymers to the acid and after-flush can minimise fines
migration and subsequent pore plugging.
Mutual solvents can effectively prevent the adsorption of emulsion breakers and cationic
corrosion inhibitors on sand and clay.
Mutual solvents should be used with either HCI or HF-HCl treatments when cationic
emulsion breakers are used.
Mutual solvents should be used on acidizing of sandstone along with suitable surfactants,
unless the specific surfactant does not appreciably adsorb on sandstone or clay.
Mutual solvents can solubilize surfactants in acid thus increasing the effectiveness of
surfactants.
If mutual solvents are used in HCl or HF-HCI sandstone acidizing, the mutual solvent should
always be in the preflush along with a suitable surfactant.
15.4.4.8 STIMULATION OF GAS WELLS, GAS INJECTION WELLS AND WATER INJECTION
WELLS
Treatment should follow the oil well stimulation procedure with these
modifications:
HCl should normally be used in the preflush or afterflush. Oil should not be
employed in the preflush or afterflush.
Gas wells should be swabbed or flowed within one hour after HF acid treatment.
It is not always necessary to swab water and gas injection wells following an HF
acid job. Within one hour after treatment, regular injection into water or gas
injection wells may be resumed.
5) A brief written outline of previous relevant well treatments should be given to the
stimulation supervisor.
When treating the well with hazardous chemicals the relevant safety wear must
be worn by all personnel in the work area.
Before rigging up treating equipment a safety meeting will be held with all
relevant personnel. The topics to be covered will include, but not be limited to,
working with pressurised equipment, handling of heavy equipment, use of
hazardous chemicals, safe working areas, emergency procedures, protective
clothing, etc.
Only authorised personnel wearing adequate protective clothing will be allowed in
the vicinity of the equipment while an acid treatment is being performed.
Good communications between the pump operator, tank operator, rig floor,
wellhead area and coiled tubing or nitrogen operator where applicable must be
maintained throughout the treatment.
All personnel should be aware of the Emergency Procedures for coiled tubing
operations.
All work areas will be chained, or roped off, and warning signs placed at access
routes. The exact requirements will be specified on the work permits.
Fire hoses will be available in the areas where acid is to be used. The hoses will
be fully charged, so that they can be used immediately should a spill occur.
Acid showers and eye baths will be available should any personnel come into
contact with acid.
Sacks of soda ash or calcium carbonate will be available for absorbing small
spills of acid.
The acid tanks and pumping unit will be positioned as close to the well as
possible to minimise the length of pressurised lines.
15.5.2.2 PRESSURE
During Stimulation operations pressure will be used to inject the fluid into the
wellbore and for the transfer of fluids between tanks and pumps.
The pressure will either be fluid pressure or energised fluid pressure. It is
important to note that when operating with energised fluid pressure, it is essential
to keep the operational personnel in safe areas when ever possible. The effect
of energised fluid pressure release is explosive.
It is essential that all pressure handling equipment carry up to date certification
for use in the pressure range specified. A pressure test and wall thickness
certificate is only proof that the equipment was acceptable on that date. Full
visual inspections should be carried out on all pressure handling equipment
during rig up. Any defects at all should result in the item being marked defective
and laid aside.
Follow the rig up and pressure test procedures rigorously for all items operating
under pressure. Any leakages should be dealt with by replacing the defective
item, followed by a re-test.
Ensure that all operational personnel in the work area are made fully aware of
the pressure hazard and are told to keep clear of the area when not actually
performing duties.
Note: All permits will be issued in accordance with the Installation Permit to
Work System.
The Area Authorities, together with the Safety Officer will make an inspection to
ensure that there is no other work going on which may affect the operation.
Only equipment with valid test certificates will be use for rigging up and during
the operation.
All work will be conducted according to the Permit to Work System.
All permits will be revalidated at the end of each shift.
Note: Permits may not be valid for 12 hours on crew change days.
The stimulation company will be provided with well details, and the nature of the
operations.
The stimulation company will provide details of the equipment and chemicals
required. This will include dimensions and weights of individual items, together
with data sheets for all chemicals that are to be used.
The stimulation company will also provide details of their quality assurance and
safety procedures. These procedures will be approved by the Company.
Note: The pressure testing will be witnessed by the Well Operations Supervisor.
Pressure tests will be monitored for 15 mins on a chart recorder. The chart will
be labelled and stored for reference.
The PRV is to be isolated during pressure test.
A pumping schedule will be prepared in advance by the service company. If during the
stimulation treatment there are any significant variations from this schedule the job will be
shut down and the cause investigated. If necessary the treatment will be circulated out of
the well, and a revised treatment performed.
Pressures
If a matrix acid treatment is to be carried out an injection test will be performed before any
treatment. This test will establish the injectivity of the formation and will give a baseline on
which to provide a preliminary estimate of the treatment effectiveness.
The maximum allowable pump pressure will be determined during the design phase of the
job. Normally the limiting factor will be the formation breakdown pressure. It is normally
undesirable to fracture the formation while performing a matrix acid treatment. Therefore a
maximum allowable surface pressure will be clearly stated in the stimulation programme.
Normally this pressure will include a safety factor.
Pump Rates
Pump rates will be clearly stated in the individual stimulation programme. The rate of
dissolution will depend on the nature of the deposits, and the speed at which the acid is
being pumped. Some treatments will require a soak period, and a slow pump rate may be
required. Other treatments may require rapid pump rates to ensure that any reaction
products are removed quickly.
The particular method used will depend on the nature of the scale in the well. The methods
for the placement of acid are given below. The method to be used will be dependent on
prevailing circumstances. As no two jobs will be the same the procedures given below are
guidelines only. The actual procedures will be dependent on the nature of the work to be
performed.
15.5.5.5 BULLHEAD
Bullheading acid can be potentially wasteful of the amount of acid used for a treatment. It is
possible that some of the acid will react with scale and other products deposited on the
inside of the tubing. These products may then be pushed into the formation resulting in
damage.
Back-flushing of spent acid may be more difficult and time consuming if bullheading is used.
An advantage with bullheading is that high rates can be pumped and rig up is more
straightforward.
Snubbing unit configurations are very flexible and can be adapted to the requirement of
different jobs for example, in a killed well, it is possible to use its hydraulic lifting system for
running in/pulling out of the well the tubing string.
The BOP stack can contain either single couple or double couple (or even more) pipe rams,
depending on well head pressure, well conditions, size of pipe to be run and type of work to
be performed.
Not Feasible operations: are those relevant to ESP completion, completion string with
down hole safety valve, control line operated. The pipe rams could not be operated without
damaging the electrical cable or the control line.
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A completion diagram of the well must be available. This should include the casing data,
tubing shoe, packers, perforations, etc., as well as KOP and maximum angle of deviation. A
brief written outline of previous relevant well operations should be given to the snubbing unit
supervisor.
The Completions and Workover Superintendent will ensure that all relevant equipment and
materials for the job are on site in a timely manner.
6) All personnel should be aware of the Emergency Procedures for snubbing unit
operations.
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Note: All permits will be issued in accordance with the Permit to Work System.
Note: Permits may not be valid for 12 hours on crew change days.
Fig. 1
Next Fig. 2 and 3 show the components of the unit istalled for the operation.
Next Fig. 4 shows the complete BOP stack including the extension between upper and lower
working BOP. This will allow room to contain equipment included in the completion/working
string.
Next Fig. 5 shows the BOP stack including the stripper.
Bleed off pressure, including inside working string and below lower working pipe
rams. The test is complete.
2) BOP stack connected to the tubing spool flange for completion pulling out
The following shall be considered for the BOP pressure test:
Before disconnecting the X-mas tree and connecting the BOP stack to the tubing
spool flange, install back pressure valve extractor on top X-mas tree, then run
and set a two way check valve in the tubing hanger.
Bleed off well head pressure to test the check valve sealing, then disconnect
extractor form X-mas tree.
Disconnect the X-mas tree seal flange from the tubing spool and install the BOP
stack on tubing spool.
Close BOP blind rams and pressure test the BOP flange connection to the tubing
spool at a pressure equal to shut in wellhead pressure. Bleed off pressure and
open blind rams.
Continue BOP pressure test as per the above steps.
Sour gas
Extreme care is required to prevent any gas leak around the pipe. The following precautions
shall be adopted:
Use double BOP system, to avoid the the risk of H2S for the personnel in case
changement of element was required.
Use H2S service top quality equipment.
Air supply and masks to be available on deck crew.
Only day light hours shall be worked, to ensure good visibility for maintenance
and repair.
Do not work when wind is not present.
Only essential personnel be present.
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Before disconnecting X-mas tree to install BOP stack, the following has to be made:
Case 1
1) Assuming no scale or paraffin are present inside tubing wall, run and set a wire line
plug below PBR. (In case of scale presence, tubing washing by coiled tubing should be
performed before RIH wire line plug).
2) Bleed down 1,000 psi (in two steps) to check for wire plug sealing.
3) RIH tubing puncher to perforate tubing near PBR. Do this maintaining over pressure
tubing to annulus at the moment of perforating. POOH tubing puncher.
4) Reverse circulate while delivering hydrocarbon to the flare. Continue operation until no
hydrocarbons are present inside the tubing.
5) Leave adequate hydrostatic pressure above down hole plug.
6) Install two way check valve in the tubing hanger, now ready for X-mas tree
disconnection and BOP stack installation.
7) At the end of BOP pressure test, the completion string is ready for POOH, after
removing the two way check valve from the tubing hanger and connecting the work
string to the tubing hanger itself.
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Case 2
1) Assuming no scale or paraffin is present on tubing wall, run and set a wire line plug in
the lower landing nipple. (In case of scale presence, tubing washing by coiled tubing
should be performed before RIH wire line plug).
2) Bleed down 1,000 psi (in two steps) to check wire plug sealing.
3) RIH tubing puncher to perforate tubing just above plug. Do this maintaining over
pressure tubing to annulus at the moment of perforating. POOH tubing puncher.
4) Reverse circulate (by pumping light brine) while delivering hydrocarbon to the flare.
Continue operation until no hydrocarbon are present inside the tubing.
5) RIH a second wire line plug (check valve, down word circulation allowed) and set it
above the first one. Pressurise annulus to check for plug sealing.
6) Install two way check valve in the tubing hanger, now ready for X-mas tree
disconnection and BOP stack installation.
7) At the end of BOP pressure test, the completion string is ready for POOH, after
removing the two way check valve from the tubing hanger and connecting the work
string to the tubing hanger itself.
8) Make up stabbing valve open to the work string. When packer unsetting, the annulus
fluid will go in contact with perforations and hydrocarbon will tend to go up. Pressure
will be present outside tubing, on stripper. If the down hole plug seals, no flow will be
monitored from the stabbing valve. On the contrary, further operations will be required
before POOH.
9) POOH completion string by stripping through BOP and stripper system.
17. WORKOVER
17.1 INTRODUCTION
A workover is an Operation to be performed on a well that for a certain amount of time will
be shut in to production, causing a production loss to the company. A lot of different aspects
have to be evaluated to select the most convenient compromise in term of cost and
efficiency.
Natural urgency of restoring maximum achievable production in a well which for some
reasons is cutting down production, shall contrast with the economic evaluation of its
schedule planning operations. Generally, speaking, unless for special reasons like
jeopardizing well safety, it is a relatively urgent problem to solve and can be scheduled in a
convenient and possibly optimized string, especially with respect to rig availability and its
best utilization.
A complete and exhaustive well analysis will be performed to evaluate all type of possible
workovers.
17.3.1.1 RECOMPLETION
This intervention is performed when:
Well problems heavily reduce the expected production.
The jeopardized minimum safety requirements need to be restored.
The operation involves the complete pull out of the completion string to eliminate the
problem. The preparation of the workover programme will address the decision of using a:
High cost service rig.
Pulling Unit.
Snubbing unit.
The intervention could be performed with coiled tubing unit, electric line, or service rig
(Pulling Unit), if the operation includes the completion pulling out of hole.
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The casing repair could be done in one of the following system, depending on production
casing problem:
Back-off: If the production casing has the problem included in a non cemented
portion up to the well head, try to recover the part of damaged casing by using
the electrically fired back-off system to unscrew a casing connection below the
damaged portion. New casing will be run and made up to the casing in hole.If
back-off doesnt allow the casing recovery, use casing cutter.
Internal casing patch: It may be used If there are casing holes or casing
breaks. It is made by a rippled metallic jacket dressed externally by fibreglass
and resin that has the function of hydraulic sealing, which is run in position and
then swaged to the casing ID. Run in section of 40 ft long, it reduces the ID by
about 0,3.
Control methods:
Flow rate reduction (it causes a reduction of the velocity in perforation tunnels
or in the sand face). Lately, same effect has been obtained with long
horizontal drains. Longer exposed formation to production reduces the
hydrocarbon velocity to enter the well.
Mechanical methods: Filters, Gravel pack, Sand consolidation.
17.3.2.6 ECONOMICS
Once all above analysis have been done, the following cost indicators shall be put together
and the whole operation evaluated.
Rig costs.
Materials costs.
Service costs.
Transportation costs.
Internal costs.
2) Prepare the killing fluid and record the mud pits level. Always start with at least twice
the well volume.
3) Inspect the mud circuit.
4) Verify the perfect efficiency of the mud pump.
5) Rig up and test surface lines.
6) Record well head shut in data (tubing, annulus).
7) Plan to circulate for more than one well cycle to homogenize the killing fluid density.
8) Plan to monitor accurately the level in the pits to check for fluid losses to the formation.
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2) The formation does not take fluid, or too high injection pumping pressure should be
required at well head:
The annulus level shall be checked and possibly filled up.
The circulation valve ( SSD ) in the tubing string above the packer shall be
opened. If an SSD valve is not present, holes in the tubing string shall be opened
(by tubing puncher) just above the packer.
The tubing filling operation is performed by reverse circulation, by pumping from
the annulus and having the tubings outlet diverted to the flare, through the choke
manifold to maintain enough tubing head back pressure to control the well. The
reverse circulation shall be continued until the killing fluid shows the same in and
out rheological characteristics.
If casing above packer can withstand high pressure, try bullheading the
remaining hydrocarbon (below SSD) to formation.
If casing above packer cannot withstand high pressure, close SSD before trying
bullheading the remaining hydrocarbon.
After packer un-setting, reverse circulate to recover the hydrocarbon pill
remained trapped behind tail pipe, below packer.
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3) If the well continues to take fluid, then the temporary plugging programme shall be
initiated.
The function of a temporary plugging pill is to plug the permeable formation with
materials that afterwards can be easily removed leaving the formation undamaged
or with minimum damage.
A temporary plugging pill shall have the following characteristics:
Easy pumpability through the production string.
The size of the solid material shall be sorted to allow bridging with the formation.
Bridge should plug only one way.
Bridge shall be easily removable either flowing the well back or with a weak acid
treatment.
4) Carrier Fluid
Shall allow pumping of the plugging material through the tubing string.
Shall allow for short period (2-3 min.) pumping stop without settling of the solid
particles.
5) Bridging Material
The choice of the bridging material shall be done on the basis of:
Type of formation.
Type of permeability (main or secondary permeability).
Type of formation fluids (water, oil, gas or a combination).
Completion configuration and down hole parameters (type of completion,
temperature, pressure etc.).
See parag. 4.7 Completion and Workover fluids and parag. 4.9Lost Circulation herein for
more information on fluids used in a well.
1) Packer un-setting:
Calculate the string weight considering the buoyancy factor.
Add shear value of packer releasing mechanism accounting for shear ring max
shear value including span.
Add frictions due to the deviation.
Include in the calculation a convenient tubing pull reduction to account for wear
of tubular (corrosion) based on field historical data.
If the calculation results exceed the pull capacity of the tubing, a contingency
procedure to cut the tubing string above the packer should be considered. In this
case the packer will be released by using a work-string, after POOH the
completion string.
2) Procedure to POOH:
Wellhead and BOP stack, including tie down releasing, are ready as per previous
parag. 17.4.2.1.
Unset the packer by pulling on the string (apply the pull above calculated), and
continue the POOH slowly, checking that the weight read on the Martin Decker is
close to the theoretical value,
After ten feet stop pulling and perform a static survey.
Close BOP (annular) and reverse circulate at least twice the well volume
monitoring the possible hydrocarbon cushions and continue until the in and out
rheological properties of the fluid are the same. Divert hydrocarbon to flare.
Perform static survey.
If the well still flows, increase the killing fluid density according to residual shut in
pressure and repeat fluid conditioning operation.
If the well takes fluid, spot to bottom hole a viscosified cushions or a temporary
plugging pill.
Perform static survey again. If the check has positive result, start POOH.
Pull the Tubing Hanger above the rotary table and break down its connection.
Make up additional tubing and run in hole the completion string, adding tubing, to
circulate as closest as possible to the perforations.
Close BOP and reverse circulate thorough choke to control the rat-hole
hydrocarbon cushions.
Perform static survey again. If the check has positive result, start POOH.
POOH the completion string, monitoring the trip tank level.
Store the tubing in lengths in the derrick, in case of carbon steel tubing, or lay
down each single tubing in case of CRA material. Install thread protection.
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Snap latch
The Snap Latch releasing from the packer usually requires less pull than the one needed for
the shear element of a retrievable packer. The packer will be recovered later by milling tool
operation.
After packers un-setting and workover fluid static conditions have been confirmed, the
POOH sequence operation shall be the same as per parag. 17.4.3.1.
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17.4.4.1 PARTIALIZATION
Partialization may become necessary when the formation starts to produce undesired fluids
like water, gas from an oil bearing zone or sand.
The phenomenon may be due to changes in reservoir conditions, such as:
Reservoir depletion.
Inefficient casing cement bond.
Wrong perforations placement.
In general terms, despite being widely used for above operations, squeeze operations are
very rarely completely successful even when accurately planned, since they are dependant
on a variety of external occurring simultaneous conditions.
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However they are frequently done in formation not well known from petrography point of view
so that volume determination, real cement path during injection and thickening time are
frequently guess parameters. For these reasons it is always better when it is required a
perfect hydraulic seal, to look for alternative pack-off solutions to be installed as a back up.
17.4.6.1 FISHING
Intervention that has the purpose to free the well from tools that for various reasons block
the well operability; the tools to be fished could have been lost for many reasons. Examples
may be:
a) Wire line tools/wire lost during wire line operations. In this case, the first
intervention is always done by wire line itself and in more serious cases by coiled
tubing.
b) Section of tubing/down hole equipment lost and/or broken during POOH.
c) Damaged section of corroded casing, or worn off by repeated operations done
inside.
Cases b and c always require a service rig or a pulling unit.
See next pages for an overview of the main tools used for workover operations.
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17.4.6.2 MILLING
This activity has the purposes to eliminate the cement plugs or the tools set in the well which
either are not retrievable or which failed to retrieve (i.e. packers, cement retainer) or to
prepare the fish head before starting a fishing job.
Next figures show samples of milling tools.
Figure 17-13
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Figure 17-14
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FIELD NAME
District/Affiliate Company
DATE:
REPORT ARPO 01 Cost center
Major Contractors
Type of Service Company Contract N Type of Service Company Contract N
Mud Logging
D. & C. Fluids
Cementation
Waste treatment
Rig-up [hh:min]
Delay [hh:min]
Lost-time Accidents [hh:min]
Rig Anchorage
Anchor Mooring Line Piggy Back Mooring Line Tension Operative Total
Bow Weight Length Weight Chain Cable [Tested] Tension Time
N Angle Type & Manufacturer [t] Cable Chain N [t] Length Length [t] [t] [hh:min]
[m] [m] [m] [mm] [m] [mm]
1
2
3
4
5
6
7
8
9
10
11
12
Note: Supervisor
Superintendent
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Operations at 07:00
Contractor Type of Service Working Stand by Arrived on Loc. Left Loc. Daily Service Cumulative Serv.
Hours Hours Date Hour Date Hour Cost Cost
District/Affiliate Company
REPORT FIELD NAME
SQUEEZE / PLUG
Type Length [m] Cap.[ l/m] Bottom [m] Cement retainer Manufacturer Model / Type De
Squeeze packer [inch] [m
Injectivity Test with: Pump Rate Testing Pr. Tot. Vol. Final Sqz Pr. Returns V
2 2
[l/min] [kg/cm ] pumped [l] [kg/cm ] [l]
2
Test [kg/cm ] [mins]
Stinger Pressure test
Annular pressure
CEMENTATION
2
Operation (y/n) [kg/cm ] [mins]
Casing Reciprocation Bump Plug Casing testing pressure
Casing Rotation Valve holding Annulus pressurization
Inner string
GENERAL DATA
3
Slurry Displacement To Surface Losses [m ]
Time [mins.] Flow Rate Pressure Total Volume Operation Description Final Press. Retur
2 2
Partial Progr. [l/min] [kg/cm ] [l] [kg/cm ] Vol.
Supervisor Superintendent
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Report[m]
From N Depth
Interval(m)
Drilled (m) Mud Type
Density (kg/l)
3
To [m] Drilled Volume [m ] Cl- concentration (g/l )
3
Phase size [in] Cumulative volume [m ]
3 3
Water consumption Phase /Period [m ] Cumulative [m ]
Mixing Mud
Others
Total
3 3
Readings / Truck Fresh water [m ] Recycled [m ]
3
Mud Volume [m ] Phase Cumulative Service Company Contract N
Dumped Transportation
Transported IN
Transported OUT
Remarks
Supervisor
Superintendent
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Well Size [] Steel Thickness Measured Depth Vertical Depth Cement Top
Situation Grade [lb/ft] Top [m] Bottom [m] Top [m] Bottom [m] M.D. [m] T.V.D. [m]
Liner
Casing
Casing
Tubing Service Company
Packer
Tubing shoe
Perforation System
Wireline Overbalance Completion fluid Density [kg/l]
TCP Underbalance Fluid in front of Perforation Density [kg/l]
Thru Tubing Differential Pressure [kg/cm2] Fluid Losses after Perforation [m3]
Data Gun Gun Gun Charge S.P.F Measured Depth Vertical Depth Pool Remarks
Type Specific. Type Top [m] Bottom [m] Top [m] Bottom [m]
Note:
Supervisor Superintendent
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GRAVEL PACK
PERFORATING WELL NAME
OHGP SBHT [C] at m Fluid losses Drilling Underreaming After Perforating After Back Surging
ICGP SBHP [kg/cm2] at m Losses [m3/h]
F&P Permeability [mD] Total [m3]
TTGP to [ ] HC [ ] Brine Losses Control LCM Volume [m3]
Well data Pilot hole Underreamed Caliper Gravel Annulus Pad Carrier Displa- Well Schetch
min Fluids cement
Top [m] max Name / Salt
Bottom [m] med Density [Kg/l]
N Starting Pumping Volume Progr. Progr.Vol. Proppant Initial Final Injection Casing Notes
Injected
Fluid Time Rate Volume Entering in Concentr. Press. Press. Index Press.
Formation
Ref. [bbl/1'] [m3] [m3] [lb/gal] [psi] [psi] [bbl/day/psi] [psi]
Notes / Remarks:
Supervisor
Superintendent
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Superintendent
District/Subsidiary
Report Date:
Well Name: Well Code:
General Information
Contract No: Contract Type: Contractor:
Service/Supply:
Drilling Completion Workover Duration Dates of Failure: Distributed By:
RIG SITE
Description of Failure:
Contractor Representative:
DISTRICT OR SUBSIDIARY NOTES:
Analysis Code:
S P E O IDENTIFICATION CODE PAG 263 OF 269
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CONTRACTOR EVALUATION
(FEED BACK REPORT 02)
District/Subsidiary
Report Date:
Well Name: Well Code:
General Information
Contract No.: Contract Type: Contractor:
Service/Supply: Distributed By:
R1 Technical Requirements
FB_01 REPORT REFERENCES
FB Report No.: Time Lost (Hr.Min): Economic Cost (M):
Category Evaluation Score (0-9)
Suitability of Equipment and Materials
Compliance of Equipment and Materials to the
Adequacy of Personnel
Meeting with Operational Programme Requirements
Meeting with Contract Operation Timings
Equipment Condition/Maintenance
R2 Management and Organisational Requirements
FB_01 REPORT REFERENCES
FB Report No.: Time Lost (Hr.Min): Economic Cost (M):
Category Evaluation Score (0-9)
Availability of Equipment and Materials
Technical and Operational Support to Operations
Capability and Promptness to Operational Requests
R3 Safety and Quality Assurance Requirements
FB_01 REPORT REFERENCES
FB Report No.: Time Lost (Hr.Min): Economic Cost (M):
Category Evaluation Score (0-9)
Meeting with the Contract Agreement DSS
Availability and Validity of Requested Certificates
Meeting with Contract Quality Assurance Terms
Event Support Documentation
Type of Subject: Issued By: Date:
Document:
Notes:
Appendix B - ABBREVIATIONS
AC/DC Alternate Current, Direct Current
AHTS Anchor Handling Towing Supply
API American Petroleum Institute
BG Background gas
BHA Bottom Hole Assembly
BHP Bottom Hole Pressure
BHT Bottom Hole temperature
BJ Blast Joint
BMT Blue Methylene Test
BOP Blow Out Preventer
BPD Barrel Per Day
BPM Barrels Per Minute
BPV Back Pressure Valve
BSW Base Sediment and Water
BUR Build Up Rate
BWOC By Weight Of Cement
BWOW By Weight Of Water
C/L Control Line
CBL Cement Bond Log
CCD Centre to Centre Distance
CCL Casing Collar Locator
CDP Common Depth Point
CET Cement Evaluation Tool
CGR Condensate Gas Ratio
CMT Cement
CP Conductor Pipe
CR Cement Retainer
CRA Corrosion Resistant Alloy
CSG Casing
C/T Coiled Tubing
CW Current Well
DC Drill Collar
DE Diatomaceous Earth
DHM Down Hole Motor
DHSV Down Hole Safety Valve
DIF Drill in Fluid
DLP Dog Leg Potential
DLS Dog Leg Severity
DOB Diesel Oil Bentonite
DOBC Diesel Oil Bentonite Cement
DOR Drop Off Rate
DP Drill Pipe
DPHOT Drill Pipe Hang off Tool
DRLG Drilling
DST Drill Stem Test
DV DV Collar
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P/U Pick up
PBR Polished Bore Receptacle
PCG Pipe Connection Gas
PDC Polycrystalline Diamond Cutter
PDM Positive Displacement Motor
PGB Permanent Guide Base
PI Productivity Index
PKR Packer
PLT Production Logging Tool
POB Personnel On Board
POOH Pull Out Of Hole
PPB Pounds per Barrel
PPG Pounds per Gallon
ppm Part Per Million
PTR Piano Tavola Rotary
PV Plastic Viscosity
PVT Pressure Volume Temperature
Q Flow Rate
Q/A Q/C Quality Assurance, Quality Control
R/D Rig down
R/U Rug up
RBP Retrievable Bridge Plug
RCP Reverse Circulating Position
RFT Repeat Formation Test
RIH Run In Hole
RJ Ring Joint
RKB Rotary Kelly Bushing
ROE Radius of Exposure
ROP Rate Of Penetration
ROU Radios Of Uncertainty
ROV Remote Operated Vehicle
RPM Revolutions Per Minute
RPSP Reduced Pump Strokes
RT Rotary Table
S (HDT) High Resolution Dipmeter
S/N Serial Number
SBHP Static Bottom Hole Pressure
SBHT Static Bottom Hole Temperature
SCC Stress Corrosion Cracking
SD Separation Distance
SDE Senior Drilling Engineer
SF Safety Factor
SG Specific Gravity
SICP Shut-in Casing Pressure
SIDPP Shut-in Drill Pipe Pressure
SIMOP Simultaneous Operations
SPM Stroke per Minute
SR Separation Ratio
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Appendix C - BIBLIOGRAPHY
Document: STAP Number
Drilling Procedures Manual STAP-P-1-M-6140
Completion Design Manual STAP-P-1-M-7100
Drilling Fluids Operations Manual STAP-P-1-M-6160
Well Control Policy Manual STAP-P-1-M-6150
Well Test Procedures Manual STAP-P-1-M-7130
General Wireline Procedures Manual STAP-P-1-M-7110
Other
API Specification No 811-05CT5
API Recommended Practices 5A5
API Recommended Practices 5C1
API Bulletin 5A3