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SERVICES
Curing a hydrate problem in particular sections of the system has been accomplished by the
following measures:-
Plug in at the surface Close in the well and depressurise the line, or apply
steam or hot water externally.
Hydrate at the stuffing Close BOP’s and bleed down the lubricator
box during wireline
operations
Hydrate in the tubing Continue injecting methanol at maximum rate taking
note of the THP at all times as this could begin to rise
with the fluid injection.
If during injection of methanol no increase in THP is observed (this will indicate that the tubing is
not completely blocked), begin to bleed down the tubing taking careful note of the volume and
type of returns.
If during injection of methanol an increase in THP is observed (this will indicate that the tubing is
blocked, then bleed down the THP to the point below the bubble point so as to create a gas cap
above the hydrate. Methanol injected will then stand a better chance of reaching the hydrate.
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Continually inject methanol at the Xmas Tree during all well operations.
Curing Hydrates
The main guidance for removal of a hydrate plug is to reduce the pressure or increase the
temperature, or use methanol, or any combination of these.
NOTE: The risk is that if pressure is bled down from one side of a hydrate it will
begin to dissolve. As it dissolves, differential pressure can act upon one side
of the plug and may cause it to be dislodged at considerable velocity.
Bleeding down can be effective in dissolving a hydrate, but it is not
recommended as a routine practice. However, once a full column of fluid
(preferably methanol) has been established above the hydrate plug then
bleeding down the pressure above to destroy the hydrate can be
considered. The full column of liquid will act as a cushion and prevent the
dissolved plug achieving high velocities caused by the differential pressure
across it.
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Although methanol is a more effective hydrate inhibitor than Glycol, it is not, however, a first
choice for injection at the wireline lubricator or flowhead during well operations, as it dissolves
sealing greases and may cause loss of seal in a grease head. Also injecting glycol without any form
of atomisation may result in the glycol adhering to the wall of the tubing/lubricator, and will not
effectively absorb free water being lifted through gas by the wireline.
A hydrate plug in the tubing string under flowing or static conditions results in; being unable to run
or pull wireline tools, unable to squeeze or circulate the well dead, and unable to flow the well to
remove the hydrates. Hydrates may prevent vital equipment, such as the Downhole Safety Valve
from functioning correctly. Thus a downhole hydrate plug gives rise to a potentially dangerous
situation and must be avoided at all costs.
A hydrate is hazardous when it forms in surface pressure control equipment preventing operation
of valves, etc or plugging lubricators or risers. The latter may fool an operator into believing that
the pressure has been bled off when pressure may be trapped behind the plug.
(% v/v) (°C)
100/0 -7 1.115
90/10 -28 1.109
80/20 -43 1.101
70/30 -60 1.091
60/40 -60 1.079
50/50 -44 1.068
Table 17.1 - Freezing Points Of Mono-Ethylene Glycol/Water Mixes
After the glycol/water has been thoroughly mixed, no separation of the solution will occur. The
glycol/water solution can therefore be left in the pump unit for the duration of the programme
without the solution deteriorating. Mono-ethylene glycol may be mixed with fresh water or sea
water without any adverse effect, although sea water is preferred as in itself it is less likely to
cause a hydrate than fresh water.
SECTION 17
HYDRATE FORMATION & PREVENTION
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SECTION 16
SUBSEA WELL INTERVENTIONS
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15 CHOKES
15.1.1 HP Production Chokes
‘K’ Choke Beans and Wrenches:
Flared Orifice entrance reduces erosion on the entrance surface.
Accuracy levels are maintained over extended periods of use.
Choke beans save time and money because replacement intervals are extended.
Cameron ‘K’ choke beans come in two styles, positive and combination. The positive bean has a
fixed orifice diameter. The combination bean has a fixed diameter and a throttling taper at the
entry. The combination bean is used with an adjustable choke needle to make incremental
changes to orifice sizes smaller than the fixed orifice.
The part numbers of the positive and combination beans are determined by desired orifice size.
‘K1’ positive bean orifice sizes range from 4/64" to 64/64". ‘K2’ positive bean orifice sizes range from
4
/64" to 128/64". ‘K3’ positive bean orifice sizes range from 4/64" to 192/64".
‘K1’ combination bean sizes range from 6/64" to 64/64". ‘K2’ combination bean sizes range form 6/64"
to 128/64". ‘K3’ combination bean sizes range from 6/64" to 192/64".
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SECTION 15
CHOKES
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Variable Rams
7
Figure 14.17 - Variable Rams 5” - 2 /8”
Operating Features:
Available with manual or automatic locking systems.
Cylinder liner is field replaceable or repairable.
Secondary rod sealing action.
Rams can be changed and repaired in the field.
Additional room must be allowed for side door openings.
Sloped ram cavity is self-draining of mud and sand.
Rams are designed to permit drill pipe hang-off.
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Operating Features:
Low in vertical height.
Ram position cannot be determined by external observation.
Well pressure assists in maintaining rams closed.
Has secondary operating rod seal.
Rams can be changed and repaired in the field.
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Operating Features:
Application in both surface and Sub-Sea applications.
Well bore assist.
Accurate preload and fast make up for ram change.
Secondary seals on operating rod.
250°F of rating for HP wells.
Automatic locking device (self adjusting).
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14.2.1 Cameron
The ‘U II’ blowout preventer provides a BOP system (including CAMRAM elastomer sealing) that
meets the API 6A rating of 250°F service. The ‘U II’ includes an internally ported hydraulic bonnet
stud tensioning system, a short stroke bonnet, bore type bonnet seals, and the proven advantages
of the ‘U’ BOP design.
The introduction of the CAMRAM packer has set a new industry standard in meeting
the 250°F and withstand excursions to 300°F. Presently, the API standard excludes
these critical sealing elements from the rating, which covers only the metal
components of the BOP system.
CAMRAN packers and top seals made with CAMLAST are available for high
temperature and high H2S service.
The bonnets of the ‘U II’ preventer are opened and closed hydraulically. The bonnet
studs are hydraulically stretched to the correct preload by pressure applied behind a
piston, which acts on a load rod in the stud. The nut is tightened and pressure is
released. Pressure is supplied by an air-powered hydraulic pump via internal porting
in each end of the BOP body.
The short stroke bonnet reduces the opening stroke by about 30%, reduces the
overall length of the preventer, and reduces the weight supported by the ram change
pistons.
The bore type bonnet seal fits into a seal counter bore in the body and has metal
anti-extrusion rings.
The ‘U II’ blowout preventer wedgelocks act directly on the operating piston tailrod.
The operating system can be interlocked using sequence caps to ensure that the
wedgelock is opened before pressure applied to open the preventer.
A ram bearing pad can be attached to the bottom of each ram to reduce ram bore
wear.
All Cameron ‘U II’ BOPs are manufactured to comply with NACE and all regulatory
body specifications.
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Table 14.2 - Annular Preventers - Gallons of Fluid Required to Operate on Open Hole
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Operating Features:
Will close on open hole (but not recommended). As the contractor piston is raised by
hydraulic pressure, the rubber packing unit is squeezed inwards to sealing against
anything suspended in the wellbore. Compression of the rubber throughout the
sealing area assured a seal-off against any shape.
Requires higher closing pressure in subsea applications. As the contractor piston is
raised by hydraulic pressure, the rubber packing unit is squeezed inward to a sealing
engagement with anything suspended in the wellbore. Compression of the rubber
throughout the sealing area assured a seal-off against any shape.
Some sealing assistance is gained from the well pressure.
No provision for measuring piston travel.
Hydril and Shaffer's annular preventers are claimed to provide positive closure with 1,500psi
closing unit pressure when the rubber elements are new.
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Operating Features:
Quick-release top latch for easier element change.
Most sizes use less closing fluid than Shaffer and Hydril annular preventers.
Overall height is less than Hydril and Shaffer annular preventers.
Weight of preventer is less than Hydril and Shaffer annular preventer in all sizes
except for 11“ 10,000psi WP.
Cameron's Type DL annular preventer requires 3,000psi hydraulic closing pressure for positive
closure with no pipe in the preventer. This requires a bypass arrangement around the 1,500psi
annular regulator on 3,000psi closing units.
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Operating Features:
Will close on open hole.
Vents isolate the hydraulic operating system from the well pressure.
Standard trim suitable for H2S service.
Operating chambers remain sealed during packer element change to prevent
contamination.
The quick-release top latch reduces time to change packing element.
The packing element contains steel reinforcing inserts forming a continuous ring that
gives maximum support as they close inward.
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Closing Pressure
Opening Pressure
Operating Features:
Will close an open hole (but not recommended).
Some sealing assistance is gained from well pressure.
Bolted cover for easier element change.
Primarily designed for subsea operations.
Has a provision to measure piston travel to gauge element wear.
Has a balancing chamber to offset hydrostatic pressure effect in subsea operations.
The chamber can be connected four ways to optimise operations for different
effects:
Minimise closing/opening fluid volumes.
Reduce closing pressure and times.
Automatically compensate (counterbalance) for marine riser hydrostatic pressure effects
in deep water.
Operate as a secondary closing chamber.
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71/16” 15,000psi WP
Operating Features:
Will close on open hole.
Sealing assistance is gained from the well pressure.
Meets the current revision of NACE standards for sulphide stress cracking.
The head has a field replaceable wear plate, which is bolted on.
Has provision to measure piston travel to gauge element wear.
If the annular packing element wears out during stripping or well killing operations, the element
can be changed without having to pull the pipe. After the pipe rams are closed and locked below
the annular preventer and both the hydraulic and well pressure below is bled off, the cover of the
preventer can be unbolted and the packing element lifted out with a tugger or hoist line. With the
element above the preventer, the damaged unit can be split and removed from the pipe. A new
element would be installed in reverse sequence of the above.
1
Figure 14.2 - Hydril Annular Preventer - ‘GK’ 7 /6" 15,000psi WP
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When stripping, the closing pressure should be regulated to the minimum required for a slight
weeping of well fluid past the element. Closing pressures higher than this will increase element
wear. The pipe should be moved slowly, particularly as tool joints pass through the element. The
manufacturers also provide information regarding recommended closing pressures during
stripping operations. Surge vessels on the closing ports will help to smooth-out surge pressures as
tool joints pass through the element.
14.1.2 Hydril ‘GK’ Annular Preventer
1
Figure 14.1- Hydril Annular Preventer - ‘GK’ 4 /16" 10,000 15,000 & 20,000psi WP
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14 PREVENTERS
SECTION 14
PREVENTERS
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Materials
General
The section covers Type ‘R’, ‘RX’, and ‘BX’ ring gaskets for use in flanged connections. Types ‘R’ and
‘RX’ Gaskets are interchangeable on ‘6B’ flanges. Only Type ‘BX’ gaskets are to be used ‘6BX’
flanges. Type ‘RX’ and ‘BX’ gaskets provide a pressure energised seal but are not interchangeable.
Design
Dimensions. Ring gaskets shall conform to the dimensions and tolerances specified below and
must be flat within 0.2% of ring outside diameter to a maximum of 0.015”.
‘R’ and ‘RX’ Surface Finish. All 23° surface on Type ‘R’ and ‘RX’
Gaskets gaskets shall have a surface finish no rougher than
63 RMS.
‘RX’ Pressure Passage Hole. Certain size ‘RX’ gaskets
shall have one pressure passage hole drilled
through their height
‘BX’ Gaskets Surface Finish. All 23° surface on Type ‘BX’ gaskets
shall have a surface finish no rougher than 32 RMS.
Pressure Passage Hole. Each ‘BX’ gasket shall have
one pressure passage hole drilled through its height
Re-use of Gaskets. Ring gaskets have a limited amount of positive interference that assures the
gasket will be joined into sealing relationship in the flange grooves; these gaskets shall not be re-
used.
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13.1.2 Design
SECTION 13
EQUIPMENT SPECIFIC REQUIREMENTS
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Tool joints are doped When running or pulling under pressure ensure TIW
properly valves are used at every joint whilst making up or
breaking out tubing.
Renew springs and ball and seats.
If necessary, drop dart plug and pump into nipple.
C. Use of HWO 1. Auxiliary Equipment - pre-emptive:
Auxiliary Gin Pole,
Equipment Counterbalance Winch
Tongs
Rams closing too slow Ensure correct preventer pump pressure is maintained for
the rams being used.
Valves sticking whilst Ensure equalise and bleed-off valves are functioning properly
opening or closing (as BOP will not open if pressure is trapped between rams).
Re-active:
Close in tubing rams below stripper BOP and manually lock in.
Bleed off pressure. Open rams and change out stripper
inserts. Ensure valves are greased properly with correct
grease.
Slow movement of jack Ensure all jack pumps are at correct settings.
Ensure sufficient hydraulic oil is in reservoir.
Check Munsen Tyson valve is functioning properly.
Jack jumps when Ensure counter balance valves are operational and free
moving up or down from grit.
Re-active:
The hazards associated with these categories and the control mechanisms are given in the
following table.
Hydraulic hose bursting Conduct proper check on all hose connection valves and
pumps.
Valve seizure Function test all Hydraulically moving parts.
Insufficient oil in Hydraulic Ensure sufficient Hydraulic oil is in the reservoir.
Reservoir
Re-active:
Tubing Sliding Through Ensure correct pressures are maintained for opening and
Slips closure of slips.
Ensure slip inserts are free from grease, pipe dope and scale
whilst RIH or POOH.
Re-active:
Close in all slips and secure with clamp prior to changing out
worn slip inserts.
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Balance Point
Passing the balance point, is the point at which the pipe, in conjunction with fluid weight in the
pipe, equals the force exerted over the diameter of the pipe by the well pressure. It is a delicate
operation as the pipe is passing from the snubbers onto the slips. The mode of operation before
this point is termed pipe light and after the balance point, pipe heavy.
During this period it is possible that the pipe may slip, therefore it is good practice to use both
snubbers and slips for a short time until the unit sees sufficient weight to make the slips operate
effectively. To help during this time, it is beneficial to move the weight from negative to positive
quickly by filling up the pipe when it is near the balance point, moving into the pipe heavy mode.
Pressure Testing
1) The Xmas tree valves should be tested for operation and leaks before the operations
commence.
2) Pressure test all items possible before rigging up.
3) Install the BHA on pipe into the Xmas tree with the two valves (usually the master valves)
closed.
4) Close the pipe rams in sequence and apply test pressure through the tree wing valve, or
other suitable port, testing the BHA check valves and each ram in turn. Use the snubbers to
hold the pipe in the BOPs.
5) Test annulars or strippers in the same manner.
6) When all pressure testing and function testing has been completed with the stripper or
lower stripper ram closed, equalise the pressure in the BOP stack with the well pressure
below the tree.
7) Slowly open the tree valves and observe for any leaks.
8) Begin snubbing pipe monitoring the strippers.
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Various configurations may be used for differing applications providing they meet with the
minimum requirements outlined above.
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During pressure testing the pipe needs to be held by the snubbers to prevent ejection from the
stack.
Stripper Rubber
If snubbing pressures are below 3,000psi and a workstring with flush joint or tapered connections
such as drill pipe or Hydril are being used, it is preferable that a stripper rubber be used as it is not
necessary to operate the stripper rams.
The stripper rubber is self energising (Refer to Figure 12.2) and the crew simply require to pick-up,
install, and snub the pipe through the stripper into the Well. However, the stripper rubber will
wear and usually needs to be changed out during long trips. Closing the stripper or the safety
rams, allows safe retrieval of the worn rubber and re-instatement of a new unit.
‘Double’, ‘Tandem’ or ‘Two Stage’ strippers are used to allow the running and pulling of greater
lengths of pipe before requiring to change the stripper rubbers. By installing a double stripper, the
upper rubber can be used first, and when it begins to leak, the lower stripper rubber is brought
into use by closing the well pressure by-pass.(Refer to Figure 12.3). When collared tubing is to be
run, the stripper rubber cannot be used.
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12.3.18 Strippers
The strippers control well pressure when snubbing or any time surface well pressure is
encountered if it is less than 3,000psi. It is a self energising unit that utilises the Well pressure to
activate the rubber. There are a variety of stripper rubber materials for different pressure regimes
and Well fluids. These will vary in Well life according to their resistance to the Well fluids, gas or
erosion due to roughness of the wall of the pipe being run, or pulled.
Strippers cannot be used when running collared pipe or any pipe with sharp shoulders on the
connections.
The main elements (refer to Figure 12.1) of an HWO unit are as follows:
Hydraulic jack assembly
Guide tube
Splined tube (only on Halliburton units)
Access window
Travelling slips
Travelling snubbers
Stationery slips
Stationery snubbers
Rotary power swivel
Power tongs
Work basket
Control panels
Hydraulic power pack
Hose package
BOP system
Equalising loop
Bleed-off line
Strippers
Circulating system.
HWO units are supplied in a range of lifting capacities (lbs in thousands), 60K, 90K, 120K, 200K,
250K, 400K and 600K. Snubbing capacity is half of this rating.
When used instead of a conventional drilling or workover rig, the Well would be killed and
plugged, the Xmas tree removed and BOPs installed on the casing head. It can also be used for re-
completing Wells as it has the capability to run and pull completion strings by running the
downhole safety valve control line through the access window.
12.3.1 Hydraulic Jack Assembly
As described earlier, the jack assembly consists of one or more hydraulic cylinders that travel in a
vertical direction to move pipe in or out of the hole. For higher snubbing or lifting power, more
cylinders are added into the system, which reduces running speed, unless larger capacity pumps
are used. The operator controls the hydraulic power to the jack as the weight of pipe changes, or
as the weight of pipe overcomes well pressure, and changes from snubbing to lifting and visa
versa.
The first snubbing units were mechanical units using mechanical advantage in order to force the
pipe in the hole against Well pressure. In the development of the hydraulic type unit, the power to
raise and lower the tubing was provided by a set of hydraulic rams, through a set of bi-direction
travelling slips or snubbers.
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NOTE: The snubbing configurations shown are generic and may not conform to
individual service companies’ policy and procedures. There is no API
standard for snubbing well control equipment and development of the
method has been driven by the users. The configurations listed meet the
absolute minimum and it would be common practice for additional safety to
be added.
The schematics are for one pipe size only and if two pipe sizes were to be used then two sets of
safeties would be needed, or variable rams installed. This would then allow double barrier
protection for changing the stripper ram sizes.
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12 SNUBBING OPERATIONS
A HWO unit is utilised on both live well interventions and dead well workovers. When utilised on
workovers, the well control is similar to a rig operation, requiring the well to be killed and plugged
and the Xmas tree replaced by a BOP stack on the casing head. The only difference in well control
equipment may be in the work strings used where check valves may be installed to the BHA as
additional primary well control.
In place of the rig circulation system, pumps, tanks, mixing hoppers and hard piping would have to
be provided unless the operation was rig assisted.
It is essential that prior to any snubbing/HWO operation the safety issues are addressed.
Reference should be made to relevant sections of the appropriate Safety Manual.
At the safety meeting all aspects of the operation and detailed contingency plans should be
discussed. Snubbing/HWO emergency procedures will form the basis of these contingency plans.
Of particular importance are the aspects of Well Control Procedures.
Under no circumstances should safety be compromised. Procedures should be observed, work
permits strictly adhered to, and equipment operated within designed parameters.
Aspects of well control must be included in the planning and equipment selection process.
Snubbing operations are performed on live wells, and particular emphasis must be given to the
required well control competencies and equipment to be used for each individual application.
However, when used in snubbing operations, the pressure control systems are significantly
different. The equipment arrangements for snubbing operations are described in the sub-sections
below.
SECTION 12
SNUBBING OPERATIONS
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Control Hoses
On a semi-submersible the injector and the BOPs may be a considerable height above the
drillfloor. This must be considered with the position of the power pack and control house,
whereby extensions to the control hoses may be required. Similarly on a platform, if the coiled
tubing is to be run from the pipe deck to the skid deck, the control hoses may again require
extensions.
Support Stand
The standard type support stand is manually operated and requires constant monitoring in live
well situations. If the operation is performed with the well on production, and cold liquids
introduced through the coiled tubing this will cause the riser to contract, the support stand may
become trapped under the injector.
A hydraulic support type stand has built in relief valves to release the pressure should the riser
shrink.
DRILLING RIG
CRANE
PEDESTALS
PACKAGES OF SAFETY
Gas Well
Gas wells cause undue wear to stripper rubbers and, hence, it may be necessary to provide an
additional stripper/packer, to complement the standard package.
Toolstring Length
The operation will dictate the length of the tool string that in turn may affect the rig up, e.g. length
of riser, pick up height of the injector and stick up height of well control equipment.
Type of Rig
A semi-submersible drilling or workover vessel requires the addition of a heavy duty lifting frame
installed between the block and the surface tree in which to support the injector and BOPs.
Drilling rigs can usually accommodate the width of injectors quite easily but in certain
circumstances the ‘A’ frame height can be restrictive.
Workover rigs tend to have smaller ‘V’ doors than conventional drilling rigs, and dimensions of this
should be checked against the injector size available.
On land well operations where there is no means of holding back the injector against the pull of
the tubing from the reel, an adjustable stand is required to support the forces with the ground.
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Specialist tooling:
Downhole motors
Jetting nozzles
Wireline type hydraulic operated tools
Through tubing packers
Bridge plugs
Perforating guns
Logging tools
The dual flapper valves are an integral element in well control as they contain well pressure from
the inside of the tubing. The dual flappers give double isolation and meet most legislative
requirements. Therefore, when the BOP tubing rams are closed well pressure is contained to both
below the rams and from the tubing, hence the well is safe for corrective actions. A split in the
tubing below the BOPs circumvents the dual flapper seals and, in this situation, the shear rams
would be closed to contain well pressure.
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Figure 11.13 - Ball Check Valve Figure 11.14 - Dome Check Valve
Figure 11.15- Flapper Check Valve Figure 11.16 - Removable Cartridge Flapper Valve
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11.1.9 Tubing
There are a number of coiled tubing manufacturers but they are mainly U.S. or Japanese
companies. Some of the US companies use Japanese supplied steel for tubing manufacture. The
normal method of tubing manufacture is to produce rolled plate steel that is cut into long flat
strips. Each strip is then progressively folded round with rollers and formed into a long spiral.
When it is completely formed into a round tube, the edges, now abutting, are welded. These
individual lengths are then welded together to produce the length required to be contained on a
shipping reel. Continuously milled tubing has now been introduced but is much more costly.
The common steel used is an American alloy grade ‘A606’ type 4 modified, suitably quenched and
tempered, which provides the best economic combination of ductility and strength to combat the
cyclic bending stresses. By specially selecting billets from the furnace to meet particularly tight
tolerances of chemistry, higher grades can be produced such as ‘QT-800’. More exotic pipe
materials are also being manufactured but have cost penalties.
11.1.10 Barrier Principles
A combination of pressure control barriers are used in coiled tubing operations to provide both
internal pipe and external pipe pressure control.
For external pressure control the barriers during normal operations are stripper/packers, annular
BOPs and BOP pipe rams. Strippers or annular BOPs are considered as primary barriers and the
BOPs as secondary barriers.
The internal barrier during normal operations is double BHA check valves. Both check valves
together are considered as the primary barrier and the BOP cutter rams secondary.
BOP shear/seal rams or cutter gate valves are barriers on both sides and are considered tertiary
barriers.
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11.1.8 Shear/Seal
This device is usually a 61/8” bore combination ram with single cut and seal rams. (Refer to Figure
11.10) This provides a single cut/seal function for installation safety and is the tertiary barrier. In
the event of a platform emergency, a designated person is responsible for its closure, but normally
the platform manager’s permission is sought, time permitting.
To illustrate the main components of a typical hydraulic ram, a sectioned drawing of a shear/seal
actuator is illustrated. (Refer to Figure 11.11).
Figure 11.12 shows the height of a typical stack up arrangement using a dual combination on the
tree, a triple combination BOP, a quick union connector, a tandem and standard stripper/packer.
A combination BOP incorporates the functions of two upper and the two lower types of rams into
one unit, and in so doing reduces rig up height and simplifies the control system. However, it
would be necessary to alter the well control procedures accordingly.
A triple combination is a model that has a slip ram (bottom) pipe ram (middle) as well as the
combination shear/blind rams (top). A triple combination combined with two radial
stripper/packers provides a shorter stack up than a conventional stack-up, (refer to Figure 11.9)
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The shear rams usually have the ability to cut stiff wireline i.e. coiled tubing with electric line cable
inside it, used on coiled tubing logging operations.
In some areas of the world, an additional Shear/Seal valve is installed between the BOPs and the
wellhead adapter as a tertiary barrier. The shear seal valve has the ability to cut the tubing and
affect a seal. It is generally tied into a higher volume hydraulic pressure supply than available from
the coiled tubing unit such as a rig Koomey or independent system etc.
The BOP is the secondary/tertiary barrier in pressure control. As a failsafe device, the BOP should
only be operated as a safety device, and with careful consideration, and not used for any other use
such as a means of “parking” the tubing while at depth.
A standard quad BOP is configured with four rams. (Refer to Figure 11.6 and Figure 11.8)
From top to bottom:
Blind Rams Blind rams only seal on open hole when the elastomers on
each ram meet and seal. If there is pipe across the ram area
the seal cannot be affected. This type of ram does not hold
pressure from above.
Shear Rams Shear rams have the ability to cut tubing. When using CT
logging i.e. tubing with logging cable through it, the shear
rams must have the capability to cut both. There is no seal on
this function. Extreme caution should be taken when
functioning any of the rams as accidental functioning of the
shear rams could potentially be very dangerous, possibly
causing a fishing job.
Slip Rams The slip ram is designed to hold the full tubing weight, and it
too has no sealing function. Caution should be used when
considering the use of these rams as the slip toolface can
significantly mark the tubing and induce an area where
premature cracking can occur.
Pipe Rams Pipe or Tubing rams are used to affect a seal against the
tubing. Wellbore pressure aids in the sealing of the ram when
a differential is created, by bleeding off above. This type of
ram does not hold pressure from above.
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11.1.5 Injector
The injector is the motive device that imparts upward or downward movement to the tubing and
is mounted above the BOPs on the wellhead. It must be supported, as the connection to the BOPs
is not designed to absorb the weight and lateral forces caused by the tension in the tubing from
the reel. This support can be a crane for land wells (providing the lifting gear and pad eyes are
rated for the weight of equipment and forces encountered), or to a mast or derrick offshore. Free-
standing frames with hydraulic jacking legs are also available where no other means of rigging up
is available.
Hydraulically driven travelling chains equipped with gripper blocks impart movement to the
tubing. The gripper blocks grip by friction that is adjustable through a hydraulic piston applying
pressure across the chains. This pressure must be sufficiently high enough to grip the tubing,
eliminating slippage, but not excessively high to crimp the tubing.
11.1.6 Stripper/Packer
The stripper is situated below the injector head in the injector head frame. It is designed to be as
close as possible to the gripper chains to prevent buckling due to snubbing forces. The stripper is
hydraulically controlled to press the rubber element against the tubing to create a seal. The
stripper rubber is exposed to wear from the roughness of the pipe OD, and will need to be
changed from time to time. This can be done on the wellhead by closing the BOPs and removing
well pressure.
The stripper/packer is located at the top of the pressure control stack-up attached to the injector
head and is the primary pressure control barrier. It is constantly energised throughout the coil
tubing operation to affect a seal against the tubing. (Refer to Figure 11.2, Figure 11.3, and Figure
11.4) As it is in constant use, on high pressure or gas wells, the elastomer sealing element can
wear out quite rapidly, hence the contingency requirement for a back-up stripper or annular BOP.
An example of such a rig up is shown in Figure 11.9. As stated above, this back-up unit would only
be brought into use if the first packing element failed. Used in conjunction with the tubing rams in
the BOPs, this provides an additional barrier and allows safer access to change the worn
elastomers in the first stripper.
In other circumstances the back-up stripper may be used to allow operations to continue without
having to repair the first stripper
Because of the increased height due to using tandem stripper/packers, an alternative radial
stripper/packer; shown in Figure 11.5. can be used. This reduces the stack up height by about half
and makes changing the elastomers a very simple task.
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These bending cycles force the tubing to exceed its elastic limit inducing fatigue, and, therefore,
reducing the working life before failure. Tubing under pressure while passing over the reel and
gooseneck dramatically decreases this cycle time to failure. Most coiled tubing service companies
have developed computer programmes, using logging databases, to determine the time to failure
for each tubing size and type of material to which a factor of safety is applied. This is an inexact
science but, due to the safety factor, there are actually very few recorded well site incidents
caused purely through tubing failure. More than likely, service life is much shorter than actual life.
All coiled tubing units (Refer to Figure 11.1) are constructed similarly and consist of:
Operators control cabin
Tubing reel
Power pack
Goose neck
Injector head
Stripper
BOP system.
Much of the recent increase in capability is due to the increased performance of downhole
motors, which provides the ability to rotate, enabling drilling and milling operations etc.
The limitation of coiled tubing is usually the pressure rating of circa 5,000psi. and the depth to
which it can be run, constrained by its relative low strength. It is also limited in its service life due
to the bending cycles over the reel, and to a lesser extent the goose neck, in conjunction with the
service conditions it encounters.
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Both the well characteristics and the type of operation should be considered as they determine
the minimum size and type of well control devices that need to be employed to safely and
successfully conduct the programme.
In coiled tubing operations both internal and external pressure control must be assessed. ‘Internal’
refers to the inside of the coiled tubing and ‘External’ to the coiled tubing annulus.
The typical Well Control Stack is:
Stripper
BOP
Riser
Shear Seal.
Starting from the top of the tree, many operators utilise a single shear/seal device that is flanged
to the tree irrespective of well conditions and the operation to be carried out. This is generally a
tertiary barrier. Other operators only use a shear/seal device when they deem it applicable. The
bore diameter and cutting capabilities of the shear/seal will depend largely on the type of
toolstring. On top of the Xmas tree or a shear/seal, if used, is a crossover flange to quick union
sectional riser continuing to the operating level, i.e. rig floor or platform deck, with any additional
stick up height that is required.
The BOP is mounted directly on top of the riser using any crossovers that are required. The BOP
can either be a conventional quad BOP, or the later style combination BOP’s. Combination BOP’s
were developed to be shorter and therefore have less stick up.
The stripper/packer or stuffing box attaches to the top of the BOPs. This piece of equipment is
normally bolted to the underside of the injector head. A tandem stripper/packer, or even an
annular BOP, can be installed between the standard stripper/packer and the BOP for additional
safety, particularly when the well conditions may cause premature stripper rubber wear.
Whichever combination of BOPs is selected in the stack-up for an operation, it should include a
closed barrier to allow safe stripper/packer rubber replacement and a backup barrier.
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SECTION 11
COILED TUBING OPERATIONS
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Pneumatics
The drive air enters the unit via a bulkhead quick connect to a pressure control valve which is pilot
controlled from the control panel, and also acts as a stop/start control. A separate supply is
plumbed to the control panel into a three way, two position valve. Position one is where the
supply is blocked with the reservoir vented to atmosphere, position two is where the supply air is
directed to the reservoir via the reservoir lid pressure controller; both allow the operator an auto
pre-set reservoir pressurisation or vent to atmosphere in one control valve.
WARNING: HIGH PRESSURE - Never allow any part of the human body to come in front
of or in direct contact with the grease outlet. Accidental operation of the
pump could cause an injection into the flesh. If injection occurs, medical aid
must be immediately obtained from a physician.
WARNING: COMPONENT RUPTURE - This unit is capable of producing high fluid pressure
as stated on the pump model plate. To avoid component rupture and
possible injury, do not exceed 75 cycles per minute or operate at an air inlet
pressure greater than 100psi. (10 bar).
Grease System
The system pump draws grease from the grease reservoir through the pump suction tube and it is
pumped to the outlet port that is split into two lines. One line delivers grease to the control panel
vent valve, allowing the operator to vent grease pressure to atmosphere via a short hose into an
alternate grease reservoir that is not in use. (This is normally permissible as grease from this
source should be clean; however, care should be taken to isolate grease from airborne
contamination). The other line is the grease supply line plumbed via a rotary valve to hose storage
reels, and then to the appropriate grease head. (Refer to Figure 10.17)
The grease return line via the hose reel, rotary valve, and system pressure gauge leads to a system
pressure control vent valve from which the vented grease flow rate is controlled. This grease is
plumbed (now at atmospheric pressure) through a short flexible hose to a waste grease container
and should not be re-used as this may be contaminated. Excessive grease returns will indicate
incorrectly sized flow tubes.
NOTE: If a 5/16” line is used, the supply pump must be fitted with at least a 3/4” ID
hose to ensure adequate supply to retain the seal.
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Flow Tubes
A range of flow tubes (refer to Figure 10.14) are available with small increments of IDs so as to
provide an effective seal over the life of a wireline that reduces in size with usage.
The OD. of the line should be measured and the size of the tubes selected for the closest fit (ID. of
flow tubes should be 0.002” - 0.004” larger than OD of wireline, or 0.004” – 0.006” depending on
whether conventional 1-6-9 line, or Dyform is used). Slip each tube in turn over the wire and
physically check that they do not grip the wire as this can lead to ‘bird caging’ of the outer strands
when running in the well. This is an effect where the drag on the outer strands gradually holds
them back with regard to the inner strands, so they become loose and spring out from the cable
like a bird's cage until they jam at the packing nut. If the packing nut is too tight it can also cause
this same effect. (Alternatively, if the tubes are too big, they will not create an effective barrier
and too much grease will be wasted)
The flow tubes are close-fitting around the wireline and they, along with the flow tube sleeves,
form the main length of the grease head. This affords sufficient length to form an effective
pressure barrier.
The flow tube sleeves are simplified body parts that hold the various other components rigidly
together and seal them. In addition, they are made of a very hard metal and the wire
predominantly bears on them, preventing wear on the other parts. The flow tube coupling forms a
junction for the flow tubes and also as the point of entry for the grease.
The Hydraulic Packing Nut is a simple but efficient device that is remotely operated by a hydraulic
hand-pump assembly. Pumping pressure into the cylinder actuates the Hydraulic Packing Nut.
When a complete seal is established, the pressure is maintained by closing the valve at the hand
pump assembly. Opening the valve and relaxing the seal relieve the pressure. Thus, the piston in
the packing nut is retracted by a strong spring when the pressure is relieved from the piston.
The body has a port and a flow hose to lead off any seepage that migrates through the line and
finds its way above the flow tubes (refer to Figure 10.13).
The optional differential air inlet pressure regulator valve, when used, controls the flow of grease
to the control head that is supplied by the grease supply system. Ideally, the grease is delivered at
a pressure of 200 psi. greater than the wellhead pressure if flow tubes are correctly sized. As flow
tubes wear, or the Braided Line tightens, grease delivery may have to be delivered at pressures up
to 1000psi, or even 2000psi maximum to retrieve the wire from the well.
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This results in the complete sealing and also lubrication of the wireline, which reduces friction.
NOTE: When calculating the amount of stem required to overcome the well
pressure, a percentage must be added to compensate for friction.
The Grease Injection Control Head is composed of three flow tube sleeves*, a flow tube sleeve
coupling, a quick union pin end, a flow hose and a line rubber and hydraulic packing nut assembly
at the upper end. The amount of flow tube sleeve used depends on the well pressure. For 3/16”
Braided Line:
3 flow tubes 0 - 4,000psi
4 flow tubes 4,000 - 6,000psi
5 or 6 flow tubes 6,000 - 10,000psi.
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Line Wiper
This is a tool that attaches to the hay pulley when the wire is being pulled to remove all
contaminants from the wire before it is spooled.
Grease Head
The grease head terminates the top of the lubricator.
The grease head is used on braided line, electric line or plain cable. It seals around cable by grease
being pumped, at higher pressure than that inside the lubricator, into the small annulus space
between a set of flow tubes and the cable filling the cable interstices. The grease, being at higher
pressure, tends to flow downward into the lubricator and also upward out of the tubes.
The upward flow is forced out through a return line for disposal by activating a cable pack off
above the tubes. Downward flow is only constrained by the differential pressure applied between
the grease and the lubricator pressure. Adjustments must be made to maintain the optimum
conditions between grease lost to the hole, amount of gas entrained in the grease returns and
differential pressure.
To supply grease under pressure the following equipment is required to rig up the Grease Injector
Head:
High pressure grease pump
Grease reservoir
Compressor
Hoses
Wiper box
Grease injector head assembly
Sheave
Crane or draw works.
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Benefits
The need for a person to climb the lubricator is eliminated.
The hand pump is positioned away from the nut itself so possible contact with escaping well fluid
can be avoided.
Operation
The Hydraulic Packing Nut Assembly includes a piston which has a permissible travel of 0.4”
enclosed in a housing. The housing has a 1/4” NPT connection for a hydraulic hose.
As hydraulic pressure is applied the piston is moved downward against the force of the spring. This
downward action is transmitted to the upper packing gland and causes the Stuffing Box packing to
be squeezed around the wireline, sealing off well fluids within the Stuffing Box.
Piston
90o Elbow
O-Rings
Grub Screw
Piston Spring
Piston Housing
For solid wirelines, only pressure containing Stuffing Boxes are utilised. The standard Stuffing Box
is available in 5,000psi. and 10,000psi. pressure ratings although higher pressure ratings are also
available.
A swivel-mounted (360° free movement) sheave wheel and guard are fitted to the top half of the
Stuffing Box. The wheel is positioned so as to maintain the passage of the wire through the centre
of the packing rubbers.
Some sheave guards on the Stuffing Box are designed to trap any wire, which breaks on the
surface before it drops downhole.
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Construction
Lubricators for normal service (up to 5,000psi.) can be made of carbon or manganese steel. Over
5,000psi, consideration should be given to sour service as quantities of H2S can be absorbed into
the steel of the Lubricator body and heat treatment becomes necessary.
All Lubricator sections must have full certification from the manufacturer or test house. A standard
colour code identifies different pressure ratings of lubricator.
Riser sections, used in offshore platforms to reach from the wellhead deck to a working deck
above, are similar to lubricator sections except they are generally much longer in length and may
be installed between the wellhead adapter and the BOPs. They may also be of even thicker section
to support the increased weight being carried.
Description
A Lubricator allows wireline tools to enter or be removed from the well under pressure. It is a tube
of selected ID and can be connected with other sections to the desired length by means of Quick
Unions.
The following factors govern the selection of Lubricators:
Shut-in wellhead pressure
Well fluid
Wireline tool diameter
Length of wireline tools.
The lowermost Lubricator section normally has one or more bleed off valves installed; a pressure
gauge can be connected to one of the valves to monitor pressure in the Lubricator. If the
Lubricator has no facility to install valves then a Bleed-off Sub, a short Lubricator section with two
valves fitted, should be connected between the Wireline Valve and Lubricator.
NOTE: To meet IWCF Barrier criteria, the needle valve configuration should be,
from the Lubricator: Needle Valve, Tee (with gauge), Needle Valve. This
maintains two Barriers in the event of one Needle Valve leaking.
Quick Unions connect Lubricator sections together and to the Wireline Valve; these unions have
Acme type threads and seal by means of an ‘O’ring, thereby requiring only tightening by hand.
(Refer to Figure 10.7)
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CAUTION: In general, unions that cannot be loosened easily indicate that high pressure
may be trapped inside. If this pressure is not bled off first, unscrewing the union
could cause a sudden release of pressure, projecting equipment parts at lethal
speeds.
The collar of the union will make up by hand when the pin end (with the ‘O’ ring) has been
shouldered against the box end. When the collar bottoms out, it should be backed off
approximately one quarter turn to eliminate any possibility of it sticking due to friction when the
time comes to disconnect it.
Rocking the lubricator to ensure it is perfectly straight will assist in loosening the quick union. In
addition, ensure that tugger lines and hoists are properly placed to lift the lubricator assembly
directly over the wellhead.
NOTE: Ensure that the correct guide is installed as an incorrect guide may damage
or cut the wire.
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Description of Operation
A mechanical or hydraulic force is applied to close the rams to seal against well pressure. The
sealing elements are arranged so that the differential pressure across them forces them closed
and upward, assisting in the sealing action.
Figure 10.6 shows the ram configuration of a Wireline Valve. Blind rams close without wire and
will also close on slickline without damage. Both 3/16” and 7/32” rams have a semi circular groove in
each of the two ram faces to permit the ram to close and seal on 3/16” or 7/32” braided line.
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Description
A Wireline Valve, (refer to Figure 10.4) must always be installed between the Wellhead/ Xmas tree
and Wireline Lubricator. This valve is a piece of safety equipment that can close around the
wireline and seal off the well below it. This enables the pressure to be bled off above it, allowing
work or repairs to be carried out on equipment above the valve without pulling the wireline tools
to surface. A positive seal is accomplished by means of rams that are manually or hydraulically
closed without causing damage to the wire.
Hydraulically actuated Wireline Valves are now more commonly used because of the speed of
closing action and ease of operation. During an emergency, often the valve is not easily accessible
to allow fast manual operation and therefore remote actuation is preferred.
Single or dual ram valves are available in various sizes and in a full range of working pressure
ratings. Dual rams offer increased safety during slick line work and allow the injection of grease to
secure a seal on braided wireline. They are used particularly in gas wells, or wells with a gas cap.
On slickline operations in low-pressure wells, a single BOP is usually installed dressed with slickline
rams to close and seal around the wire. On high-pressure wells a dual BOP is used, the lower rams
dressed for slickline and the uppers with blind rams. The injection point is used to pump grease if
there is leakage past the rams.
When running cable, a dual BOP is used with both rams dressed for the particular cable size, and
bottom rams inverted with a grease injection point between the rams. (Refer to Figure 10.5 )
In a situation where slickline and braided line are both being used, a triple BOP would be installed
with the lower and middle rams dressed for the braided line and the upper for slickline.
On electric line jobs, triple BOPs are used, the upper rams being blind.
Wireline Valves are fitted with an equalising valve that allows Lubricator and well pressure to
equalise prior to opening the rams when wireline operations are to be resumed. Without this, if
the valve rams were to be opened without first equalising, the pressure surge could blow the
toolstring or wire into the top of the Lubricator, causing damage or breakage.
WARNING: SINCE THEY ARE SUCH A VITAL COMPONENT IN CONTROLLING THE SAFETY OF
THE WELL, IT IS IMPORTANT THAT WIRELINE VALVES ARE REGULARLY
PRESSURE AND FUNCTION TESTED.
The Pump-in Tee, when rigged up, is placed between the Wellhead adapter and the wireline BOP.
Therefore, Quick Union sizes and pressure ratings must be compatible with all surface equipment.
Pump-in Tees may be required as part of a wireline rig-up. By connecting a kill-line to the
Chiksan/Weco connection, the well can be killed in an emergency situation. This line can also be
used to pressure test or release pressure from the surface equipment.
NOTE: On some locations, the pump-in tee will be part of the wellhead adapter.
The relative positions of some of these components are shown in the following sections.
10.3.1 Wireline Lubricators and Accessories
The wireline lubricator, when assembled, acts like a pressure vessel on top of the Xmas tree into
which the wireline tools are ‘lubricated’. It consists of:
Wellhead adapter
Wireline BOPs or wireline valve
Lower lubricator section(s)
Upper lubricator section(s)
Stuffing box or grease head
Line wiper.
It is extremely important that a wireline lubricator pressure rating meets the maximum
anticipated surface well pressure. Lubricators must be designed, not only to withstand the stress
caused by internal pressure but also from stresses caused by jar action or high pulling forces.
To install the tools, the lubricator must first be isolated from well pressure at the Xmas tree,
usually by the swab valve, and all pressure bled off through an appropriate bleed-off valve. The
lubricator is then broken out at the connection immediately above the BOPs. The Wireline tools,
after attaching to the toolstring, are pulled up into the lubricator bore, and the lubricator re-
installed. The lubricator should then be pressure tested to a minimum of SITHP, before opening
the tree and running in the hole.
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Electric line
Cable used on electric line units can be either mono-conductor, coaxial or multi-conductor braided
line and supplied for various service conditions. Each particular type has a range of sizes and
specific uses according to the required service or tool being run. Careful handling of electric line is
essential, especially with the smaller sizes and when rigging up, to prevent line damage and
penetration of the core insulation leading to subsequent loss of signal.
Slickline
Slickline is a high-strength mono-filament steel line and is available in common sizes of 0.082”,
0.092”, 0.108” and 0.125”. 0.136” and 0.142” are also available now for heavy duty slickline work.
These are also supplied for various service conditions. Being slick the OD of the wire is easy to seal
around using a simple packing device called a stuffing box whereas the cable requires a grease seal
arrangement.
Braided Line
Braided wireline used for heavier duty wireline operations is supplied in 3/16” and 7/32” sizes.
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The hay pulley is the device used to turn the wire from the horizontal plane to the vertical up to
the lubricator stuffing box sheave. As well as turning the wire it also moves the forces generated
on the wire into the same axis as the lubricator reducing any possible bending moments. It has
been known for a hay pulley failure due to severance of the tie down chain, causing the lubricator
to break off the well.
10.2.4 Winch
The winch consists of the wireline reel driven by a hydraulic motor controlled from the console in
the cabin, all of which is mounted in the unit frame. Hydraulic power is supplied from the power
pack.
The reel controls have a forward and reverse directional valve, a number of gear ratios to cover a
wide range of speeds and a hydraulic bypass valve for fine control within each gear range. The reel
is driven by chain drive from the gearbox and has a brake band. If there are two reels on the
winch, slickline and braided, there is an additional manual operated clutch system for reel
selection.
Mechanical wireline also known as slickline (as the line has a smooth OD), is used to conduct
mainly mechanical operations such as:
Installing flow controls.
Installing gas lift valves.
Depth finding.
Plugging.
Bailing.
Paraffin cutting.
Tubing gauging.
Setting bridge plugs.
Fault finding.
Fishing.
Logging - through-tubing BHP gauges or the latest electronic solid state logging tools
such as spinners, CCLs, etc.
The slickline unit can also be rigged up with braided line for heavy-duty wireline operations such
as running heavy, large tools or performing heavier duty fishing operations.
A more recent development in wireline services is the Heavy Duty Wireline Unit used mainly for
fishing jobs where regular fishing methods have failed. These units, in conjunction with heavy-duty
tooling, are so powerful they can destroy normal wireline tools and devices, if desired.
Although wireline handles most tasks required for well servicing, it is obviously limited in its
capabilities. It also has a role in dead well servicing, as it is normally required for plugging the well
to make it safe prior to Xmas tree removal and BOP installation. It is also used to conduct remedial
operations such as setting bridge plugs, re-perforating etc. It’s greatest limitation, due to using
gravity as it’s motive force, is in working in high angle or horizontal wells with inclination angles
higher than 70°, although recent developments such as ‘Roller Bogies®’ have been successfully
used in deviations up to 80+°.
10.2.1 Wireline Units
As pointed out earlier, there are two types of wireline unit - the electric line or logging unit and the
mechanical or slickline unit. Both types of unit are constructed similarly in that they have:
Power pack
Operator’s/engineer’s cabin
Winch, including a wireline drum or reel
Spooling or measuring head
Weight indicator and pulleys.
Wireline units must be self contained and able to be mounted on a truck (or trailer) or portable to
enable trucking and/or shipping to the well site. A typical wireline unit is shown in Figure 10.1.
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10 WIRELINE OPERATIONS
10.1 INTRODUCTION
Most well servicing is accomplished using wireline methods which are relatively simple to rig up
and conduct operations, compared to other methods. Wells in which Wireline Services are
performed may contain a wide range of wellhead pressures (WHP), for example from a few psi. up
to several thousand psi. This pressure is normally due to the natural pressure of the producing
formation into which the well has been drilled. Working in a pressurised well allows remedial or
investigative work to be performed without ‘killing’ the well. Although killing the well is safer, it is
a costly, time consuming exercise requiring a rig and perhaps damaging the producing formation
in the process.
Current Wellhead Pressure Equipment and practices allows a wire to be run in and out of the well.
Various wireline tools can be run and retrieved with a high degree of safety. Despite this, wireline
operations with pressure in the well require highly-qualified personnel and rigorous operating and
safety procedures, since the safety/control of the well is under their management.
The development of wireline pressure control systems have made this service one of the safest in
the industry.
Braided line (i.e. electric line and swab line) and slickline pressure control equipment is similar in
design and operation but do have some differences which are outlined below.
This is achieved by communicating with the tools through the conductor cable.
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SECTION 10
WIRELINE OPERATIONS
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BOPs are usually compact for manipulation into position above the Xmas tree or onto a riser often
used in platform arrangements. They are fitted with flexible hoses to enable ease of installation
and to reach between the BOP hydraulic control system and the BOPs when in situation. The
connections on the BOP must be compatible with the riser/tree connection and lubricator or be
supplied with appropriate crossovers.
Well intervention pressure control procedures are addressed in Sections 10 to 12.
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9.1 GENERAL
Well interventions in the context of IWCF are servicing operations conducted through the Xmas
tree (through-tree) on live Wells. These are carried out by the following methods:
Wireline (electric, braided line and slickline)
Coiled tubing
Snubbing.
Well service operations or workovers on dead Wells where the Xmas tree is replaced by Well
control equipment, are carried out by:
Drilling rigs
Workover rigs
Hydraulic workover units.
During workovers, it is probable that Well interventions with wireline and/or coiled tubing are
required as part of the work programme to prepare the Well for tree removal, or establish
production post workover.
Many offshore installations have drilling rigs onboard used for the drilling phase of a development.
These units are often retained to conduct Well servicing operations on fields which frequently
have Wells requiring servicing, although it is becoming more common for the drilling units to be
demobilised, and dead Well servicing to be accomplished by a Hydraulic Workover Unit. Where a
drilling rig is available for Well servicing, it is obviously more economic for it to be used than
mobilising an HWO unit.
On installations that have not retained the drilling rig, or on small platforms (drilling performed
with a jack-up rig), the HWO unit is commonly used. This is due to their easy deployment and their
small footprint.
On subsea Wells, normally the only means of conducting a Well intervention is to use a semi-
submersible vessel (drilling unit, DSV or specialised Well servicing unit) from which a workover
riser can be deployed. However, if the work programme can be conducted solely with wireline,
this can be successfully carried out by subsea wireline systems deployed from Well servicing
vessels (for example the Stenna Seawell). These vessels also have the capability to carry out
subsea tree change outs once appropriate barriers have been installed by wireline.
Well control equipment used on Well interventions in live Wells is specific to the particular service
being used for the intervention, albeit BOPs and strippers all operate under the same principles.
The main differences in the systems usually lie in the design of BOP ram elements, strippers or
stuffing boxes, grease heads used in wireline braided line operations, and the configuration of
these above the Xmas tree.
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WELL INTERVENTION SERVICES
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Choke Valve
The Choke Valve is used to restrict, control or regulate the flow of hydrocarbons to the production
facilities. This valve is operated manually or automatically and may be of the fixed (positive) or
adjustable type. It is the only valve on the Xmas tree that is used to control flow. It is sometimes
located downstream at the production manifold.
NOTE: All other valves used on Xmas trees are invariably of the gate valve type
providing full bore access to the well. These valves must be operated in the
fully open or closed position.
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8.11 WELLHEADS
8.11.1 Tubing Heads
At the drilling stage, casing is run and cemented in a well to line the well to protect against
collapse of the borehole, to prevent unwanted leakage into or from rock formations and to
provide a concentric bore for future operations. Various strings of casing are run, i.e. conductor,
surface string (which provides a base for the wellhead) followed by one or more intermediate
strings depending on the target depth and expected conditions in the well. At the completion
stage, production tubing is run to act as a flowline between the formation and surface. Unlike
casing, production tubing is not cemented in the hole so the entire tubing weight must be
supported by a suspension system suitably installed in a tubing head. The tubing head is
positioned on top of the uppermost casing head of a well and is used to suspend the production
tubing and to produce an effective seal between tubing and casing.
Tubing heads are composed of a body, a hanger-sealing device (tubing hanger), and a mechanism
that retains the hanger. Figure 8.22 shows a typical modern compact wellhead.
The wellhead equipment installed on top of the tubing head serves to control and directs the flow
of well fluids from the production tubing string. Surface equipment may range from a simple flow
cross with stuffing box to an elaborate Xmas tree. Choice of surface tree depends on well fluid
production method (natural flow or artificial) and the wellhead pressure encountered. In general,
most surface trees are comprised of at least one master valve, at least two wing or flow valves
(one of which may be hydraulically operated), and one swab valve utilised in wireline operations.
(Refer to Figure 8.23).
Wellhead equipment (spools, valves, chokes) are either screwed, flanged or a combination of
both. Wellheads with screwed connections are used for pressures not exceeding 1,000psi. (69
bar); those with screwed valves and chokes not exceeding 5,000psi. (345bar). However, most
operators specify flanged connections, even for low pressure wellheads since they are less
susceptible to leakage, easier orientated and, especially in the larger sizes, easier manipulated.
NOTE: API test pressures for all wellhead, including pressure control equipment
and downhole equipment, is twice the rated working pressure for
equipment up to 5,000psi and 11/2 times working pressure for 5,000psi and
above.
With regard to subsea wellheads, there is no API standard and manufacturers all have their own
specific design that includes some means of orientation in order to align the subsea tree inlets and
outlets to the flowlines or indeed in a subsea manifold system.
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NOTE: Like mandrel type hangers, landing nipple hangers are provided with a top
thread for the landing joint, an internal left hand thread or wireline profile
for the installation of a back pressure valve, and can be supplied with
extended necks to facilitate secondary sealing. Also, ram type tubing heads
are available with control line outlets to allow an SCSSV to be incorporated
in the tubing string.
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Outlets these provide access to the annulus (e.g. for pressure monitoring or gas lift)
during production.
Test Port permits the pressure testing of the hanger seal assembly, lockdown screw
packing connection between flanges, and the secondary (isolation) seal.
Tubulars up to and including 41/2“ are classified as tubing, over 41/2“ is casing. In large capacity
wells, casing size tubulars are often installed as the production conduit.
Tubing selection is governed by several factors. Anticipated well peak production rate, depth of
well, casing sizes, well product, use of wireline tools and equipment, pressures, temperatures, and
tubing/annulus differential pressures are among those which must be considered.
To meet various completion designs, there is a wide range of tubing sizes, wall thickness (weights)
and materials to provide resistance to tubing forces and differing well environments. The best
tubing selection is the cheapest tubing which will meet the external, internal and longitudinal
forces it will be subjected to, and resist all corrosive fluids in the well product.
Tubing in the main is supplied in accordance to API specifications which has a range of materials to
resist most of the potential corrosive well conditions but today where deeper high pressure sour
reservoirs are being developed, the API range is not suitable. To fill this gap in the market steel
suppliers provide propriety grades. These grades are usually high chrome steels designed for
various high temperature and sour well conditions up to 24% chrome.
For ease of identification, tubing is colour coded to API specification. Some specialist supplier's
steels are not covered by the code and provide their own specific codes. Refer to these codes to
ensure the tubing is according to requirements.
Suspension of the tubing is accomplished usually by threads, slips or any other suitable device, i.e.
rams.
The tubing head consists of a spool piece type housing where the internal profile of the top
section is a straight or tapered cylindrical receptacle (bowl) into which the tubing hanger is landed,
suspending the tubing and sealing off the volume between the tubing and the casing. A tapered
mandrel type tubing hanger system is shown in Figure 8.19.
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8.10.8 Tubing
The purpose of using tubing in a well is to convey the produced fluids from the producing zone to
the surface, or in some cases to convey fluids from the surface to the producing zone. It should
continue to do this effectively, safely and economically for the life of the well, so care must be
taken in its selection, protection and installation.
The tubing must retain the well fluids and keep them out of the annulus to protect the casing from
corrosion and well pressure which may be detrimental to future well operations such as
workovers.
Tubing connections play a vital part in the function of the tubing. There are two types of
connection available today; API and premium connections. API connections are tapered thread
connections and rely on thread compound to affect a seal whereas the premium thread has at
least one metal-to-metal seal. Premium connections are generally used in high pressure wells.
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NOTE: Activation can occur from the operation of remote-control pressure sensing
pilots, fusible plugs, plastic line, sand probes, level controllers or emergency
shutdown (ESD) systems.
Surface control manifolds are generally supplied as complete systems containing a reservoir,
pressure control regulators, relief valves, gauges, and a pump with manual override.
Manifolds, in combination with the various pilot monitors, have many different applications, e.g.
controlling multiple Wells using individual control, multiple Wells using individual pressures and
any combination of these.
Other additional features have been incorporated into surface control manifolds when the system
is integrated with other pressure-operated devices. A control panel, designed to supply hydraulic
pressure to a surface safety valve (SSV) and hydraulic pressure to an SCSSV, contains circuit logic
for proper sequential opening and closing of the safety valves, i.e.
Sequential closing:
SSV first
SCSSV second.
Sequential re-opening:
SCSSV first
SSV second.
Sequential logic is incorporated to increase the service life of hydraulic master valves and SCSSVs
to prevent SCSSVs becoming flow cut by high velocity wells.
Improvements have also been made in the monitoring systems, e.g.:
Sand erosion probes installed on a flowline to monitor sand flow production.
Quick exhaust valves, which allow rapid exhausting of control line pressure, to speed
up valve closures.
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NOTE: The API Standard allows some leakage through downhole Safety Valve, which is why
some companies do not consider them to be Barriers.
Permitted Leakage;
Gas Leakage allowed - upto 900scft/hr (25.5m³/hr)
Fluid Leakage allowed - upto 6.3gal/hr (0.4m³/hr)
NOTE: It is extremely important that pressure data is fully and accurately recorded.
After initial installation, leak tests should be carried out periodically; this accomplishes three
functions:
To test the integrity of the seal in the safety valve.
To test that the lock mandrel in a wireline retrievable valve is still properly locked.
To cycle the valve to prevent 'freezing' in wells where they have been sitting in either
fully open or fully closed position for extended periods of time.
NOTE: Authorised personnel should conduct all the above tests on all Sub-Surface
Safety Valves.
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Statistics have proven that the TRSV valve is more reliable than the WRSV and that the flapper is
more reliable than the ball mechanism, therefore the TRSV flapper valve is considered to be the
most reliable of all.
SCSSVs utilise only the ball or flapper type closure mechanisms.
Both categories are supplied with or without internal equalising features. The equalising feature
allows the pressure to equalise across the valve so it can be re-opened. Valves without this feature
need to be equalised by pressure applied at surface.
The equalising valve having more operating parts is less reliable than non-equalising valves,
however, with the latter, equalisation pressure is often difficult to provide and often more time
consuming.
NOTE: An equalising sub should be installed between the lock mandrel and the
regulator to facilitate the equalisation of pressure.
The valve is held open by a spring force that may be increased by adding spacers or changing the
spring. The relationship between flow rate and differential may be adjusted by changing the bean
size. The valve when closed will remain in this position until pressure is applied at surface to
equalise across it when the spring will return to the open position.
NOTE: Pulling Should Not Be Attempted Unless Pressures Have Been Equalised And
The Valve Is Open.
These valves are still in use today but also a derivative, the Injection Valve, which is normally
closed, is widely used in injection wells. This injection valve opens when fluid or gas is injected and
travels to the fully open position when the predetermined minimum injection rate is reached,
(refer to Sub-Section on Injection Valves).
Ambient Safety Valves
This type of direct-controlled safety valve is a fail safe closed valve which is pre-charged with a
calibrated dome (chamber) pressure prior to running. Ambient controlled valves will open when
the well pressure reaches the set point of the dome calibration. The valve will close when the
flowing pressure of the well, at the point of installation, drops below the pre-determined dome
pressure. Ambient type safety valves are also generally referred to as a ‘storm chokes’.
This type of valve is not limited by a flow bean which gives it a large internal diameter and, hence,
a large flow area making it suitable for high volume installations possibly producing abrasive fluids.
Ambient type safety valves are run with an equalising assembly to allow equalisation across the
valve should it close, and a lock mandrel to locate and lock the valve in the landing nipple.
NOTE: Both pressure differential and ambient controlled sub-surface safety valves
close on pre-determined conditions. They do not offer control until these
conditions exist. In addition, valve settings may change if flow beans
become cut. Surface controlled safety valves should be considered in such
cases.
Injection Valve
Injection valves are normally closed valves installed in injection wells. They act like check valves
allowing the passage of the injected fluid or gas but close when injection is ceased.
The closure mechanism is usually either, a ball or flapper type that opens when the differential
pressure from the injected medium equalises the pressure below the valve. As the injection rate is
increased to the pre-calculated rate, the differential acts on a choke bean and overcomes a spring
to move the mechanism to the fully open mode. If the injection rate is insufficient or fluctuating,
the mechanism will be damaged and possibly flow cut.
The flapper-type valve is the most popular as its operation is less complicated and is less prone to
damage if the injection rate is not high enough.
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General application: where intervention by General application: where larger flow area is
wireline is available desired for the tubing size
High pressure gas wells High volume oil and gas wells
NOTE: SCSSVs are set below any possible depth where damage could occur to the
valve from surface impact or explosion
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SPMs are installed in the completion string to act as receptacles for the following range of devices:
Gas lift valves
Dummy valves
Chemical injection valves
Circulation valves
Differential dump kill valves
Equalising valves.
It is essential to understand the operation of the device installed in a SPM before conducting any
well intervention, as it may affect well control. Refer to Figure 8.12 for a typical SPM and
The application of SSDs as a circulation device means they must be positioned as close as possible
to the packer, normally within 100ft.
Used for selective zonal production, a number of SSDs can be installed in a single completion string
between isolation packers and selectively opened or closed by wireline or coiled tubing methods.
Coiled tubing is generally used in high angle or horizontal wells where wireline tools cannot be
jarred effectively.
SSDs are available in versions that open by shifting an inner sleeve either, upwards or downwards,
by the use of an appropriate shifting tool. When there are more than one SSDs in a well, the
sleeves may be opened and/or closed with selective shifting tools without disturbing sleeves
higher up in the string.
CAUTION: Tubing and annulus pressures must be equalised before an SSD is opened to
prevent wireline tools being blown up or down the tubing.
A common fault with SSDs is that seal failure usually leads to a workover, although a pack-off can
be installed as a temporary solution. The top sub of the SSD incorporates a nipple profile, and the
bottom sub has a polished bore. This enables the installation of the pack-off, sometimes also
termed a straddle.
Mechanical
Run on a workstring, it is set by manipulation of the tubing i.e. by applying compression or tension
in combination with rotation depending on the particular setting mechanism for that packer.
Hydraulic
Can be run on a workstring or on the tubing string. When the desired setting depth is reached, the
tubing is plugged below the packer with a check valve, standing valve or a wireline plug. Hydraulic
pressure is applied to the tubing to set the packer.
Electrically on Wireline
This is more commonly used with permanent packers, but retrievable packers, i.e. permatrieve,
are also set with this method. The packer is attached to a wireline setting adapter, connected to a
setting gun on the end of the wireline and run in the wellbore. On reaching the desired depth an
electrical signal transmitted to the gun activates an explosive charge and, through a hydraulic
chamber, provides the mechanical forces to set the packer.
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Completion Variations
Retrievable Packers
These are often run into the wellbore on the production tubing string, but can also be set
individually on Wireline. As the name implies, retrievable packers can be recovered from the well
after setting by a straight overpull, usually around 40,000#, with the tubing.
Permanent Packers
These are installed in the wellbore either by Wireline or Coiled Tubing, or as an integral part of the
production tubing string. A permanent packer may also be considered as an integral part of the
casing. Older type permanent packers can only be removed from the well by milling operations.
However, more modern permanent packers can be retrieved by cutting the centre mandrel with a
chemical cutter, but these packers are not covered in this manual.
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8.5 PACKERS
A packer is a primary safety device used to provide a seal between the tubing and the casing which
allows Well Control. With a suitable completion string, this seal allows the flow of reservoir fluids
from the producing formation to be contained within the tubing up to the surface. This isolates
the production casing from being exposed to well pressure and corrosion from well effluents or
injection fluids.
A packer is tubular in construction and consists basically of:
Case hardened slips to bite into the casing wall and hold the packer in position
against pressure and tubing forces.
Packing elements that seal against the casing.
Figure 8.4 gives examples of typical packer installations and shows common types of packers.
In general, packers are classified in two groups:
Retrievable (Refer to Figure 8.5)
Permanent (Refer to Figure 8.6)
Packers may be further classified according to the number of bores required for production i.e.
Single One concentric bore through the packer for use with a single tubing
string.
Dual Two parallel bores through the packer for use with two tubing strings.
Triple Three parallel bores through the packer for use with three tubing strings.
A typical packer description, therefore, might be: 95/8“, dual 31/2“ x 31/2“, hydraulic-set retrievable
packer.
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Landing nipples are supplied in ranges to suit most tubing sizes and weights with API or premium
connections and are available in two basic types:
No-Go or Non-Selective (or Selective by a Top or Bottom Shoulder).
Selective.
8.3.2 Selective
In the selective system, the locking devices are designed with the same key profile as the nipples
and selection of the nipple is determined by the operation of the running tool and the setting
procedure. The selective design is full bore and allows the installation of several nipples of the
same size and type.
Uses of landing nipples are to:
Plug tubing from above, below or from both directions for pressure testing.
Leak detection.
Install safety valves, chokes and other flow control devices.
Install bottomhole pressure and temperature gauges.
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8.1.1 Mule-Shoe
This type of guide would be second choice on any completion design. Essentially it has the same
function as the Bell Guide but incorporates a large 45° angle cut on one side of the guide, (refer to
Figure 8.2a). It would only be used when the completion tailpipe has to be run into another
packer, or past a Liner Hanger. Should the guide hang up on a casing item such as a liner or packer
top while being run, rotation of the tubing will cause the 45° shoulder to ‘kick’ into, and enter the
liner or packer. This item has a very limited re-entry chamfer, and has been known to cause severe
re-entry difficulties for toolstrings in deviated Wells.
8 COMPLETION EQUIPMENT
In general, a well completion should provide a production conduit which:
Maximises the safe recovery of hydrocarbons from a gas or oil well throughout its
producing life.
Downhole accessories used should be designed to provide the safe installation and retrieval of the
completion, and flexibility for sub-surface maintenance of the well using wireline, coiled tubing or
other methods.
Different types of wells present distinct design and installation problems for engineers. Most
completions are just variations on a few basic design types and, therefore, in the majority of cases,
the equipment used is fairly standard. However, there is a move to more versatile and complex
equipment as used, for example in Smart Wells, but that is beyond the scope of this manual. An
overview of the equipment commonly used in single and dual string completions is given in the
following sections.
The detailed operation of some the items such as sliding side doors (SSDs), side pocket mandrels
(SPMs) and packers will not be covered in this manual. However, the relative location of these
tools in a completion and their functions in intervention work or workovers will be addressed.
Figure 8.1 shows a schematic drawing illustrating the location of equipment in a generic oil well
completion.
In order ensure compatibility between the manual and course lecture, the completion description
will start from the bottom of the completion and work ‘uphole’.
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SECTION 8
COMPLETION EQUIPMENT
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An alternative method of using a circulation kill method is to use coiled tubing that can be run into
the well under pressure. The well can then be killed by pumping mud down the small bore coiled
tubing and back up the tubing/coiled tubing annulus. The procedure is the same as for the reverse
circulation kill though, of course, this is actually a forward circulation procedure. The backpressure
is held as before on the tubing to control the bottomhole pressure.
This method would be used where it was not possible to establish communication around the
tubing shoe or through a sliding sleeve, and where it is not desirable to bullhead.
As the completion tubing is normally full of well fluids, and the tubing/casing annulus full of
completion or packer fluid, it is easier to conduct a reverse circulation as the gravities of the fluids
will tend to keep them segregated as they are pumped up the tubing. The preferred method is to
install a wireline set plug as low as possible in the well below the packer, (e.g. packer tailpipe), if
possible, to isolate the formation from the kill fluid, and then reverse circulate to kill the well.
Forward circulation is not recommended as it involves higher circulating pressures and disposal of
formation fluids through the tubing spool side outlets is very troublesome to handle effectively.
For these reasons this method is not described.
Bullheading is only recommended where it causes no damage to the formation. Some operators
have strict policies stating under which conditions this method may be used.
Lubricate and bleed is the least preferred and is only used when there is some obstacle to
conducting the other methods. For instance, it may be a combination of an obstruction in the
tubing that prevents the running of wireline to open a circulating path (e.g. a partially closed valve)
and a blockage or tight formation preventing bullheading.
SECTION 7
PRODUCTION WELL KILL PROCEDURES
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The pressure losses occurring during production well kill operations, are usually incalculable due to
the lack of information on the relevant factors. These pressure losses are, therefore, not usually
taken into account during well kill operations and are used as an additional safety factor.
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NOTE: It is the abnormal and subnormal pressures that cause the most problems
and, the further they deviate from normal, the greater the difficulties in well
control
If the permeable formation does not outcrop, then a third factor influences the formation pore
pressure:
Forces exerted on the trapped fluid by compaction or movements of internal forces
within surrounding formations.
If the resulting pore pressures are above 0.465psi/ft they are said to be abnormal.
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The former uses Diatomaceous Earth formed as a cake on the faces of plates pressed together
through which the fluid is pumped.
To provide the properties required for each of the above, many types of fluids are utilised, e.g.
drilling muds, milling fluids, brines (including seawater), salt saturated brines, diesel and dead oil.
Some like the drilling or milling fluids, must have cuttings carrying capability, cool the bit or mill
and reduce friction to deliver hydraulic energy downhole. Others used, say for circulating
purposes, or to provide an overbalance only, may be clear brines or seawater etc. Completion or
packer fluids are usually solids free to prevent drop out and sticking. These are also dosed with
biocide, corrosion and/or scale inhibitors for long term protection of the formation and tubulars
exposed to the fluid. However, one important function of them all, whether used as a completion
fluid or in a re-completion, is that they must provide an overbalance at the packer depth, in case
of a leak, to control well pressure.
Generally, the most economic fluid, which meets all of the criteria is used and, if possible, it should
be solids free and non-damaging. This criteria would tend to result in clear brines being used as
they are cheap, readily obtainable, easily transportable and easily filtered in normal weight ranges.
However the points, which make them desirable, are also their worst features in that they have no
bridging capability, and are easily lost into the formation (unless the well is plugged). In this case, a
LCM pill is usually placed against the formation to prevent or reduce the losses.
The solids in the LCM pill are often designed to be removed by post re-completion flushing or
acidising. The use of a high viscous pill as an LCM is not recommended as the long chain molecules,
which plug the pores, cannot be removed by these methods.
To prevent the risk of these occurring, it is obvious that well interventions require thorough
planning to minimise formation damage.
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All completion and service equipment, especially the tubing should be thoroughly cleaned before
being installed and thread dope used sparingly.
If the well is to have an open hole type completion, then the well fluids programme should be
designed to prevent formation damage. However, in practice this is difficult and most engineers
acknowledge damage will be caused to some extent. In the situation where LCMs need to be used
to support the workover fluid, the engineer must select a material, which can be easily removed
afterwards. Sized salt or calcium carbonates are examples where the former is cleared by flushing
with water, and the latter with an acid wash.
6.1.3 Producing
Although it may be of some surprise, damage can occur during the producing phase of a well. This
is normally due to the production of asphalt, wax or scales but can also be due to other chemicals
contacting the formation.
Common types of damage:
Reduced permeability if formation is in contact with corrosion, scale or paraffin
inhibitors.
Formation or perforation blocking with precipitated scale.
Asphalt deposition around the wellbore can cause plugging and oil wetting, which in
turn can cause emulsion blocking.
Permeability reduction due to movement of fines through the reservoir.
Altering relative permeability detrimental to production due to increasing water
production.
Clay swelling due to contamination with incompatible brines or water.
Plugging due to contamination with fill, silt or crud.
6.1.1 Drilling/Casing
Drilling fluids usually contain chemicals and/or solids as bridging agents to control the loss of
drilling fluids. Fluid losses can lead to well control problems and are also expensive to replenish,
especially when using the more exotic mud systems such as Pseudo or Oil based muds etc.
Drilling fluids cause the following types of damage:
Solids plugging of pores, vugs or fractures either natural or induced.
Clay swelling reducing permeability.
Filtrate penetration detrimentally changing the relative permeability to producing
fluids.
Similar damage can be caused during the casing cementing process for the production casing by
cement pre-flushes and cement slurries.
Non-damaging drilling fluids are often used to penetrate the producing formations when the wells
are to be completed with open hole, barefoot or gravel pack type completions. In the main,
however, damage done during the drilling is not a serious problem in most wells as they are
usually to be perforated. The perforating depths, under normal circumstances, exceed the depth
of any damage areas. They also generally have a total flow area greater than the tubing area;
hence there is little impediment to achieving maximum production rates. Perforating is usually
carried out in a clear non-damaging fluid such as brine or fresh water so that minimal post
perforating damage is caused.
6.1.2 Completing
The damage caused during the completion phase, compared to drilling, is generally minimal if
good completion designs and practices are employed. Most damage caused would be through
contamination by fluids or pills used containing loss control materials (LCM) and other foreign
bodies.
Possible damage may be:
Plugging of pores, vugs and fractures by LCM.
Clay swelling due to incompatible well fluids.
Deposition of mill scale, rust or thread dope.
Perforating tunnels plugged by perforating debris from the shaped charges.
Perforating tunnel compaction or crushing caused during the perforating process.
Cleaning up at too high a rate causing movement of formation fines to plug pores.
With current technology it is easy to complete wells and displace to clean filtered brines or fresh
water before perforating, thereby reducing the risks of any damage occurring. Also, most
perforating is done with an underbalance pressure in the tubing, which reduces the amount of
invasion. Displacing the tubing (fully or partially) to a lighter gravity fluid such as diesel, base oil or
fresh water creates this underbalance. If a fluid cannot provide sufficient underbalance or if a very
high underbalance is demanded, nitrogen can be used although it is much more costly.
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SECTION 6
PREVENTION OF FORMATION DAMAGE
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You will note that some of the above have already been addressed in previous sections. With
regard to the others in the list, there may be a number of possible solutions for each problem. For
instance:
Reservoir problems such as formation damage and low permeability can sometimes
be improved by stimulation operations, such as, acidisation or hydraulic fracturing.
In oil or gas Wells where there is liquid hold up or gas slip, this is often countered by
installing smaller diameter tubing strings. These may be Reeled Tubing strings
installed inside the original completion by large size CT units. This tubing reaches
down into the sump and provides a smaller flow area to improve liquid lift. These
reeled strings are normally 23/8“, 27/8” or 31/2” OD and are run and hung off on a
wireline lock, tubing packer, or similar device.
The tubing is snubbed into the Well by normal CT methods from large reels. When
the correct length of tubing is in the Well and has been attached to the lock mandrel,
it is run to setting depth and set on regular size CT.
The main disadvantage with this solution is the high weight of such large reels, which
is often above the lifting capacity of some offshore installations. Smaller, more
manageable, reel sizes entail more undesirable offshore connections to make up the
full length of tubing required. These problems, however, are outweighed when set
against the costs of a full programme to re-complete.
An artificial lift system is usually required in any low permeability Well to give
adequate production rates. A work programme to re-complete this type of Well is
required once the Well flow has reached the minimum economic acceptable natural
flow. If the Well has already been on gas lift and it is no longer efficient, then the
design should be reviewed to optimise the existing gas lift mandrel spacing against
re-completing with the optimum mandrel depths.
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A full workover programme usually entails the placement of an overbalance kill fluid against the
formation, unless it can be isolated using a plug. For example, a Wireline plug in a permanent
packer tailpipe, or setting of a through tubing plug in the casing above the producing zone(s).
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Sand placement in the sump may solve the problem in circumstances where there is a sufficient
height of sand as the vertical permeability of a column of sand is high and blocks water flow.
Cement squeezes have probably been the commonest means of plugging off water producing
zones in the past utilising workover methods. This often requires killing the Well, pulling the
completion, cementing and re-completing.
High production liner or monobore type completions have been specifically designed for through
tubing operations. This enables water control by simply installing a through tubing bridge plug by
wireline or CT, after which cement can be squeezed, if necessary.
Cement squeezing by CT below regular packer style completions using modern through tubing
tooling, is now also common practice.
Water blocking by creating a gel in the formation is a much more recent development. This entails
pumping chemicals to the formation, which react after a pre-determined period of time to form a
gel. The viscosity of the gel is so high that it remains in the formation pores, blocking the flow of
water trapped behind the gel. This method is usually expensive due to high chemical costs.
Plugging back of water producing zones may on occasions require the Well to be re-completed if
the packer has to be moved, or if shallower zones need to be perforated and brought on stream.
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5.1 GENERAL
Many servicing operations can be conducted by rig workovers, however live well intervention is
preferred as killing a well risks fluid invasion of the formation, thereby causing potential formation
damage.
The primary objective of Well intervention operations is the management of Wells to provide
optimum Well production. This is achieved by conducting live Well remedial operations, obtaining
downhole reservoir data or preparation of the Well for a dead Well workover (if live Well servicing
cannot solve a problem). Occasionally, gathering of downhole reservoir data is a secondary
objective only opportunistically taken when an intervention is planned for other reasons. This data
are usually to provide Well information on lateral and vertical movement, current location of oil,
water and gas and identifying and producing the zones.
There are many reasons for remedial live Well intervention, Well operations, most notably to:
Remove obstructions to flow such as tubing blockage with sand, wax or asphalt.
Eliminate excessive water or gas production.
Repair mechanical failure.
Improve production through well stimulation, re-completions or multiple
completions on low productivity Wells.
Enhance production by conducting Well stimulation such as hydraulic fractures on
high productivity Wells.
Increase production by bringing other additional potentially productive zones on
stream.
Before a well is entered, a complete analysis must be made of the current Well status, the reasons
for work carefully established, the associated risks identified and appropriate contingency
measures planned in the event of operational failure.
All oil and gas Wells will encounter some impairment to production during it’s producing life and
Well service operations need to be planned either, to rectify, or improve, the conditions within the
Wellbore. Therefore, common servicing operations such as cleaning out fill, re-perforating,
chemical treating, acidising, fracturing or a combination of these techniques are routinely carried
out to enhance production.
A description of these main Well problems is discussed in the following sections.
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SECTION 5
REASONS FOR WELL INTERVENTIONS
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COMMON CALCULATIONS
ANNULUS FLUID = usually in pounds per gallon (ppg)
Calculation = ppg x 0.052 x depth = Annulus hydrostatic pressure
GAS COLUMN PRESSURE = must find Conversion factor (Gas Table)
Find depth of Gas Column, (Left hand side of table on Gas Table)
Find Gas Gravity (at top of table) then cross-reference
Correction factor x SITHP (Shut in tubing head pressure) = Press. At bottom of gas column
i.e. Well depth 4000’ - Gas Gravity 0.7 - SITHP 2500psi = Correction Factor 1.102 x 2500(SITHP) =
2755psi
Example:
Tubing Capacity = 0.00829 bbl/ft (Barrels per foot) x 9000 = 75bbls
Pump Displacement = 0.0899 bbl/stroke
Tubing Shoe at = 9000ft MD (Measured Depth for Volume Calculation)
To Calculate Number of Pump Strokes to Displace Tubing Volume
= Tubing Capacity
Pump Displacement x Tubing Shoe Depth (MD)
i.e. 0.00829
0.0899 = 0.0922 x 9000 = 830 strokes
DICTIONARY
MD = MEASURED DEPTH – (for calculating volumes)
RVD = TRUE VERTICAL DEPTH – (for calculating pressure)
FORMATION PRESSURE = Bottom hole pressure (at formation)
FORMATION GRADIENT = Average weight of all fluid & gas in the well
HYDROSTATIC HEAD = Weight of fluid/Gas column (At bottom of column)
UNDERBALANCE = Hydrostatic head is “LESS” than Formation Pressure
OVERBALANCE = Hydrostatic head is “MORE” than Formation Pressure
KILL FLUID = Calculated hydrostatic pressure equal to bottom hole pressure
PUMP BOTTOMS UP = Pump down tubing and return fluid from the bottom of the Well,
up the annulus to the surface (Drilling Term requiring Annulus
Volume calculation)
VOLUME OF WELL = Total fluid in annulus and tubing
COMPLETION FLUID = Fluid in the Well during completion (usually left in annulus)
COMPLETION FLUID DENSITY = Weight of completion fluid per gallon
OIL DENSITY = Weight of oil per gallon
SIWHP = Shut in well head pressure
SITHP = Shut in tubing head pressure (Same meaning as above)
CIWHP = Closed in tubing head pressure (Same as above)
CITHP = Closed in tubing head pressure (Same as above)
FORWARD CIRCULATION = Down tubing/up annulus
REVERSE CIRCULATING = Down annulus/up tubing
BULLHEADING = Pumping down tubing into formation
THIEF ZONE = A zone/formation that takes fluid
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VOLUMES
It is important that Well Services personnel are able to calculate volumes as well as pressures. This
is important for any pumping or killing operations undertaken.
Where pressure calculations are calculated using ‘TVD’, calculations for volume must use ‘MD’
(Measured Depth).
If the appropriate tables are not available, i.e. Baker Tech Facts or Halliburton Red Book, then the
following
Calculations can be used:
The capacity of a section of pipe in bbl/ft. Is:
C = Where D = diameter in inches
Having obtained the capacity of a length of pipe from tables or from calculation, the total fluid
volume can be
Easily calculated by:
Fluid volume = capacity x length (i.e. MD measured depth)
= 0.865
HP of oil column = 0.865 SG x 0.433psi/ft x (8,200 - 4,000)ft
= 1,573psi
Total HP in tubing
= HP of gas + HP of oil
= 652psi + 1,573psi
= 2,225psi
Differential pressure across circulation device
= HP of annulus - HP of tubing
= 4,387psi - 2,225psi
= 2,162psi from annulus to tubing
If the circulation device were to be opened, then the opening toolstring would be exposed to
2,162psi differential pressure. If using wireline, this pressure differential will need to be equalised
before opening the device, otherwise, there is a high risk of having the toolstring ‘blown up the
hole’.
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Correction Factors(Gravity)
Well Depth
0.6 0.7 0.8 0.9
3,000 1.064 1.075 1.087 1.098
3,500 1.075 1.089 1.102 1.115
4,000 1.087 1.102 1.117 1.133
4,500 1.098 1.115 1.133 1.151
5,000 1.110 1.129 1.149 1.169
5,500 1.121 1.143 1.165 1.187
6,000 1.133 1.157 1.181 1.206
6,500 1.145 1.171 1.197 1.224
7,000 1.157 1.185 1.214 1.244
7,500 1.169 1.204 1.232 1.264
8,000 1.181 1.214 1.248 1.282
8,500 1.193 1.239 1.266 1.304
9,000 1.206 1.244 1.282 1.324
9,500 1.218 1.259 1.302 1.345
10,000 1.232 1.275 1.320 1.366
10,500 1.244 1.289 1.338 1.388
11,000 1.257 1.306 1.357 1.410
11,500 1.270 1.322 1.376 1.433
12,000 1.282 1.338 1.395 1.455
12,500 1.297 1.354 1.415 1.477
13,000 1.311 1.371 1.434 1.500
13,500 1.324 1.388 1.455 1.523
14,000 1.338 1.405 1.475 1.548
14,500 1.352 1.422 1.495 1.573
15,000 1.366 1.438 1.515 1.596
Table 4.1 - Gas Correction Factors
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Using the calculations already given in earlier sections and the gas correction factors, hydrostatic
pressures in relatively complicated systems can now be determined.
Example
What is the differential pressure between the annulus and tubing at a circulation device installed
at a depth of 8,200ft TVD in the tubing string?
The following are the well conditions:
The tubing/casing annulus is filled with a10.29ppg brine.
The well is shut in at surface with a CITHP of 600psi
There is a gas cap of 0.6SG gas from 4,000ft
There is 32API oil from 4,000ft to 12,000ft
To help in the calculation, it is sometimes better to make a sketch. (Refer to Figure 4.1).
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Example
A 10,500ft TVD well has two fluids in the well, a 15 ppg fluid from TD to 7,125ft and 8.33ppg fluid
to surface, what is the HP at the bottom of the well ?
HP of 15ppg fluid = 15ppg x 0.052 x (10,500 - 7,125)ft
= 15ppg x 0.052 x 3,375ft
= 2,633psi
HP of 8.33ppg fluid = 8.33ppg x 0.052 x 7,125ft
= 3,086psi
Total HP = 2,633psi + 3,086psi
= 5,719psi
4.1.5 Gas Correction Factors
Most well servicing operations entails working with live wells whether using a through-tubing
method or rig intervention. Even with a rig operation, the well must be prepared by being killed
prior to the intervention. This involves dealing with gas in the well.
Production wells with gas in the fluids will exert a static surface pressure equal to the formation
pressure less the hydrostatic pressure in the production bore. The gas entrained in the production
fluids will segregate from the liquids as shown in Figure 4.. In a static situation, the closed in tubing
head pressure (CITHP) and hydrostatic pressure will balance the formation pressure.
As discussed earlier, gas is also a fluid and exerts a hydrostatic pressure. Being compressible,
pressure affects the density of the gas. A set of correction factors are used to calculate hydrostatic
pressures at varying TVDs with a range of gas gravities (refer to Table 4.). The correction factor,
according to the TVD of the gas column and the gas gravity, is multiplied by the CITHP:
HP = Correction factor x CITHP
Example
What is the HP of a 5,000ft TVD column of 0.7 SG (Correction factor i.e. 1.129 see table) gas with a
closed in tubing head pressure of 1,650psi
HP of gas = 1.129 x 1,650psi
= 1,863psi
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Example
What is the Hydrostatic Pressure of a 500ft TVD column of fresh water?
HP = 0.433psi/ft x 500ft
= 216.5psi
Example:
What is the hydrostatic pressure of a 6,750ft well, filled with a 0.478psi/ft pressure gradient fluid,
which has a TVD of 6,130ft?
HP = 0.478psi/ft x 6,130ft
= 2,930psi
Example
A 12,764ft TVD well is filled with a 15ppg fluid, what is the BHP.
HP = 15ppg x 0.052 x 12,764ft
= 9,956psi
Equipped with this knowledge, it is now easy to calculate the hydrostatic pressure with two or
more fluids in a well provided the depths (TVD) of the fluid interfaces are known. Using the same
formula, the HP for each fluid section is calculated in the same way and the sum of the individual
calculations gives the HP at the bottom hole or well.
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141.5
SG = 131.5 + API
Example:
What is the SG of 30° API oil.
141.5
SG = 131.5 30
o
= 0.876
4.1.4 Hydrostatic Pressure
Hydrostatic pressure (HP) is the pressure developed by a fluid at a given true vertical depth in a
well irrespective of the measured depth (Refer to Figure 4.2). ‘Hydro’ means water, or fluids,
which exert pressure and ‘static’ means motionless. So hydrostatic pressure is the pressure
created by a stationary column of fluid. The hydrostatic pressure of any fluid can be calculated at
any true vertical depth (TVD) provided the pressure gradient of the fluid is known.
The previous calculations have dealt with fluid pressure with a gradient of one foot depth but it is
now simple to determine the pressure exerted by a fluid at any true vertical depth by multiplying
that pressure gradient by the true vertical height of the column in feet. The true vertical height of
the column is the important factor in the equation, as its volume or shape is irrelevant.
The equation is: HP = PG x TVD
where:
HP = Hydrostatic pressure
PG = Pressure gradient
TVD = True Vertical Depth
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A cubic foot of fresh water weighs 62.4 pounds therefore the weight per gallon is 62.4/7.48 =
8.33ppg.
Example:
The pressure gradient of a 10 ppg fluid = 10 ppg x 0.052 = 0.52psi/ft
Example:
Find the weight of a fluid, which has a gradient of 0.465psi/ft
0.465 psi / ft
0.052 = 8.94ppg.
This constant is probably the most useful constant used in calculations.
4.1.2 Specific Gravity
Many fluids in the oilfield are also expressed in specific gravity (SG) as well as weight in ppg. It is
also necessary to be able to convert SG to pressure gradient in order to calculate hydrostatic
pressures.
SG is the ratio of the weight of a fluid (liquid) to the weight of fresh water. Fresh water weighs
8.33 ppg and salt water is nominally valued at 10 ppg. Therefore, the SG of salt water is:
10 ppg
= 1.2
SG of Salt Water = 8.33 ppg
The SG of fresh water is 1.0. As the gradient of fresh water is known to be 0.433psi/ft, to obtain
the gradient of a fluid, it is simply necessary to multiply its SG by 0.433psi/ft
Example:
What is the hydrostatic pressure (HP) exerted by a true vertical 5,000ft column of brine with a SG
of 1.17.
HP of brine = 1.17 x 0.433psi/ft x 5,000ft
= 2,533psi
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4 PRESSURE BASICS
Pressure is usually expressed as the pounds of force that is applied against a one square inch area,
i.e. pounds per square inch (psi). Therefore, when a gas is placed in a pressure tight container, it
exerts a pressure on all sides of the container. If the gas pressure is 100psi, it exerts a force of
100lbs on each square inch of the container area. Similarly, if a liquid is placed in a can, it exerts a
pressure on the sides and bottom of the container due to the weight of the liquid, which is also
expressed as psi. In well control, both of these effects are of the utmost importance.
Pressure can be expressed as absolute or as gauge pressure. Absolute pressure includes
atmospheric pressure that is also applied due to the weight of the atmosphere and is 14.7psi.
Some gauges, especially BHP gauges, are calibrated in absolute terms, but regular gauges showing
psig indicate they have been calibrated at atmospheric pressure, and the 14.7psi is excluded.
Although this is a relatively small amount and can be ignored in most instances, it is important
when gathering data for reservoir analysis.
SECTION 4
PRESSURE BASICS
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If there is a failure or wear to the primary barrier system, two barriers must be closed around the
pipe to make repairs, but not necessarily the secondary safeties, e.g.
If the stripper rubber is leaking, both the stripper rams can be closed or a
combination of strippers and safeties.
If the top stripper ram is leaking, the lower stripper can be closed along with a safety
or both safeties.
Etc.
As with any primary barrier, if the internal check valves leak, the string must be pulled to repair
the valves before operations can be recommenced.
The stab-on safety valve (stabbing valve or kelly cock), is an inside secondary barrier used solely as
a temporary arrangement to allow dropping of the plug into the secondary downhole barrier
landing nipple.
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Secondary
Two safety (pipe) BOP rams or one safety with an annular preventer.
SCSSV, if pipe is above it.
Tertiary
BOP shear and blind rams, or a shear/seal valve or BOP incorporated into the BOP
stack or directly on top of the Xmas tree.
Secondary
Stab-on safety valve (always ready and located in the workbasket).
Wireline plug installed in the BHA by dropping it into the workstring.
Tertiary
A shear/seal valve or BOP.
Kill pump facility to install an overbalance fluid.
When running a tapered string, either two sets of safety rams are required or variable rams are
used.
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Secondary
Shear and Blind rams incorporated within the BOP.
Tertiary
Shear/seal BOP mounted directly on top of the Xmas tree.
In the North Sea region, it has almost become obligatory to use shear/seal BOPs due to a number
of instances where primary and secondary barrier systems failed to deal with some particular well
control occurrences.
When conducting operations, a failure of the inside primary well control barrier will entail
cessation of activity and retrieval of the BHA for repair to the barrier system.
NOTE: Some well interventions are conducted without BHA check valves as it is
necessary to reverse circulate. In these cases the primary inside well control
is the BOP shear rams and a shear/seal BOP becomes the secondary.
3.4.4 Snubbing
There are a number of snubbing BOP arrangements for different pressure regimes, running
parallel or tapered strings or deploying long BHAs.
A stripper rubber can be used when well pressures are less than 3,000psi, dependent upon the
material used and the size, although stripper BOPs are always installed regardless of the well
pressure as contingency.
Annular preventers are used in two situations, when long toolstrings are to be deployed which can
close on various diameters or for quick shut-in on pipe with upset or collared connections to
prevent moving the pipe. The latter is usually dictated by company policy.
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Secondary
Two wireline BOP rams (in conjunction with a grease pump) that can close and seal
around the wire.
Xmas tree upper master, if the wire is broken and ejected.
SCSSV, if toolstring is above it.
Tertiary
Wireline cutting valve (usually UMV designed for Wire cutting).
Shear/seal valve or BOP installed directly onto the top of the Xmas tree.
In general, tertiary barriers are rarely used unless a heavy-duty wireline operation is being carried
out.
Secondary
Pipe and Slip Rams incorporated within the BOP.
SCSSV, if the tubing is not straddling it.
Tertiary
Shear and Blind Rams incorporated within the BOP.
Secondary
Wireline BOP rams/valve which can close and seal around the wire.
Xmas tree upper master, if the wire is broken and ejected.
SCSSV, if toolstring is above it.
The BOP rams can be used for stripping wire out of a well but only when absolutely necessary.
Stripping through the BOPs is only carried out to find the free end of the wire to enable wireline
recovery.
Tertiary
Wireline cutting valve (Usually UMV designed to cut wire)
BOP/Shear Seal Valve installed directly on top of the Xmas Tree.
Xmas tree valve, if absolutely necessary.
In the event of primary and secondary failure with no tertiary barriers available, a Xmas tree valve
may be used to sever the wire, as they can usually cut wireline, although the valve seat may be
damaged. The valve used for this should be the upper master for two reasons:
If the lower master is used and damaged, it requires the well to be plugged before
repair.
If the swab is used and damaged the well cannot be used for production as there is
no longer double barrier protection from the production fluid.
In the event of the upper master being used to cut Wireline, the valve should be inspected and
relevant parts repaired/replaced at the earliest convenience.
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Additional barriers can be installed downhole, as a back up to a failed primary or secondary barrier
or to allow removal of the Xmas tree for repair or for installation of workover BOPs. These barriers
may be:
Wireline plugs
Bridge plugs
Cement plugs.
Ice plugs
Overbalanced hydrostatic fluid
Barrier Integrity
Mechanical barriers must be tested, preferably from the direction of flow. Tests on closed type
barriers should be leak tight. The leakage rate on closable barriers such as Xmas tree valves etc.
should be the API leakage criteria: 400cc/min or 900scf/hr with the exception of sub-surface safety
valves used in well plugging (refer to note above in list of closable barriers). Each operator should
develop procedures for testing Xmas tree and sub-surface safety valves to meet this criterion. This
is problematic in subsea completions where there are long undulating production flowlines and
riser systems which makes it difficult to calculate leakage rates for various well GORs and
downstream volumes; however to help, formulae are provided in API 14A.
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Barriers are conveniently arranged into three main categories of pressure control, namely:
Primary
Secondary
Tertiary.
Each of these consists of at least one, or a combination of mechanical barriers described below.
The categorisations or classifications are described in section 3.3.
NOTE: These categories may not be the terms used in some areas of the world,
especially where the common language is not English.
* Sub-surface safety valves are acceptable as barriers during normal operations if they are
tested in accordance with the test criteria given below, however, to be used for well plugging, i.e.
for Xmas tree removal before a rig operation, it must be leak tight.
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3.1 GENERAL
This section describes the well control methods and practices employed on the various well
intervention servicing methods and includes a section to explain barrier theory.
The most significant factor to consider is whether they are live well or dead well interventions as
this will have an impact on the equipment required and methods of well control employed. Dead
well interventions, in terms of the IWCF, are classified as workovers and well control methods for
these are covered in the IWCF drilling test. The methods addressed in this course are those used
specifically in live well interventions.
There is a distinct difference between rig workover operations and live well interventions.
Workover well control uses a combination of barriers and procedures in a systematic method to
contain pressure downhole whereas live well interventions use a system of barriers to contain
pressure at surface. Barrier theory and these systems are described in the following sections.
A rule common to well intervention activities worldwide regarding pressure control is that a
minimum of two independent and tested barriers shall be available at all times. In any
circumstance where either of the barriers has failed, or there are indications that it is likely to fail,
immediate action must be taken to re-instate or supplement that barrier and return the well to
double barrier protection.
The ‘primary barrier’ is the term used to describe the first line system of pressure containment
and ‘secondary barrier’ the next line of defence. Nowadays, it is common, especially in high-
pressure wells, to install a third line of defence or a ‘tertiary’ barrier.
The particular status of a well, for given operations and well circumstances, will have different
barriers in place. For instance, the completion provides barriers in the form of individual Xmas tree
valves and a sub-surface safety valve*, however, when running coiled tubing or a snubbing
workstring, these cannot be closed and, therefore, are not available barriers until the BHA is above
them.
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SECTION 3
WELL CONTROL METHODS
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Definitions:
Workover – Well Servicing Operations conducted on dead Wells. (Usually with
a rig and BOP’s in stalled on the wellhead).
Well Intervention – Well Servicing operations conducted on live Wells.
Workover – Well Control
Well Intervention – Pressure Control
Barrier Theory – A Barrier is any device, fluid or substance that prevents the flow of
Wellbore Fluid.
Double Barrier Protection – A minimum of Two Tested Barriers should be available at all times
Not Barriers – Any mechanical device cannot be considered a Barrier if it has a
toolstring through it.
Types of Barriers – Primary, Secondary and Tertiary.
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Underground Blowout An uncontrolled flow of formation fluids from a sub-surface zone into
a second subsurface zone.
Underbalance The amount by which formation pressure exceeds pressure exerted by the
hydrostatic head of fluid in the wellbore.
Valve, Float A device that is positioned as either open or closed, depending on the position of a
lever connected to a buoyant material sitting in the fluid to be monitored.
Valve, Poppet The opening and closing device in a line of flow that restricts flow, by lowering a
piston type plunger into the valve passageway.
Valve, Relief A valve that opens at a present pressure to relieve excessive pressures within a
vessel or line whose primary function is to limit system pressure.
Valve, Shut-off A valve which operates fully open or fully closed to control the flow through a
conduit.
Valve, Sub Surface Safety A completion safety valve installed at a depth below the surface
according to various criteria.
Viscosity A measure of the internal friction or the resistance of a fluid to flow.
Watt A unit of electromotive force.
Wireline BOP (valve) Preventers installed on top of the well or drill string as a precautionary
measure while running wirelines. The preventer packing will close around the wireline.
Xmas Tree The head terminating a completion with a set of valves to control well flow and well
servicing activities.
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Secondary Barrier Is the second line of defence from an uncontrolled well flow. It is usually
brought into use when the primary barrier has failed or requires repair.
Shear Rams Blowout preventer rams with a built in cutting edge that will shear tubulars that may
be in the hole.
Shear/Seal BOP The name used for a device used as a tertiary barrier on well interventions, which
has the ability to cut wire or pipe and seal.
Snubbing The process of installing pipe into a well where the well pressure is greater than that of
the weight of pipe in the hole. It has also come to mean any of the live well interventions carried
out by a hydraulic workover unit.
Snubbers Term used to describe inverted slips used when the snubbing unit is in pipe light
mode.
Soft Close In To close in a well by closing a blowout preventer with the choke and choke line valve
open, then closing the choke while monitoring the casing pressure gauge for maximum allowable
casing pressure.
Sour Gas Natural gas containing hydrogen sulphide.
Space Out Procedure conducted to position a predetermined length of tubing/drill pipe, so that no
connection or tool joint is opposite a set of preventer rams.
Space-Out Joint The joint of tubing/drill pipe which is used to hang off operations so that no
tool joint is opposite a set of preventer rams.
Squeezing Pumping fluid into a formation.
Stack The assembly of well control equipment including preventers, spools, valves, and nipples
connected to the top of the casing head.
Stripper A device which packs-off around wire or pipe run into the well and seals. They may be
self energised or hydraulically activated.
Stripping The process of running pipe through a stripper with or without pressure in the well.
Swabbing The lowering of the hydrostatic pressure in the wellbore due to upward movement
of tubulars and/or tools.
Tertiary Barrier Is a third line of defence against an uncontrolled well flow, and in well
interventions is usually a device, but may also be an overbalanced fluid. Is only used when the
primary and secondary barriers have failed or been compromised.
Transducer The device located in the solenoid valve box that is actuated by hydraulic pressure,
and converts the force to an electrical signal for indication on a meter. The electrical output signal
is in proportion to the hydraulic input pressure.
Tubulars Drill pipe, drill collars, tubing, and casing.
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Packing Rubber elements used in wireline stuffing boxes to seal around slick wirelines.
Pack-off or Stripper Rubber A device with an elastomer packing element that depends on
pressure below the packing to effect a seal in the annulus. Used primarily to run or pull pipe under
low or moderate pressures.
Pipe Rams Rams whose ends are contoured to seal around pipe to close the annular space.
Separate rams are necessary for each size (outside diameter) pipe in use.
Plug Valve A valve whose mechanism consists of a plug with a hole through it on the same axis as
the direction of fluid flow. Turning the plug 180° opens or closes the valve. The valve may or may
not be full-opening.
Pore Pressure Pressure exerted by the fluids within the pore space of a formation.
Potable A liquid that is suitable for drinking.
Pressure Gradient, Normal The normal pressure divided by true vertical depth.
Pressure Integrity Test (PIT) Application of pressure by superimposing a surface pressure on a fluid
column, in order to determine the pressure at which the well can withstand before a well
intervention. This test is less than formation fracture pressure to prevent formation damage.
Pressure Transmitter Device that sends a pressure signal to be converted, and calibrated to
register the equal pressure reading on a gauge. The air output pressure in proportion to the
hydraulic input pressure.
Primary Pressure Control The primary well control system or device on the wellhead.
Pump A device that increases the pressure of a fluid, and moves it to a higher level using
compression force from a chamber and piston that is driven by a power source.
Ram The closing and sealing component on a blowout preventer. One of three types - blind,
pipe, or shear - may be installed in several preventers, mounted in a stack on top of the wellbore.
Blind rams, when closed, form a seal on a hole that has no drill pipe in it; pipe rams, when closed,
seal around the pipe; shear rams cut through drillpipe and then form a seal.
Recorder A device that records outputs of pressure, temperature, continually on a chart to
provide continuous reading.
Regulator A device that varies and controls the pressure of a liquid or gas that passes through
its chamber.
Replacement The process whereby a volume of fluid, equal to the volume of steel in tubulars,
and tools withdrawn from the wellbore is returned to the wellbore.
Reservoir The container for storage of a liquid. The reservoir houses hydraulic fluid at
atmospheric pressure as the supply for fluid power.
Rupture Disc A device whose breaking strength (the point at which it physically bursts) works to
relieve pressure in a system.
Safety Factor A margin added to a figure or value purely for safety.
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Kick Intrusion of formation fluids into a wellbore containing kill or drilling fluid.
Kill Fluid Density The unit weight e.g. pounds per gallon (lbs/gal), selected for the fluid to be
used to contain formation pressure.
Kill Line A high-pressure fluid line connecting the mud pump and the wellhead. This line allows
fluids to be pumped into the well or annulus with the blowout preventer closed to control a
threatened blowout.
Kill Rate A predetermined fluid circulating rate, expressed in fluid volume per unit time, which is
to be used to kill the well.
Kill Rate Circulating Pressure Pump pressure required to circulate kill rate volume.
Leak-off Test Application of pressure by superimposing a surface pressure on a fluid column, in
order to determine the pressure at which the exposed formation accepts whole fluid.
Lights A name used in snubbing operations to describe snubbers or inverted slips.
Lost Circulation (Lost Returns) The loss of whole well control fluid to the wellbore.
Lost Returns See Lost Circulation.
Lubrication Alternately pumping a relatively small volume of fluid into a closed wellbore system,
and waiting for the fluid to fall toward the bottom of the well.
Lubricator The pressure containing tubulars mounted above the Xmas tree for installing wireline
or coiled tubing toolstrings in live wellbores.
Manifold Header The piping system that serves to divide a flow through several possible outlets.
Meter An instrument, operated by an electrical signal that indicates a measurement of pressure.
Micron A millionth of a metre or about 0.0004”. The measuring unit of the porosity of filter
elements.
Minimum Internal Yield
Pressure The lowest pressure at which permanent deformation will occur in metals.
Needle Valve A shut-off two-way valve that incorporates a needle point to allow fine
adjustments in flow.
Normal Pressure Formation pressure equal to the pressure exerted by a vertical column of
water, with salinity normal for the geographic area.
Opening Ratio The ratio of the well pressure to the pressure required to open the blowout
preventer.
Overbalance The amount by which pressure exerted by the hydrostatic head of fluid in the
wellbore exceeds formation pressure.
Overburden The pressure on a formation due to the weight of the earth material above that
formation. For practical purposes, this pressure can be estimated at 1psi/ft of depth.
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Closing Unit The assembly of pumps, valves, lines, accumulators and other items necessary to
open and close the blowout preventer equipment.
Closing Ratio The ratio of the wellhead pressure to the pressure required to close the blowout
preventer.
Control Panel, Remote A panel containing a series of controls that will operate the valves on
the control manifold from a remote point.
Corrosion Inhibitor Any substance which slows or prevents the chemical reactions of corrosion.
Cut Fluid Well control fluid, which has been reduced in density or unit weight as a result of
entrainment of less dense formation fluids or air.
Displacement The volume of steel in the tubulars and devices inserted and/or withdrawn from
the wellbore.
Fluid Weight Recorder An instrument in the fluid system that continuously measures fluid
density.
Tubing Safety Valve An essentially full-opening valve located on the rig floor with threads to
match the tubing in use. This valve is used to close off the tubing to prevent flow.
Drill Stem Test (DST) A test conducted to determine production flow rate and/or formation
pressure prior to completing the well.
Equivalent Circulating
Density (ECD) The sum of pressure exerted by hydrostatic head of fluid, drilled solids, and friction
pressure losses in the annulus divided by depth of interest and by 0.052, if ECD is to be expressed
in pounds per gallon (lbs/gal).
Feed-in (Influx, Inflow) The flow of fluids from the formation into the wellbore.
Filter A device whose function is the retention of insoluble contaminants from a fluid.
Flow Meter A device that indicates either flow rate, total flow, or a combination of both, that
travels through a conductor such as pipe or tubing.
Flow Rate The volume, mass, or weight of a fluid passing through any conductor, such as pipe
or tubing, per unit of time.
Flow Target A bull plug or blind flange at the end of a T to prevent erosion at a point where
change in flow direction occurs.
Fluid A substance that flows and yields to any force tending to change its shape. Liquids and
gases are fluids.
Fluid Density The unit weight of fluid; e.g., pounds per gallon (lbs/gal).
Formation Breakdown An event occurring when bottomhole pressure is of sufficient
magnitude that the formation accepts fluid from the hole.
Formation Integrity The ability of the formation to withstand applied pressure.
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Blow-out Preventer The equipment installed at the wellhead to prevent damage at the surface, in
the event of blow-out, while restoring primary well control. The BOP allows the well to be sealed
to confine the well fluids and prevent the escape of pressure.
Blowout Preventer Drill A training procedure to determine that rig crews are completely
familiar with correct operating practices to be followed in the use of blowout prevention
equipment. A dry run of blowout preventive action.
Blowout Preventer Operating
Control System The assembly of pumps, valves, lines, accumulators and other items
necessary to open and close the blowout preventer equipment.
Blowout Preventer Stack The assembly of well control equipment including preventers, spools,
valves and nipples connected to the top of the wellhead or Xmas tree.
Blowout Preventer Test Tool A tool to allow pressure testing of drilling or workover blowout
preventer stacks and accessory equipment, by sealing the wellbore immediately below the stack.
Bleed Off Valve An opening and closing device for removal of pressurised fluid.
Bottomhole Pressure Depending upon context, either a pressure exerted by a column of fluid
contained in the wellbore, or the formation pressure at the depth of interest.
Bottoms-up Is the term describing the time at which fluid that was at the bottom of the hole
reaches surface.
Bullheading A term to denote pumping well fluids back into a formation in a well kill operation.
Casing Head/Spool The part of the wellhead to which drilling or workover blowout preventer
stack is connected.
Casing Pressure See Back-Pressure.
Casing Seat Test A procedure whereby the formation immediately below the casing shoe is
subjected to a pressure equal to the pressure expected to be exerted later by a higher drilling fluid
density, or by the sum of a higher drilling fluid density and back pressure created by a kick.
Check Valve A valve that permits flow in only one direction.
Choke A diameter orifice (fixed or variable) installed in a line through which high pressure well
fluids can be restricted or released at a controlled rate.
Circuit Breaker An electrical switching device able to carry an electrical current, and automatically
break the current, to interrupt the electrical circuit if adverse conditions such as shorts or
overloads occur.
Circulating Head A device attached to the top of drill pipe or tubing to allow pumping into the
well without use of the Kelly.
Clamp Connection A pressure sealing device used to join two items without using conventional
bolted flange joints. The two items to be sealed are prepared with clamp hubs. A clamp containing
two to four bolts holds these hubs together.
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SECTION 2
GLOSSARY FOR WELL CONTROL
OPERATIONS
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Conversion of annular D2 d2
area to bbls/ft bbls / ft
1.029.42
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SECTION 1
FORMULAE AND CONVERSION FACTORS
COMMONLY USED IN WELL CONTROL
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4 PRESSURE BASICS.................................................................................................................................................. 48
4.1 FUNDAMENTALS OF FLUIDS AND PRESSURE ................................................................................................................. 52
4.1.1 Fluid Pressure ............................................................................................................................................................ 52
4.1.2 Specific Gravity.......................................................................................................................................................... 54
4.1.3 API Gravity................................................................................................................................................................. 55
4.1.4 Hydrostatic Pressure ................................................................................................................................................. 55
4.1.5 Gas Correction Factors .............................................................................................................................................. 57
g) The Invigilator, who has no knowledge of oilfield technology, mark the test paper from a
standard key. Therefore if the answers you give on your test paper are ambiguous e.g.; you
mark two answers when only one is requested or one answer when two are requested, or the
calculation cannot be read, you will get zero points for that question:
h) Please check your paper when you have finished – to ensure that all questions (on both sides of
the pages) have been answered.
When you have completed your paper, please hand it to the Invigilator with all your working paper
and leave the room quietly. Do not remove any test material or notes made during the test from
the room. Else your paper may be voided.
10. Results: -
The Certification Centre manager will give you your results. Do not wait around outside the test
room or bother the Invigilator while he or she is grading the test papers.
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f) If you want to change an answer that you have marked or entered on the paper, draw two lines
through the answer box – then tick the correct box or enter your new answer.
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a) Candidates are required to bring their passport to the test centre on the morning of the test
session. The invigilator will check the passport details against the personal details on the
candidate’s registration form.
b) Candidates will be given a registration form to complete before the test session commences.
This must be completed in BLOCK letters (EN MAJUSCULES) (MIT GROSSEN BUCKSTABEN) using
a pen or ballpoint. Please ensure that your name, date and place of birth are as stated on your
passport.
c) This is a ‘closed book’ exam; therefore brief cases, textbooks, calculation tables, and any other
materials which candidates bring with them must be left outside the room before the test
commences.
a) Candidates will require a calculator, pen and ruler to complete their written test papers. A
candidate’s final answer(s) to each question must be clearly marked in pen or ballpoint.
b) The test centre will provide candidates with ‘Formula Sheets’ and blank working paper. All working
papers must be handed to the invigilator with each completed test paper.
c) Candidates may only leave the test room during the written tests with the Invigilator’s
permission. Candidates are recommended to take a short break.
8. Examination Tips: -
a) Unless otherwise requested, you must only mark one answer for each question.
b) If you are asked to select more than one answer, the precise number will be indicated in the
question.
c) All multiple choice questions must be answered by placing an ‘X’ in the appropriate answer box.
d) The answer(s) to calculation questions must be written clearly in the space provided. The
marking scheme provides sufficient margin to allow for rounding of calculations.
e) You must answer all calculation questions based on the data given. Do not make assumptions
about data that has not been provided. Do not assume that the data is incorrect and that you
may change it before the calculation.
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Certification Programme
d) Well Intervention ‘Combined Operations’. This Programme includes Coiled Tubing, Wireline and
Snubbing Operations.
2. The Certification programme contains a minimum of three written test paper sections: -
a) A written test on Pressure Control Completion Equipment (compulsory for all candidates).
d) A candidate nominated for the ‘Combined Operations’ programme must sit and pass all four
equipment test papers and P & P paper to obtain a certificate.
3. Each of the four programme options is available at Level 1. or Level 2. The different levels cannot be mixed.
4. Candidates or their employers are required to nominate the programme and test level to the
Accredited Certification Centre. It is possible to sit both test levels at the same test session.
5. The time allowed for the written test papers in each programme is as follows:
Level 1. and 2: -
i) Completion Equipment Test plus coiled Tubing, or Wireline or,
Snubbing Equipment – 1 hour.
OBJECTIVES
The individual objectives are to assist the delegate to:
Identify various types of completions and their impact on well interventions.
List the well parameters necessary to conduct a safe well intervention.
List the parameters necessary to conduct a well kill operation.
Identify well pressure control problems from available well data i.e. pressure, volume
and flow characteristics.
Identify possible problems and implement solutions to various well pressure control
problems.
Understand pertinent legislative guidelines, standards and best practices.
Determine if pressure control equipment is fit for purpose.
Obtain IWCF certification.
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FOREWORD
Well pressure control is the most critical consideration in the planning and performing of any well
servicing operation.
The awareness of well pressure control in the prevention of injury to personnel, harm to the
environment and potential loss of facilities must be fully appreciated by planning engineers and
well site personnel. This appreciation must include personnel in having a sound knowledge of
legislative requirements, completion equipment, pressure control equipment and operating
practices and procedures.
‘Well Intervention’ and ‘Workover’ are commonly used terms to describe servicing operations on
oil and gas wells and which have, in the past, had many different interpretations. However, in
general, ‘Workover’ describes well service operations on dead wells in which the formation
pressure is primarily controlled with hydrostatic pressure. Workover operations are carried out by
a drilling rig, workover rig or Hydraulic Workover Unit (HWO) where the Xmas tree is removed
from the wellhead and replaced by a blow out preventer (BOP) equipment. ‘Well Intervention’ is a
term used to describe ‘through-tree’ live well operations during which the well pressure is
contained with pressure control equipment. Well Interventions are conducted by wireline, coiled
tubing or snubbing methods. Snubbing operations today are now usually conducted with HWO
units.
This S-D Consulting Course is designed to provide essential knowledge to delegates participating in
Well Intervention Pressure Control.
Well pressure control equipment used by wireline, coiled tubing and snubbing units is so termed
as it must control well pressure during live well intervention operations. It significantly differs from
BOP systems used on dead well workovers. As most well servicing is now conducted by live well
intervention methods these are fully addressed as part of the course. The term Well Control
specifically applicable to drilling or workover operations using hydrostatic pressure is not
addressed in this manual.
To have an understanding of well operations conducted by live well intervention methods and the
associated pressure control equipment, it is first necessary to have, or obtain, a basic knowledge
of completion designs, completion equipment, practices, well service methods and their
applications. An overview of these is given in the early sections of the manual.
Training in well intervention well pressure control is an essential part in ensuring the competence
of personnel involved in the planning and carrying out of live well servicing operations. The S-D
Consulting Oilfield Services WELL INTERVENTION WELL CONTROL TRAINING COURSE and course
materials intend to provide this essential knowledge in order to help delegates to obtain an IWCF
(International Well Control Forum) certificate in Well Intervention Pressure Control.