D Operations Manual Work over and Testing Procedures
Version 1.0
Work over and Test Operation Procedures
Contents 1. Rig Moving and Installation 2. Well Killing Operation 3. Swabbing Operation
4. Squeezing Cement Operation 5. Sand Flushing Operation 6. Drill Cement Plug Operation 7. Drill Out Bridge Plug Operation 8. PCP Running Operations 9. Tubing Convey Perforation Operation 10. Wire line Perforation Operation 11. Down hole Tools Setting Procedures
Introduction: This comprehensive manual has been compiled for the main purpose of serving as a guide to Work over Operations personnel and a reference to Work over Engineers. And it has been considered the main work over and testing operations as well killing, cementing, drilling, wire line….etc. This manual is written in such a way that it is clear, easy to follow, and simple to achieve benefits for Asawer company personnel. So this Manual has been arranged as versions to be updated annually.
Rig Move Procedures and installation Move to a new location 1. Checking and securing the safety access to the new location. 2. Communicating with the Company related about the underground power cables before burying and drilling in any anchor. 3. Checking the high voltage power lines on the location. Working within 5 meters from them is prohibited. 4. Checking all location if need construction or preparing. 5. Checking and making sure that the ground under the Rig structure shall be level off, firm and strong. Equipment pins and safety pins shall be in places. 6. Equipment on location shall be positioned reasonably. Mud tank and shacks to be placed more than 30 meters away from wellhead, BOP controller system and generator 25 meters away from wellhead, Mud pump apart from Mud tank more than 5 meters. 7. Standing behind the rig or trucks is prohibited during the night shipment from one location to another. 8. Check the tubing and casing pressure. 9. Checking guy lines should be installed.
Procedures of Rig up & Rig down R/U: 123456-
Pre –safety meeting and distribute duty for crew members. Spot the rig on base flat metal. Mechanic has to check hydraulic and air system. Lifting rig carrier on base jacks (the load of rig must be on base jacks). Release guy lines for rig carrier. Distribute crew member to monitor handling lines and electric cable while perform RU. 7- Mechanic raises the mast (part-1). 8- Put safety derrick pins on the right position to secure the derrick. 9- Pull down two small winch lines about 10m. 10- Release brake and let swab line down smoothly. 11- Mechanic Extend the mast (part-2), so driller must be control the brake and let traveling blocks go down slowly.
12- Derrick man put safety pins on the right position. 13- Install support jacks. 14- Secure carrier lines (derrick back lines) and guy lines. R/D: 1234-
Pre –safety meeting and distribute duty for crew members. Prepare monkey broad, disconnect electrical cable and derrick safety pins. Release guy lines and derrick back lines. Distribute crew member to monitor handling lines and to be sure it not hanging. 5- Raise traveling blocks near crown. 6- Mechanic retracts the mast (part-2). 7- Release derrick safety pins. 8- Pull up the swab line and wenches lines slowly. 9- Release support jacks. 10- Lower mast (part-1) down. 11- Arrange handling lines on rig carrier. 12- Release basic jacks.
Well Killing Procedure Killing Well With Normally Circulation: The killing fluid should be pumped from tubing then turn back from annulus between tubing and casing to circulate. This method would be favorable to protect pay zone. 1. The measured killing fluid density, viscosity and usage on the well site should meet the demand of program. 2. As to wells with high gas production and without sand produced the flow line with needle valve should be applied to control the drainage of gas. 3. The check valve at inlet and needle valve at outlet should be installed when connecting operational lines for killing well with normally circulation. 4. Pressure test inlet line of killing well operation without leakage in 5 minutes to be qualified. 5. The well cleanup with water to release gas should be more than one and half round. 6. The pump rate should be no less than 500 L/min while flushing the well and the pump couldn’t be stopped during circulation. 7. Needle valve could be applied to control the balance between inlet pumping rate and outlet pumping rate during circulation. 8. The killing fluid meeting the demand of design should be used to kill well with normal circulation immediately after flushing well with clean water one round. 9. The difference between measured killing fluid density at inlet and at outlet should be less than 0.02 Kg/m3 after one round well killing with normally circulation. 10. Well killing is qualified when no overflow observed at both inlet and outlet. Killing Well With Reverse Circulation: 1. The killing fluid is pumping from annulus between tubing and casing and turn back from tubing to circulate. This method is applicable to high pressure oil wells with large production it’s difficult to apply positive circulation. 2. Killing lines and working procedures for reverse circulation operation is the same to positive circulation operation.
Swabbing Procedure Preparation: 1. The ID of swabbing string should be of same specification. 2. The drift check with standard drift gauge for tubing should be conducted before RIH swabbing string. 3. The total length of stuffing box and lubricators should be at least 2 meters more than the length from rope socket to swab cup, which should be safe and reliable to prevent blowout. Operation Procedures: 1. Link braided line, rope socket and sinker bar, and connect lubricators. 2. Connect swab mandrel without swabbing cup to sinker bar to check the ID of tubing and 6 marks shall be made on the swab line (3 marks when the in lubricator, 2 marks after 50m and one marks after 100m from first marks). 3. Link swab cup after POOH sink bar, then put into swabbing head. Continue RIH swab after connecting lubricators with the speed no more than 150m per min. The submergence should be controlled within 200m. 4. It should not be run too deep when unclear of liquid depth and be tried gradually to deepen. 5. Check the lubricators once every 5 times swabbing and make sure the packing of lubricators in good condition. 6. If blowout is observed while swabbing then POOH until swab enters into lubricators and then close swab valve. 7. The pressure difference should not be too large when swabbing for sand produced formation and the uplifting speed should be reduced. Squeezing Cement Procedures 1. RIH squeezing string to designed depth. 2. Connect and flush surface lines, then pressure test 15-20MPa without leakage in 5-10 minutes to be qualified. 3. Circulate down hole fluid, and check whether the surface system in good condition or not and to decrease down hole temperature. 4. Conduct trivial squeezing with clean water to test water absorbing index and casing expansion rate (injective test to determine the feed rate). 5. Mix cementing slurry according to design. 6. Normally displace designed volume of cementing slurry according to design requirement. 7. Normally displace specific volume of displacement fluid according to design requirement and the displacement rate should be controlled to 0.5m3/min. 8. POOH string to the position for reverse circulation. 9. Reversely circulate to wash out extra cementing slurry.
10. POOH string to designed depth, and assemble stopcock and pressure gauge at the top of tubing string. 11. Multi-squeeze until the pressure stable, then close the casing valve to wait on cement. Sand Flushing Procedure 1. RIH sand flushing string to tag sand level with one bevel edge at the bottom of the string. 2. Uplift sand flushing bevel edge 3m above sand level. Lower down string slowly and smoothly after normal circulation with pump and the pump rate should meet the demand of working plan. 3. Full circulation should be conducted for each joint with flushing time no less than 15 min. 4. Each duty should cooperate with each other closely to control RIH speed according to pump pressure and outlet pump rate. 5. When over 5 joints are flushed continuously, the RIH could be continued only after flushing one round. 6. When malfunction happens to pump and the pump must be stopped to dispose, the string should be uplifted to 10m above initial sand level and trip up and down repeatedly. 7. Normal circulation must be kept when troubles happen to uplifting equipment. 8. When serious leakage of formation and no sand flushing fluid returning to surface are found during sand flushing operation, the flushing should be stopped. Uplift flushing string above initial sand level and trip up and down repeatedly. The job could be continued with methods such as wax ball plug-off, sand flush with united large rate pumps, and sand flush with gasified fluid…and so on. 9. The outlet pump rate should be controlled for the sand flush of high pressure flowing wells to be balanced with inlet pump rate so as to prevent blowout. 10. After sand flushing to designed depth or bottom hole which is the top surface of cement plug the pump rate should be kept above 400L per min to continue circulation. It is qualified after sand cut less than 0.2 percent. Then uplift string more than 20 m, then detect sand level repeatedly after waiting for sand settlement 4 hours later and record the depth.
Drill Cement Plug Procedures 1. Preparation: 1.1 Equipment 1.1.1 Lifting equipment: Workover rig, Downhole service rig. 1.1.2 Drill tool: hydraulic power swivel, downhole screw driller, or rotary table. 1.1.3 Circulating equipment: Cementing truck, Mud pump. 1.1.4 Drill bit: OD of the bit (winged scraping bit) should be less 6-10mm than ID of the casing. Measure the ID, OD, length of the Bit, thread type. 1.1.5 Killing fluid (high pressure wells) Based on the well condition, prepare the killing fluid. The volume is 1.5 or 2 times of the volume of the well bore. 1.2 Prepare pipe(tubing or drill pipe) 1.2.1 Based on the operation program, prepare the drilling pipe(tubing or drill pipe) 1.2.2 Pipe rack height is 0.3m above the ground. Measure the pipe 3 times by 3 persons, the difference is less than 0.2m/1000m. 2. Operation: 2.1 Use downhole screw driller to drill cement plug 2.1.1 Before RIH the downhole screw driller, test it on surface. 2.1.2 The BHA as following (from bottom to top): bit (or winged scraping bit) + downhole screw driller + DC (heavy weight DP) +Drilling jar +lifting sub +tubing (or drill pipe). 2.1.3 The filter unit should be installed at surface in the circulating pipe. 2.1.4 Above 5m of the cement plug level, normally circulated till stable, slowly lower the string, WOB:5-10KN, fluid annulus return speed should be more than 0.8m/s. 2.2 Use power swivel to drill cement plug. 2.2.1 The BHA as following(from bottom to top): bit(or winged scraping bit)+ Drill collar + Drilling jar + lifting sub + tubing(or drill pipe)+ power swivel Above 5m of the cement plug level, normally circulated till stable, start the power swivel, after the swivel running normally, lower the string lowly, WOB:510KN, 40-60rpm, fluid annulus return speed should be more than 0.8m/s. 2.3 Use rotary table to drill cement plug 2.3.1 The BHA as following(from bottom to top): bit(or winged scraping bit)+ drill pipe+ Kelly pipe 2.3.2 Above 5m of the cement plug level, normally circulated till stable, start the rotary table, after the rotary table running normally, lower the string slowly, WOB:10-25KN, 60-120rpm, fluid annulus return speed should be more than 0.8m/s. 2.4 Quality requirement 2.4.1 Record the ID, OD and length of drill tool, pipe string, and draw the sketch map.
2.4.2 Pipe thread must be painted by pipe dope, the thread torque is in the range of the pipe required. 2.4.3 Be sure that there is no junk on top of cement plug level. 2.4.4 If use downhole screw driller, the drill fluid must be clean to meet the requirement of downhole screw driller. 2.4.5 Make a short trip every 3-5m of footage. 2.4.6 Avoid the casing damage. 2.4.7 The drill fluid must be compatible with the formation. 2.4.8 To the designed depth, RIH casing tool gauge or scraper to Drilled designed depth, and clean the wellbore with 1.5-2.0 times of wellbore volume fluid.
Drill out bridge plug procedures 1. Preparation: 1.1 Prepare for the drill pipe and drill collar and crossover. 1.2 Prepare for the milling bit: wash over milling shoe, rock bit, flat-bottom mill, concave mill 1.3 Well control unit 1.4 Weight indicator, pressure gauge 1.5 Milling fluid. 2. Operation 2.1 Washover methods 2.1.1 BHA assembly (from bottom to top): washover milling shoe + washover pipe + junk basket + drill string (DC+DP). 2.1.2 At the very beginning of washover the BP, as following: Lower the string, put 10-20KN weight on the BP, marked on the drill pipe, pull up string 1-2m to make sure that the milling shoe is not contacted with the BP. Circulation and rotate the drill pipe at 60-100rpm, the fluid of returning speed in annulus is more than 0.8m/s. In 15 mins, put 10-20KN weight on BP gradually. 2.1.3 Washover the BP, WOB: 10-20KN, the rotary torque is no more than the string required torque. 2.1.4 After released the BP, pushed it to PBTD. If the PBTD is not required to leave junks, then RIH fishing tool to take out all junks. 2.2 Milling method 2.2.1 At the very beginning of wash over the BP, as following: Lower the string, put 20-40KN weight on the BP, marked on the drill pipe, pull up string to original weight. Circulation and rotate the drill pipe at 60-100rpm, the fluid of returning speed in annulus is more than 0.8m/s. In 15 mins, put 20-40KN weight on BP gradually. 2.2.2 Milling the BP, WOB: 20-40KN, the rotary torque is no more than the string required torque. 2.2.3 After released the BP, pushed it to PBTD. If the PBTD is not required to leave junks, then RIH fishing tool to take out all junks. 2.3 Rock bit (Drilling bit) Method: 2.3.1 BHA (from bottom to surface): rock bit + bit sub + drill collar + drilling jar + drill string. 2.3.2 beginning of BP drilling as following: Lower the string, put 10-20KN weight on the BP, marked on the drill pipe, pull up string 1-2m to make sure that the drilling bit is not contacted with the BP. Circulation and rotate the drill pipe at 60-100rpm, the fluid of returning speed in annulus is more than 0.8m/s. In 15 mins, put 10-20KN weight on BP gradually.
2.3.3 Drill out the BP, WOB: 10-20KN, the rotary torque is no more than the string required torque. 2.3.4 After released the BP, pushed it to PBTD. If the PBTD is not required to leave junks, then RIH fishing tool to take out all junks. 2.4 Quality requirement 2.4.1 If there is junks on top of the BP, it must be fished and make the BP level clean. 2.4.2 The milling fluid must be compatible with the formation. 2.4.3 Before POOH, make a round circulation. 2.4.4 If no obvious footage, cannot put more weights on bit in order not to damage the casing.
PCP Running Procedures 1. Design for tubing and rod string: 1.1 The design for tubing string plays an important role in lowering pump operation. The typical structure design of tubing string is as following: Structure Attachment and function Remarks Tubing Hang the tubing on the well head equipment hanger Tubing The upside connects tubing hanger; the Connect to the pump string downside connects pump and channel to hanger position reach flow to surface Stator Stop pin Tubing anchor Screen pipe Tail pipe
Contain plastic caves to make the rotor lifting the flow by rotation Restrict the position when down the rotor to the well Prevent the stator from rotating to lead to the Sliding anchor or tubing thread loose torque anchor Oil flow passage Equip according to the requirement Increase weight and stability 5-10(or 3-6 tons) tubing.
1.2The rod design structure is as following: Structure Attachment and function Polished rod Transfer torque and raise rotor Pony rod Sucker rod Rod centralizer Rotor coupling Rotor
Remarks Its length should be more than rotor length Adjust the polished rod 1 set pony rod which have different length Fall the rotor to the desired depth, transfer Determine the total the torque length according to the pump hanger Fall one set every 6-10 sucker rods Use according to the well conditions Connect sucker rod and rotor
Helical rod installs into stator to lifting flow by rotation. 2 Running in PCP Pump 2.1 Prepare 2.1.1 Before RIH check tubing anchor direction. It is the inner thread is upside; the outer thread is downside. 2.1.2 Before run in hole check relief valve (drain tubing). There are six shear pin on t the relief valve. One shear pin can bear 5MPa pressure. Set the pump opening pressure to the max when leaving factory. Before run in hole, check that the number of shear pin is in condition and that the pump opening pressure is correct. When fix shear pin, distribute them symmetrically. 2.1.3 Run in hole pcp pump 2.1.4 Run in the PCP pump string according to the design. 2.1.5 When mounting the relief valve, be careful do not use the wrench to grip the slip sleeve so as avoid break the shear pin. 2.1.6 Snap tight all tubing connection. 2.1.7 After run in hole some meters depth, rotate the pipe string toward clockwise direction, then test the tubing anchor if it can be gripped. Go on work after the test finished. 2.1.8 Carry the tubing hanger into the wellhead and lower it slowly. Rotate the tubing hanger toward anticlockwise direction as it touches the wellhead. Running in hole PCP Rotor 3.1 Run in the PCP rotor string according to the design. 3.2 Snap tight all rod connections during installation. The recommended rods’ 3
screw-on-torque values are listed in table below.
Recommended PCP Rod Strings’ Screw-on-Torque Values Rod OD Screw-on-torque Rated Torque (mm) (N·m) (N·m) 22 600 940 25 700 1050 28.6 1000 2000 36 1200 2500 38 1300 2700 42 1500 3200 48 2000 4200 3.3 The last few sucker rods to be run in should be installed slowly. 3.4 When inserting the rotor into the stator, the rod string may rotate to right. 3.5 Put all the rod weight on stop pin. Make a mark on sucker rod which marks the zero rod weight. Recheck the landing by pulling up and setting back down on the stop pin again. 3.6 Pick up rod string off the stop pin until rod string weight is achieved, then refer to the weight indicator. The slump will be taken out and rod will be tension. 3.7 Mark the sucker rod as the rod string weight mark. Note: Lifting the rotor from the ground slowly to avoid the rotor being curved. 4 Installation of Drive Head 4.1 Use level gauge to help to keep the wellhead flange in the horizontal level in order to decrease the polished rod broken failure. 4.2 Pick up the drive head with the workover rig’s cat line. Be sure to keep the drive head balanced while lowering it over the polished rod so as no to be bond the polished rod. 4.3Pick up the rod string the required distance and mark the rod at this point which is the operating point. Recommended Rod Pull Back Space vs. Different Pump Depth Pump 700 800 900 1000 1600 Depth (m) Rod Pull 0.55 0.65 0.75 0.85 1.4 Back Space (m) 4.4Place the clamp on top of hex shaft and be good tighten. 4.5 Thread the drive head into the flow tee or hammer union making sure not to
over tighten. 4.6 Connect the power cable with motor and control. 5 Commissioning 5.1 Open the production valve and oil pipeline valve. 5.2 Start up the motor and observe the current and volatage changes at the same time. 5.3 When oil flows from the flowline, shut off the producing valve then observe the well head pressure. If the pressure rises and no abnormal changes emerge, PCP system is proven to be all right and could be put into production. Tubing Conveyed Perforating Procedures Tubing Conveyed Perforating is running the perforation gun with tubing. Procedure : 1. Get the well information from well operation program; 2. Get the perforation request from the well operation program; 3. Draw the Gun String sketch for the operation; 4. Prepare the Gun on surface; 5. Double check the Gun String before sent to wellsite; 6. Confirm the Gun String is well-assembled; 7. Make sure all the safety regulations are well performed; 8. Safety meeting is necessary before lifting the gun; 9. The Safety Space Gun must be long enough to ensure the gun under surface when make up the Fire Head; 10.Gun must be RIH with smoothly and keep the RIH speed in 10-15stands; 11.The Tubing and Annular must be well covered to protect something unexpected drop in; 12.The fluid height both in Tubing and in Annular are enough to keep the gun fire safely; 13.GR/CCL depth correlation logging must be done for confirm the gun face the planning information; 14.BOP is well installed on the wellhead, function and pressure test must be done on the BOP facilities; 15.Drop bar or Pump to fire the gun with observing on the wellhead and casing gauge to detect the perforation on surface. 16.POOH perforated gun with smoothly. Wireline Conveyed Perforating Procedures Wireline Conveyed Perforating is running the perforation gun with wireline. Operation Procedures: 1. Confirm there is no potential blow out; 2. Get the well information from well operation program; 3. Get the perforation request from the well operation program; 4. Draw the Gun String sketch for the operation;
5. Prepare the Gun on surface. 6. Double check the Gun String before sent to well site; 7. Confirm the Gun String with Company man; 8. Make sure all the safety regulations are well performed; 9. Safety meeting is necessary before lifting the gun; 10.Casing must be drifted with wireline; 11.Make sure turn off all the power, radio, mobile phone and so around location; 12.The Wireline BOP must be qualified and well installed; 13.Make sure all the power switch for firing gun are turn off; 14.Gun must be RIH with smoothly, POOH to check if there is any block; 15.The fluid height in Annular is enough to keep the gun fire safely; 16.Fired gun after confirming the gun is facing to the deigned formation; 17.POOH perforated gun with smoothly.
Downhole Tools Setting Procedures
[DBP (Drillable Bridge Plug) + CR(cement retainer)](7’’, 9 5/8’’): 1- Reach to the setting depth put a mark above the holding slips Of the tubing and it will be a reference point. 2- Pick up 2 feet. 3- Turn to the right 15 turns. 4- Back again to the setting depth 5- Over pull 10 Tons in case of 7’’ casing & 15 Tons in case of 9 5/8’’casing 6- Go back again to the Neutral weight of the Tubing. 7- Apply down 10 Tons in case of 7’’ casing & 15 Tons in case of 9 5/8’’casing. 8- Go back again to the Neutral weight of the Tubing. 9- Over pull 2 Tons. 10- Turn to the right 4 turns until the weight indicator release the over pull. 11-Move the tubing up and down until you sure the tool is free. 12- Pressure test the Bridge plug to 1000 psi if there is no perforation above it. For Cement Retainer conduct the same procedures of DBP. To sting in go down and Apply between (2-4) tons, and start the injectivity test. To sting out apply over pull (2-4) tons. RBP (Retrievable Bridge plug) (7’’, 9 5/8’’): Setting procedures: 1- Reach to the setting depth put a mark above the holding slips Of the tubing and it will be a reference point. 2- Pick up 70 cm.
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Start turn to the right 4 turns while you going down Apply down Weight Over pull weight Go back to the neutral weigh Apply down weight between (2..5)Tons to release the fishing tool and turn to the left Half turn and keeping hold the pipe wrench and start pull it Gradually until it is free.
Unset procedures:1- Reach to setting depth and circulate above the fishing Neck of the RBP. 2- Apply down weight between(10-15) Tons depend on the Size of casing (7”,9 5/8”). 3- Over pull the same weight above depend on the size of casing. 4- Repeat the step No (2 &3) one time more to confirm that you catch the RBP. 5- Over pull the 2 Ton and start turn to the right until the weight is release. 6- Wait Five Minutes until the elements relax. 7- Continue turn 15 Turns. 8- Go up and go down passing the setting depth to confirm the tool is free
Packer (7’’, 9 5/8’’):
Setting Procedures 1- Reach to the setting depth put a mark above the holding slips Of the tubing and it will be a reference point. 2- Pick up 60 CM 3- Turn to the right between (one turn to three turns)depend on depth 4- Apply down weight between(10….15) Tons depend on size of Packer.
Unset Procedures 1- Take out the weight 2- Wait Five Minutes until the element is relax. 3- Start pull one Join and monitor the weight indicator If the J slot it is manual position you need to turn to the lift While pulling the one Join 4- Go down passing the setting depth to confirm the Packer is free.
Conclusion: Finally I hope that I have managed to cover the major work over & testing operations. And I hope to benefit for all. I ask my god to enjoy everyone with health and wellness till meet you in the next version.
