SAPESCO

SAHARA PETROLEUM SERVICES

Coiled Tubing Operations Safety

Standards

PREPARED BY: REVIEWED BY: APPROVED BY:

Name: Name: Name:

Position: Position: Position:

Signature: Signature: Signature:

COPY NO. ( )

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Rev. Date : 23/10/2001
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Standards

1. PURPOSE
To prevent accidents, injuries, damage to equipment, loss of process or environmental damage
during coiled tubing operations.

2. SCOPE
This standard defines the minimum safe operating requirements for SWS coiled tubing
operations.

3. POLICY
SAPESCO policy requires that this standard will be followed for all coiled tubing operations.

4. RESPONSIBILITY
4.1 The Operation Manager is responsible to comply with these standards and provide:
0 Correctly equipped and maintained equipment
ㄱ The necessary personnel for safe operations
ㄴ The correct training according to these standards so that employees understand
their responsibilities.

4.2 The Sales and Technical personnel are responsible for collecting all necessary
information to plan and prepare coiled tubing job procedure.These persons must
communicate all information in the job procedure to the Job Supervisor.

4.3 The Job Supervisor on location must comply with all standards, and must not allow
SAPESCO employees to be exposed to risk levels that are not acceptable.

4.4 The Operations Manager is responsible to assign enough people to the job to safely
perform all tasks. These persons must consider the amount of equipment, how the
equipment will be installed, and the length of the job. Most coiled tubing
operations require three or more persons. These persons must have the correct
training and skills for the job assigned.

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5. FORMS :

 Job call and request (WF-09-0001)

 Coiled Tubing Checklist (Wf-090012)
 Prejob Safety and Operations Meeting ( WF-09-0003)
 Figure 1
 Figure 2

6. ACTION

6.1 Job Preparation.

6.2 Job Categories.
6.3 Equipment & Operations: Requirements & Limits.
6.4 Equipment Location.
6.5 Setup & Connection.
6.6 Wellhead Connection.
6.7 Pressure Testing & Function Testing.
6.8 Minimum Inspection Requirements For Well Control Equipment.
6.9 C.T Operations.
6.10 Stopping operation for the night – with or without an operator on-site.
6.11 Safety Equipment and Safety System.

6-1 JOB PREPARATION

6.-1-1 PLANNING AND DESIGN

6.1.1.1 Sales staff accompanied by technical and operations managers if required are
responsible to hold a planning meeting with the customer to review the job
design, job procedures and contingency plans.

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6.1.1.2 It is recommended to collect the following information during the job design
phase. This information is used to develop a safe and complete job design.

6.1.1.2.1 Well bore characteristics:

ㄷ Casing sizes, weights and depths for the areas where the coiled tubing is
operated.
ㄹ Tubing sizes, weights, grades and depths.
ㅁ Description of down hole well completion, including dimensions and
depths of equipment. This information must include a wellbore diagram.
ㅂ Location and dimensions of the obstructions or restrictions in the well
completion.
ㅅ Directional survey.
ㅇ Type and density of fluids in the wellbore.
ㅈ The specifications of the wellhead and the surface equipment. The
specifications must describe the connections where the coiled tubing
equipment will be installed.
ㅊ Location, type and function of any wellbore safety devices.
ㅋ Perforation depth.
ㅌ Known problems with the wellbore.

6.1.1.2.2 Reservoir information:

ㅍ A description of the well history (H2S, problems, etc.).
ㅎ Reservoir characteristics.
ㄱ Description and location of all zones that communicate to the wellbore.
ㄴ Estimated frac and pore gradient.
ㄷ Current flow pressure and shut in tubing pressure.
ㄹ Current flowing bottomhole pressure and shut in bottomhole pressure.
ㅁ Maximum possible shut in pressure.
ㅂ Type of fluids and estimated maximum production rates.
ㅅ Any conditions which can cause erosion, corrosion, or other problems.

6.1.1.2.3 Other items which can change the job design:

ㅇ Location plan (for example, overhead electrical wires).
ㅈ Regulatory restrictions.
ㅊ For offshore work, deck limits on the size and loads, positions of barges
and equipment, placement of the equipment, etc.
ㅋ Identification and classification of any zoned hazardous areas.
ㅌ Plans for surface handling of wellbore fluids.
ㅍ Review of safe operating limits for all lifting equipment.

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6.1.1.3 SWS job planning must include revision of the following items:
ㅎ Type, size, configuration and pressure rating of surface well control
equipment.
ㄱ Responsibilities of personnel.
ㄴ Bottomhole assemblies, including downhole flow control devices.
ㄷ Review of on-site pressure test procedures.
ㄹ Review of wellhead connections and any adapter requirements.
ㅁ Review of job procedures (customer and SWS).
ㅂ Review of contingency plans.

6.1.2 SAFETY MEETINGS.

6.1.2.1 Before start any work at a location, a safety meeting must be held between SWS
crew, the customer representative and if applicable personnel from other
companies assigned to the job. Before this meeting, a location assessment can be
done to identify any hazards. All actions to control these risks must be discussed
at this meeting.

Job responsibilities for equipment installation, connection and testing must be

defined to SWS crew by job supervisor. Equipment function and pressure testing
must be planned. NO SMOKING and safe areas must be idetified by client
representative.

6.1.2.2 After the equipment is connected and tested, a final safety meeting must be held
before beginning work. Safety meeting format attached shows the minimum
information to be available at this meeting. Locations can expand this checklist
for their operations. The customer representative must attend this meeting. The
persons in charge for the customer and for SWS must be identified in the
meeting.

6.2 JOB CATEGORIES

6.2.1 Coiled tubing operations have two categories based on the maximum
operating wellhead pressure which is the maximum pressure that is planned
during the coiled tubing operations or the maximum pressure during operations
or when the well is shut in. The same definition applies to oil or gas wells.

6.2.2 The two categories are:

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0-3500 psi (0-24,150 kpa)

3500-7000 psi (24,150-48,300 kpa)

Each of these categories has equipment requirements and operational limits.

These limits are defined in Section 8.

6.2.3 A working pressure up to 3500 psi is normal. If the job design indicates that the
operating wellhead pressure can be more than 3500 psi, the requirements of the
next highest category must be followed. Always consider the maximum
possible pressure.

6.3 EQUIPMENT AND OPERATIONS; REQUIREMENTS AND LIMITS

6.3.1 Figure1 defines the minimum OPERATIONS REQUIREMENTS AND LIMITS

for all categories of coiled tubing operations.

6.3.2 Figure 2 defines the minimum EQUIPMENT REQUIREMENTS AND LIMITS

for all categories of coiled tubing operations.

6.3.3 Configurations for BOP stack and wellhead assembly:

6.3.3.1 For normal operations up to 3500 psi (24,150 kpa), the following
configurations are required, starting from the top of the assembly. All
equipment have a working pressure of 10,000 psi (69,000 kpa) and a TP of
15,000 psi (103,500 kpa).
ㅅ Normal Stripper Assembly
ㅇ Blind Rams
ㅈ Shear Rams
ㅊ Kill Line Inlet
ㅋ Slip Rams
ㅌ Pipe Rams

6.3.3.2 For operations from 3500 psi to 7000 psi (24,150-48,300 kpa), the following
configurations are required starting from the top of the assembly. All
equipment have a working pressure of 10,000 psi (69,000 kpa) and a TP of
15,000 psi (103,500 kpa) TP.
ㅍ Radial Or Side Door Stripper
ㅎ Tandem Side Door Stripper

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ㄱ Blind Rams
ㄴ Shear Rams
ㄷ Kill Line Inlet
ㄹ Slip Rams
ㅁ Pipe Rams
ㅂ Flow Cross With Two Flanged Outlets and Double Valves
ㅅ Pipe Ram

6.3.4 The SWS well control equipment must have a working pressure rating equal to
or greater than the wellhead or BOP connected to SWS equipment.

6.3.5 ACCUMULATORS

6.3.5.1 Accumulators, like pressure vessels, must meet the requirements of ASME
Section VIII Division 1.

6.3.5.2 Accumulators can be charged only with nitrogen. The charge pressure must
be checked before beginning work on any well. The recommended charge
pressure must be shown on a permanent tag or plate fastened to the
accumulator.

6.3.5.3 The accumulator volume must be large enough to allow a complete cycle,
“close-open-close”, for all BOP system components in the following
sequence:
ㅇ Close the slip rams
ㅈ Close the pipe rams
ㅊ Close the shear rams and shear the coiled tubing
ㅋ Close all other well control stack rams
ㅌ Open all well control stack rams
ㅍ Close all well control stack rams

The accumulator must have the capability to perform this sequence of operations at
the wellbore pressure.

6.3.6 Use two down hole check valves or one double falpper check valve for all jobs
unless the director approves the operation without these valves.

6.3.7 Install combustible gas detectors when you are working on a gas well when gas
is vented to the atmosphere within 100 feet (30 m) of the SWS equipment. The
gas detectors must be installed near the coil tubing unit. The alarm on the gas

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detector must be set at two levels, 20% LEL for low-level warning, and 50%
LEL for high-level warning.

When a low-level alarm is heard, the gas level must be monitored and all
personnel must be ready to stop operations and secure the well.

When the high-level alarm is heard, all personnel must stop working, secure the
well, stop all the equipment and leave the area. You can return when the gas level
is below the 20% LEL.

6.3.8 Use a windsock or wind indicator when you work on gas wells or wells where
there is a presence of H2S.

6.4 EQUIPMENT LOCATION

The following equipment positions are required for coiled tubing operations.

6.4.1 LAND OPERATIONS

6.4.1.1 Equipment Positioning: Place the equipment upwind or crosswind from the
wellhead or flowback outlet.

6.4.1.2 Accessibility: Make sure you do not block access to the control cabin.

6.4.1.3 Other equipment on site: If possible, place the pumping equipment and
treating lines on the same side of the coiled tubing unit as the reel swivel. If
possible, do not place treating lines under or over the equipment.

6.4.1.4 Crane Position: When you use a crane, position the crane on the opposite
side of the wellhead that has the coiled tubing unit. This is the best position
to fasten the injector head.

6.4.1.5 Electrical lines. All high-voltage lines can form an arc across long distances.
Cranes and loads must be kept at least 20 feet (6 m) from all electric lines.

6.4.1.6 Distance from wellhead: Keep heavy equipment at least 6 feet (2 m.) from
the edge of the well cellar openings.

6.4.1.7 Put chocks under the truck wheels when the trucks are in position.

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6.4.1.8 Space between equipment: Make sure that there is enough space between
the equipment for personnel to move around the equipment.

6.4.1.9 Clear equipment overview: The operator must have a clear view of the
injector head. The person responsible for operating the coiled tubing reel,
must also have clear view of the reel.

6.4.2 OFFSHORE OPERATIONS

Follow above requirements if applicable when you work offshore. The

following additional requirements must be followed.
6.4.2.1 Securing equipment: The tubing reel must be fastened to the deck to prevent
movement during operation.

6.4.2.2 Deck load distribution: Review deck load distribution with offshore or barge
personnel during the job planning. Always use the maximum weight of the
coiled tubing or tanks full of liquid.

6.4.2.3 Keep the decks clear of any oils or other fluids.

6.4.2.4 When you transport equipment on barges, make sure all equipment is fastened
to the deck.

6.5 SAFE SETUP AND CONNECTION

The following procedure apply to most types of jobs. When you work on floating rigs,
additional procedures will be required.
SAPESCO policy requires that personnel who work at a height above 6 feet (2m.) must
wear a safety harness. This safety harness must be connected to a solid connection
point above personnel.

6.5.1 Wind Speed: Check the wind speed. For most jobs, do not assemble or
disassemble equipment if the wind speeds are more than 25 mph (40 kph).
Job operations can be continued in wind speeds to 40 mph (64 kph).
Consider possible sudden gusts of wind.

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6.5.2 Confirming positions: Make sure the injector control is in the “neutral”
position. Make sure the remote pilot control for the pressure relief valve is
retracted completely. The pressure gauges for the injector control must
indicate 0 psi/kpa.

6.5.3 Personnel awareness of potential hazards: When you place the walkways and
steps, make sure all personnel know the location of possible danger to fingers
and hands.

6.5.4 Injector head positioning: When you place the injector head on the ground,
place it directly in front of the wellhead, with the front toward the reel.
Make sure the support legs are installed correctly. Use only the short steel
legs. Make sure the injector head is fastened to strong points to prevent
movement.

6.5.5 Power pack checks: If the engine is running, stop the engine. Release all
pressure from the accumulator, the pneumatic and the hydraulic systems.
Connect all necessary hoses to the injector head.

Hose connections must be fitted with unions which only allow the hose to be
connected into the correct port on the injector head.

6.5.6 Injector head checks: Check and make sure that all guards are in position
before you start the injector chain drive system. Personnel must not put any
parts of their body in any position where they can come in contact with any
moving parts of the injector. Make sure that personnel are not on the
equipment during operation.

6.5.7 Reel checks: Move the reel toward the injector. Make sure the reel brake is
applied and remove the safety chain from the reel.

You may need to adjust the reel to remove the safety chain, therefore release the
reel brake and then adjust the reel.

Make sure you apply the reel brake again before any person tries to remove
the safety chain.

6.5.8 Tubing stab in: Raise the levelwind to the top as needed. Prepare to install
the coiled tubing into the injector

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6.5.9 Bottom hole assembly: When the tubing is in the injector head, prepare the
end of the tubing to connect the bottomhole assembly. When the bottomhole
assembly is connected, test the connector by pulling at least 5000 lb. (2270
kg.) of force.

Personnel must not work under the injector head when it is only supported by
a crane. Make sure the support legs are in position.

6.5.10 Wellhead: If you must release the pressure on the wellhead before you
remove the upper flange or connection, follow this procedure:
ㅎ Make sure the lower master valve, located below the side arm outlets on the
wellhead, is closed.
ㄱ Open the upper master valve and the side arm valves to release any pressure
on the wellhead.

When you perform this task, make sure the lower master valve is not leaking. If
wellbore pressure is leaking through the lower wellhead master valve, close all
wellhead valves and advise the customer representative. Do not continue any
operations when the lower master valve is leaking.

6.5.11 BOP installation: Install the wellhead adapter connection to allow installation
of the SWS BOP. Fasten the SWS wellhead equipment in position with
chains to prevent any movement.

6.5.12 BOP testing: Function test and pressure test the BOPs to PT-1 (see Section
on Pressure Testing).

6.5.13 Observing crane capacity: Install the injector head and fasten it with the
support legs and chains. Make sure the crane supports the weight of the
injector and the BOPs.

On offshore rigs, the rig crane is used to lift the injector head. An air winch on the
rig floor can be used to move the injector head to the rig floor.

6.5.14 Instrument check: Install and set all counters and the weight indicator to zero
(0).

6.5.15 Communications function verification: Make sure the communications

system is functioning.

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6.5.16 Final testing: Perform the final pressure test to PT-2 (see Section on Pressure
Testing). Hold the final safety meeting and proceed with the job.

Note: The customer representatives must operate the wellhead valves. SWS
Supervisor can operate the valves, only under direct instructions from the
customer. Always count and record the number of turns needed to open the
master valve. Use the same number of turns to close the master valve.

6.6 WELLHEAD CONNECTIONS

6.6.1 THREADED CONNECTIONS

Connections to wellhead can be made with threaded adapter only if:

ㄴ The maximum operating wellhead pressure does not exceed 2000 psi (13,800
kpa).
ㄷ There is no flanged connection on the wellhead where you can use a flanged
adapter.
ㄹ There is no H2S present.

When a threaded adapter is used to connect to the wellhead, the following requirements
must be followed.

6.6.1.1 Inspect the threads of both the SWS adapter and the wellhead. Do not install
the adapter if either of the threaded connections is damaged. Do not install
the adapter if the wellhead threads are worn.

6.6.1.2 Tighten the threaded adapter into the wellhead

6.6.1.3 The largest coiled tubing which can pass through a threaded adapter has an
outside diameter of 1.75”.

6.6.1.4 The injector head must be supported with steel legs and a 4-point guy wire or
chain system. A platform support is permitted.

6.6.1.5 The injector head must be leveled to prevent any side loading forces on the
threaded adapter.

6.6.1.6 The BOPs must be installed directly to the wellhead adapter. Do not
install a lubricator below the BOPs.

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6.6.2 FLANGED WELLHEAD CONNECTIONS

Unless the conditions described in 6.13.1 exist, the coiled tubing must be connected to the
wellhead with a flanged connection.

Note: Flanges must have only ONE set of bolt holes. Flanges with multiple sets of
bolt holes must not be used on adapters. Destroy all flanges that have multiple
sets of bolt holes.

6.6.2.1 Inspect both the wellhead and the SWS flanges to confirm that:
ㅁ Flanges are the same type
ㅂ The pressure ratings are the same
ㅅ If required, the flanges are rated for H2S
ㅇ The ring seal grooves are the same
ㅈ The bolt holes align correctly
ㅊ The ring and face surfaces are clean and not damaged

6.6.2.2 When you connect the two flanges, make sure that :
ㅋ No grease, oil or other lubricant are applied to a flange surface. The flanges
must be connected when they are clean and dry.
ㅌ The flanges are leveled when you connect them.
ㅍ Only approved API bolts and nuts, are used and that the bolts or nuts are of
the correct size for the bolt holes.
ㅎ The flanges evenly by tightening the nuts slowly. Tighten the bolts in a cross
pattern, not in a sequence around the flange.

6.6.2.3 If you are connecting to the wellhead without releasing the wellhead pressure:
ㄱ Make sure the upper master valve or swab valve is closed.
ㄴ Release the pressure contained between the upper master valve or swab valve
and the top flange.
ㄷ The upper master valve or swab valve directly below the SWS equipment
must hold the well pressure from below the valve. SWS personnel must not
make a connection to the wellhead if the well is leaking through the upper
master valve or the swab valve.

6.6.2.4 Do not install the riser directly on to the wellhead adapter. A single ram
BOP must be installed first on the wellhead, as the minimum requirement .

6.7 PRESSURE TEST AND FUNCTION TEST

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6.7.1 PRESSURE TEST AT LEVEL ONE (PT-1)

This is the first level of pressure tests to be done during equipment installation and before
installation of the injector head.

6.7.1.1 The maximum limit for pressure test on PT-1 is defined as follows:
ㄹ 1 ½ times the maximum expected wellhead operating pressure
ㅁ The maximum working pressure of the surface well control
equipment, or the wellhead connections.
The lowest of these two pressures is used as the maximum test pressure.

6.7.1.2 Connect the hydraulic hoses and perform a function test. Open and close each
actuator. Make sure that each actuator is functioning.

6.7.1.3 Equipment to be tested are as follows:

ㅂ Blind rams
ㅅ Bop body
ㅇ Kill lines and valves
ㅈ The top valve on the wellhead (customer valve)
ㅊ Flanges, spools, tee’s, adapters, changeovers, and outlet valves
(sapesco equipment)

6.7.1.4 The pressure test is performed as follows:

ㅋ Install the BOP on the wellhead.
ㅌ Connect the treating iron from pumping equipment to the reel
manifold, kill port, flow tee, etc.
ㅍ Fill the lines with water and test against the farthest plug valve.
Repeat the tests for all lines and test each isolation valve in the closed
position.
ㅎ Open the blind rams and fill the surface BOP stack with water. Close
the blind rams both hydraulically and manualy.
ㄱ Open the blind ram pressure equalizing port and make sure that the
test fluid flows freely. Be careful because the port has a small
diameter opening. Use the centrifugal pump for this operation.
ㄴ Close the pressure equalizing valve and pressure test the BOP body,
blind ram, flow tee valve, well head x-over or well head adapting flange
and well head crown valve through the kill line of BOP.

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ㄷ Bleed off the pressure and open the blind ram manually first and
hydraulically.

6.7.2 PRESSURE TEST AT LEVEL TWO (PT-2)

This is the second level of pressure tests to be done during equipment installation
and is done only in case the max expected working pressure inside the coiled
tubing is higher than the max expected well head operating pressure or max
rating pressure of the surface well control equipment or wellhead and wellhead
connections.

6.7.2.1 The maximum pressure test limit for PT-2 is defined as follows:
ㄹ 1 ½ times the maximum expected working pressure inside the coiled
tubing as indicated in the job program.

6.7.2.2 Parts tested at PT-2 are as follows:

ㅁ Coiled tubing string
ㅂ Treating line between CT reel and fluid pump unit.

6.7.2.3 The pressure test is performed as follows:

 The coiled tubing must be stabbed in the injector head.
 Install the coiled tubing connector.
 Pull test the connector to 5000 lb.,for internal connectors and 10000 lb.,
for external connectors, then release the tension
 The injector head must be hooked and lifted up with the crane. Section of
injector legs must be installed to provide safe condition to operators during
work underneeth the injector head.
 Enough traction pressure must be applied on the CT to hold the CT
properly during this test. (minimum 500 psi)
 Reel brake or chain must be applied during this test to avoid reel
movement during the test
 CT reel must be flushed with enough amount of water to avoid presence of
air gaps inside the CT string.
 Stop pumping water and wait till pressure inside the CT bleed to 0 and
water stop coming from the CT end.
 Install the blind plug (test plug ) at the end of the CT.
 Pump slowly through the coiled tubing and pressure test to the PT-2 test
limit.
 The test must be done in steps as follow.

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* Incraese the pressure to 1000 psi and stop pumping to check for
possible leaks.(keep test for 5minutes)
* Repeat the above in 1000 psi-steps
* When PT-2 test limit is achieved, keep the test for 15 minutes.
* If the test is OK bleed off the pressure gradually to 0.

6.7.3 PRESSURE TEST AT LEVEL THREE (PT-3)

This is the third level of pressure tests to be done after the injector head is rigged up
on e top of the BOP and well head.

6.7.3.1 The maximum limit for a pressure test on PT-3 is defined as follows:
ㅅ 1 ½ times the maximum expected wellhead operating pressure
ㅇ the maximum working pressure of the surface well control equipment,
or the wellhead connections.
The lowest of these two pressures is used as the maximum test pressure.

NOTE.
Lift the injector head with crane and lower the CT string through the injector
head for 10 ft and make sure that CT is coming out of the injector head free of
defects or damage that may occurred by injector chain or applying too much
pressure on the inside tension circuit. This check must be done before installation
of BHA.

6.7.3.2 Parts tested at PT-3 are as follows:

ㅈ Coiled tubing string
ㅊ Treating line between CT reel and fluid pump unit.
ㅋ BOP tubing ram.
ㅌ Tandam stripper if used
ㅍ Side door stripper.
ㅎ CT double flapper check valve
ㄱ Well head connection.
ㄴ Well head crown valve.

6.7.3.2 The pressure test is performed as follows:

Install the coiled tubing BHA and pump some water at minimum pumping rate till
water flows through the BHA to assure that BHA is not plugged or check valve is not
installed in the wrong direction. When you perform this check, run the pump at

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idle speed on the highest gear. Overpressure shutdowns at less than 1500 psi
(10,350 kpa).
ㄷ Connect the injector to the wellhead. Fasten all components in position.
Set the weight indicator and depth counter to zero (0).
ㄹ Measure from the bottom of the injector frame to the center of the pipe
ram. Add at least one foot to this measurement. RIH so that the coiled tubing,
BHA, is below the pipe rams and assure that CT is in the front of the pipe ram
based on the counter readings. Close the pipe rams on the coiled tubing.
ㅁ Open the pipe ram pressure equalizing valve, close the kill port isolation
valve and circulate slowly to make sure the port is not blocked. When you
perform this check, run the pump at idle speed in the highest gear. Set the
overpressure shutdowns at less than 1500 psi (10,350 kpa).
ㅂ Retract all strippers. Pump slowly until test fluid leaks past the upper
stripper. Stop the pump.
ㅅ Close the pressure equalizing valve.
ㅇ Pump slowly through the coiled tubing and pressure test the pipe rams to
the PT-1 test limit.
ㅈ Energize the upper stripper to a minimum pressure of 500 psi/3500 kpa.
Open the pipe ram pressure equalizing valve and allow the pressure to build
up 200 psi above the tubing ram and keep it for 5 minutes. This is for low
pressure testing on the stuffing box and BOP top connection. Open the
equalizing valve till the pressure is equalized above and below the pipe ram
then close the equalizing valve and open the pipe ram.Use the pump to increase
the pressure to test the stripper to the PT-1 limit if needed. Stop the pump.
ㅊ Check that all pressure gauges have the same pressure reading.
ㅋ If a lower stripper is used, energize the lower stripper to a minimum
pressure of 500 psi/3500 kpa. Retract the upper stripper. The lower stripper
must hold the test pressure. Energize the upper stripper and retract the lower
stripper to test the upper one. During this operation, Make sure there is
enough pressure applied to the traction system. The coiled tubing can be
pushed from the injector when the pipe rams are opened. Check with
operations manager for optimum pressure based on manufactirer
recommendations. The force that pushes the coiled tubing from the injector is
equal to the cross-section area of the tubing (in inches), multiplied by the
pressure (in psi).
ㅌ Release the test pressure to 1500 psi (10,350 kpa) through the flow tee
and a choke or the kill port.
ㅍ Release the pressure inside the coiled tubing back to the pump unit
gradually to zero psi. Make sure that the check valves hold at least 1500 psi
(10,350 kpa).

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Note: The check valves can be tested at the facility by installing them in the test bay
upside down with a double box adapter. This test will allow the check valves to be
tested at a higher pressure and reduce possible loss of time caused by leaking
check valves.

ㅎ Release all the remaining pressure through the flow tee or kill port.

6.7.3.4 Before you open the well, close all chokes and kill port valves. Energize the
upper stripper to a pressure required for the wellhead pressure. Pump through the
coiled tubing slowly until the pressure above the wellhead valves is equal to the
wellhead shut in pressure.

6.8 MINIMUM INSPECTION REQUIREMENTS FOR WELL

CONTROL EQUIPMENT

Maintenance and testing procedures must be carried out for all well control equipment on a
regular basis.

6.9 COILED TUBING OPERATIONS

6.9.1 LOWERING AND RAISING THE COILED TUBING FROM THE HOLE

6.9.1.1 The Injector motors and relief valves must be at the lowest settings. Use
these settings to prevent damage if the coiled tubing hits an obstruction down
the hole. These settings can prevent damage to the tool string if the string
becomes stuck during the removal of the tool string from the hole.

6.9.1.2 The operator of the coiled tubing unit must monitor the weight indicator. If
there are indications of an obstruction, the injector must be shifted to the
“neutral” position immediately.

6.9.1.3 All coiled tubing units must have a weight recorder that records both pulling
and pushing forces.

6.9.1.4 The BOP system pressure must be in the “ON” position when the coiled
tubing is in the hole. This position allows the BOP to actuate quickly.

6.9.1.5 The area under and to each side of the coiled tubing from the reel to the
injector must be considered as a high-pressure pumping line. It is

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recommended that this high risk area is closed off to all personnel and that
you install a sign marked “DANGER - HIGH PRESSURE - KEEP CLEAR”.

6.9.1.6 The systems for depth measurement, weight indication and pressure
monitoring must function at all times.

6.9.1.7 Check all guy lines or chains during the job and make sure they are tight.

6.9.1.8 Check the crane or rig load indicator to make sure the weight of the injector
and BOP is supported.

6.9.1.9 To drop balls during a job, connect a secondary bypass line with additional
plug valves. The ball can be placed in this line and pumped down the coiled
tubing without breaking any connections.

6.9.1.10 When you pull the tubing through the wellhead, the injector motors and relief
valve must be set at the minimum setting. The pulling rate near the wellhead
must be less than 20 feet per minute (6 m per minute).

6.9.1.11 Never pull the coiled tubing from the stripper until the well is closed and
the pressure above the wellhead is released.

6.9.1.12 See the Operations Limit Chart (Figure 2) for more information.

6.9.2 CIRCULATING FLUIDS

6.9.2.1 The overpressure switches must be set at the maximum permitted operating
pressure.

6.9.2.2 During circulation, the following items must be checked at the

return tank:
ㄱ The flow rate into the well
ㄴ The flow rate from the well
ㄷ The pit or tank level (volume increases or volume decreases)
ㄹ Indications of oil or gas
Always monitor these items to prevent the well from discharging fluid at a rate that
is faster than the pumping rate into the well.

6.9.2.3 The flow rate from the well must be controlled with an adjustable choke.

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6.9.2.4 All fluids must be removed from the tubing reel with nitrogen to empty the
reel at the end of the job.

6.9.2.5 When you pump acid, make sure the acid inhibitor is the correct type for
coiled tubing. Make sure the tubing reel is flushed after the job to remove
any acid.

6.10 STOPPING OPERATIONS FOR THE NIGHT - WITH OR

WITHOUT AN OPERATOR ON-SITE

6.10.1 All coiled tubing must be removed from the well if there is no SWS operator
on site.

6.10.2 If coiled tubing is removed the wellhead must be shut in using the customer
wellhead valves. There must be a customer master valve installed above any
side arm outlets on the wellhead. This upper master valve must be closed.
Release all pressure above the upper customer master valve. Release all
pressure on SWS equipment and close the SWS plug valves to isolate the
SWS equipment from the wellhead. If the pumping equipment is connected to
the coiled tubing unit or the wellhead, there must be a check valve between the
SWS pumping equipment and the wellhead.

6.10.3 The injector must be supported by steel legs and fastened with a chain at the
four corners. A hydraulic jack stand can be used instead of the steel legs. If
the injector can not be supported, the injector assembly must be removed to
the SWS BOP stack.

6.10.4 Close and manually lock the blind rams.

6.10.5In case of interrupted operations where the customer requires that all the
equipment remain connected with tubing in the well, the following procedure
must be followed:
ㅁ At least two SWS employees must remain on location. One employee
must be a qualified operator for coiled tubing operations and must have well
control training.
ㅂ If SWS crane is on site, one SWS person must be a qualified crane
operator in addition to the coiled tubing operator.
ㅅ The SWS employees must have communications on site to contact
emergency services.

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ㅇ There must be enough lighting so that the personnel can monitor all the
equipment.
ㅈ The security requirements must be reviewed. Make sure SWS employees
are safe.

6.11 SAFETY EQUIPMENT AND SAFETY SYSTEMS

6.11.1 Following are the minimum requirements for the control cabin module:
ㅊ A First-aid kit and at least one eyewash bottle mounted inside the cabin.
ㅋ A 30 lb. (15 kg.) dry chemical fire extinguisher mounted outside the control
cabin.
ㅌ All BOP controls must have double lockout protection (example, cover and
push pins). Handles on the blind rams and shear rams must be painted red.
ㅍ A reel direction lockout device.
ㅎ Mechanical locks to support the cabin in a raised position.
ㄱ A manual pump for use as a backup system.
ㄴ An air horn.
ㄷ Emergency shutoff switch to stop all engines.
ㄹ Dual acting load cell and Martin Decker gauge to show pulling and pushing
forces on the tubing.

6.11.2 Following are the minimum requirements for the power pack module:
ㅁ Safety relief valve on the air system.
ㅂ Guards on all belts, fans and rotating shafts.

6.11.3 Following are the minimum requirements for the injector head:
ㅅ Hooks for a safety harness at the correct position.
ㅇ Fall protection frame or work platform.
ㅈ Guards over all moving or rotating machinery parts.

6.11.4 Following are the minimum requirements for the coiled tubing reel:
ㅊ Guards over all drive chains.
ㅋ Locking chains and chain binders.

6.11.5 Following are the minimum requirements for the power hose reel, control hose
reel and BOP control hose reel:
ㅌ Spring-loaded control valves that return to the neutral position with pressure
relief valves.

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ㅍ Chain guards on all drive chains.

ㅎ All hoses and their connections must be marked with numbers to prevent the
wrong connections. The hoses and their connections can be fitted with different
unions to prevent the wrong connections.

6.11.6 Following are the minimum requirements for the gooseneck:

ㄱ Safety hooks to attach a safety harness.

6.11.7 Other safety equipment requirements that apply to all parts of the coiled tubing
unit are as follows:
ㄴ Guards on all rotating machinery. Yellow and black warning labels on all areas
where there is a danger.
ㄷ Handrails installed on all walkways and platforms.
ㄹ Stairs installed on the cabin to allow the safe cleaning of the front window.
ㅁ Reflective tape applied to all mobile units, unless prevented by local
regulations.

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