Chapter

WORKOVER OPERATIONS

Revision-0
March 2009
 ADCO
DRILLING MANUAL
Volume-2/Chapter-2: Workover Operations

Table of Contents
SECTION 1 WELL BARRIERS ACCEPTANCE CRITERIA ..................................... 4
1. Barriers Acceptance Criteria ........................................................................... 4

SECTION 2 WELL CONTROL IN WORKOVER OPERATIONS ............................ 19

1. Introduction.................................................................................................... 19
2. Checking Well Integrity and Installing Pressure Barriers ............................... 19
3. Un-plugging the Well and Checking Wellhead Pressure ............................... 19
4. Killing the Well ............................................................................................... 20
5. Testing Wellhead ........................................................................................... 27
6. Checking for Trapped Pressure and Bleed off Procedures ........................... 27
7. Nippling down X-Mas Tree & Nippling up BOP ............................................. 27

SECTION 3 RECOVERING OLD COMPLETION STRINGS .................................. 29

1. General.......................................................................................................... 29
2. Recovering Completion - General Procedure ................................................ 29
3. Releasing Hydraulic Packers......................................................................... 31
4. Recovering Dual Completion ......................................................................... 36
5. Abandoning Completion Tail and Packer(s) .................................................. 41
6. Recovering 7" scab liner ................................................................................ 41

SECTION 4 FISHING GENERAL GUIDANCE ....................................................... 43

1. Standard Fishing Assembly ........................................................................... 43
2. Overshot ........................................................................................................ 43
3. Releasing Spear ............................................................................................ 44
4. Taper Tap / Pin Tap....................................................................................... 44
5. Reverse Circulation Junk Basket ................................................................... 45
6. Fishing Magnet .............................................................................................. 45
7. Milling Tools................................................................................................... 45
8. Hydraulically Activated Mills .......................................................................... 46
9. Fixed Milling Tools ......................................................................................... 46
10. Special Mills................................................................................................... 47
S.G. ADM Volume-2 Page
Date Issued: 30/03/2009 Last Revision:
Rev-00/09 Drilling Operation -B 2-2
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DRILLING MANUAL
Volume-2/Chapter-2: Workover Operations

11. Fishing of Radio-Active Wireline Tools .......................................................... 47

SECTION 5 SIDETRACKING OPERATIONS ........................................................ 50

1. Sidetracking in Open hole ............................................................................. 50
2. Sidetracking Inside Casing ............................................................................ 55

SECTION 6 REMEDIAL CEMENTATIONS ............................................................ 67

1. Balanced Cement Plugs ................................................................................ 68
2. Squeeze Cementing ...................................................................................... 71
3. Cementing Through Coiled Tubing ................................................................ 73
4. Squeezing Off the Aquifers............................................................................ 74

SECTION 7 SETTING INTERNAL CASING PATCH.............................................. 75

1. Well Preparation ............................................................................................ 75
2. Procedure ...................................................................................................... 75

SECTION 8 SECURING WELL WITH SHALLOW SET CASING PACKER .......... 77

3. When to Secure the Well ............................................................................... 77
4. Minimum Barriers Requirements ................................................................... 77
5. Safety Precautions ........................................................................................ 77
6. Securing Well Procedure ............................................................................... 78

S.G. ADM Volume-2 Page

Date Issued: 30/03/2009 Last Revision:
Rev-00/09 Drilling Operation -B 2-3
Printed on: 19/08/2008
 ADCO
DRILLING MANUAL
Volume-2/Chapter-2: Workover Operations

SECTION 1

WELL BARRIERS ACCEPTANCE CRITERIA

Well barrier acceptance criteria are technical and operational requirements that need to be
fulfilled in order to qualify the well barrier for its intended use.

Refer to ADM Vol-1, Chapter-1, Section-12 (Pressure Barriers) for details on Well Barrier
Policy for Drilling / Workover operations.

1. Barriers Acceptance Criteria Sheets

Followings are the technical and operational requirements need to be fulfilled during
drilling / workover operations in order to qualify the well barrier for its intended use.

1.1 Fluid Column

Features Acceptance Criteria
Description This is the fluid in the well bore
Function The purpose of the completion fluid column as a barrier / barrier element is
to exert a hydrostatic pressure in the well bore that will prevent influx of
formation fluid.
Design, • The hydrostatic pressure shall at all times be equal to the estimated or
Construction measured pore/reservoir pressure, plus a defined safety margin (as
and Selection mentioned later in Sec-10, Clause-1).
• Critical fluid properties and specific actions shall be described prior to
start any operation.
• The density shall be stable within specified tolerances under down hole
conditions for a specified period of time when no circulation is performed.
• The hydrostatic pressure should not exceed the formation fracture
pressure in the open hole including a safety margin
• Changes in well bore pressure caused by tripping (surge and swab) and
circulation of fluid (ECD) should be estimated and included in the above
safety margins.
Initial Test Stable fluid level shall be verified. Critical fluid properties, including density
and shall be within specifications.
Verification
Use • It shall at all times be possible to maintain the fluid level in the well
through circulation or by filling
• Acceptable static and dynamic loss rates of fluid to the formation shall be
pre-defined (e.g. 20 bbls/hr for producers and 50 bbls/hr for injectors is
acceptable for tripping)
• There should be sufficient fluid materials, including contingency materials
available on the location to maintain the fluid barrier with the minimum
acceptable density.

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Volume-2/Chapter-2: Workover Operations

Features Acceptance Criteria

Monitoring • Fluid level in the well and active pits shall be monitored continuously.
• Fluid return rate from the well shall be monitored continuously.
• Flow checks should be performed upon indications of increased return
rate, increased volume in surface pits, increased gas content, flow on
connections or at specified regular intervals. The flow check should last
for 15 min. Exploration wells: All flow checks should last for 30 min.
• Measurement of fluid density (in/out) during circulation shall be
performed regularly.
• Measurement of critical fluid properties shall be performed every 1/2
circulating hour and compared with specified properties.
• Parameters required for killing of the well must be defined and recorded.

Impairment • Flow of formation fluids.

• Unable to monitor fluid level.
• Unable to maintain fluid level or required volume.
Table 1.1: Acceptance & verification criteria for Fluid column as a barrier

1.2 Casing
Features Acceptance Criteria
Description • This element consists of production casing/liner
Function The purpose of casing/liner is to provide a physical obstruction to
uncontrolled flow of formation fluid or injected fluid between the bore and the
back-side of the casing
Design, • Casing-/liner strings, including connections shall be designed to
construction withstand all pressures and loads that can be expected during the
and selection lifetime of the well including design factors.
• Minimum acceptable design factors shall be defined for each load type.
Estimated effects of temperature, corrosion and wear shall be included in
the design factors.
• Dimensioning load cases with regards to burst, collapse and tension /
compression shall be defined and documented.
• Casing design can be based on deterministic, probabilistic or other
acceptable models.
Initial test • Casing/liner shall be leak tested to maximum anticipated differential
and pressure.
verification • Casing/liner that has been drilled through after initial leak test shall be re-
tested during completion activities.
Use Casing/liner should be stored and handled to prevent damage to pipe body
and connections prior to installation.

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Features Acceptance Criteria

Monitoring • The A-annulus shall be continuously monitored for pressure anomalies.
B-annulus should be monitored if applicable based on well completion
and the type of well.
• If wear conditions exceed the assumptions from the casing-/liner design,
indirect or direct wear assessment should be applied (e.g. collection of
metal shavings by use of ditch magnets and wear logs).
Impairment • Leaking casing/liner.
• Unable to leak test.
• Unable to monitor annulus pressure.
• Unable to monitor or control/assess casing wear.
Table 1.2: Acceptance & verification criteria for casing as a barrier

1.3 DRILLING BOP

Features Acceptance Criterea
Description The element consists of drilling BOP with kill/choke line valves.
Function The function of the BOP is to provide capabilities to close in and seal the
well bore with or without tools/equipment through the BOP.
Design, • The drilling BOP shall be constructed in accordance with ADM – volume-
construction 1, Chapter -3.
and selection • The BOP WP shall exceed the maximum well design pressure including
a margin for killing operations.
• It shall be documented that the shear/seal ram can shear the drill pipe,
dual string tubing, wireline, coiled tubing or other specified tools, and seal
the well bore thereafter. If this can not be documented by the manufacturer,
a qualification test shall be performed and documented.
• When using tapered string there should be pipe rams or variable ram to
fit each pipe size.

Initial test & All BOP equipment Function and pressure tested frequently as per policy
verification and documented.
Use The drilling BOP elements shall be activated as described in the well
control action procedures.
Impairment • Failure of annular / Shear ram. (should be repaired immediately)
• Failure of Pipe ram (repair immediately if no back up for that pipe size
otherwise at earliest convenient time)
• Failure of kill/choke line valves. (If both valves in series failed then repair
immediately otherwise after setting casing)
Table 1.3: Acceptance & verification criteria for BOP equipment as a barrier

1.4 Wellhead
Features Acceptance criteria
The element consists of the wellhead body with annulus access ports and
Description
valves, seals and casing/tubing hangers with seal assemblies.

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Volume-2/Chapter-2: Workover Operations

Features Acceptance criteria

Its function is to provide mechanical support for the suspending casing and
Function tubing string and production tree and to prevent flow from the bore and annuli
to formation or the environment.

• The Working pressure for each section of the wellhead shall exceed the
Design, maximum anticipated well shut in pressure the section can become exposed
construction to plus a defined safety factor.
and selection • There shall be access ports to all annuli to facilitate monitoring of annuli
pressures and injection/bleed-off of fluids.
The wellhead body (or bodies and seals), annulus ports with valves
Initial test
and the casing or tubing seal assemblies shall be leak tested to
and
maximum expected shut in pressure for the specific hole section or
verification
operation.
A wear bushing should be installed in the wellhead whenever movement
Use
of tools/work-strings can inflict damage to seal areas.
• Annuli wing valves shall be pressure and function tested frequently.
• Pressures in accessible annuli shall be monitored and recorded
continuously.
Monitoring • Annulus valve(s) should normally be closed and should only be opened
for the purpose of adjusting the annulus pressure
• Movements in the wellhead during well testing (shut-in/start-up) should
be observed and compared to design values.
• Leaking seals or valves.
Impairment • Unable to leak test.
• Unable to monitor accessible annuli.
Table 1.4: Acceptance & verification criteria for Wellhead as a barrier

1.5 Deep Set Tubing Plug

Features Acceptance criteria
This element consists of a equalizing body with a locking or anchoring
Description device and a seal between the bore of the tubing and the body of the
plug.
Its purpose is to provide a temporary seal in the bore to prevent flow
Function
from the reservoir and U-tubing.
Design,
construction It shall comply with same requirements that apply to packers.
and selection
• It shall by preference be leak tested to the maximum expected differential
Initial test pressure in the direction of flow.
and • Alternatively, it shall be inflow tested or leak tested in the opposite
verification direction to the maximum expected differential pressure, providing that
ability to seal both directions can be documented.
It shall be set at a depth, which allows balancing of the pressure under
Use
the plug with a hydrostatic fluid column above the plug.

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Volume-2/Chapter-2: Workover Operations

Features Acceptance criteria

Monitoring The tubing pressure above the plug should be monitored regularly.
Impairment Inability to pass pressure testing or monitoring requirements.

Table 1.5: Acceptance & verification criteria for downhole plugs as a barrier

1.6 Surface Controlled Sub-Surface Safety Valve

Features Acceptance Criterea
Description This element consists of a tubular body with a close/open mechanism that
seals off the tubing bore.
Function Its purpose is to prevent flow of hydrocarbons or fluid up the tubing.
Design, • It shall be
construction - surface controlled,
and selection - hydraulically operated,
- fail-safe closed,
- flapper type.
• It should be placed a minimum of five joints below surface
Initial test It shall be tested with both low and high differential pressure in
and the direction of flow. The low pressure test shall be maximum 1000 psi
verification
Monitoring The valve shall be leak tested at specified regular intervals as follows:
• test duration shall be 30 min every six months
• Acceptance of downhole safety valve leakage tests shall meet API RP
14B requirements being:
- 900 scf/hr for gas,
- 6.3 gal/hr for liquid.
• If the leak rate exceed the accept criteria, the test can be attempted
three times to verify the valve status. If the acceptance criteria is still
not meet, further investigation and remedial action shall be
undertaken, consider involving the drilling/well operations department.
Impairment Failure to pass the regular tests and maximum allowable leak rate.

Table 1.6: Acceptance & verification criteria for SCSSSV as a barrier

1.7 Wireline lubricator

Features Acceptance criteria
This element consists of a body with a lubricator connection in both
Description
ends.

The function is to provide lubricate space for wireline BHA/tools over the
Function
closing device when run into and out of well.

Design, • The wire line Lubricator shall be constructed in accordance with API
Spec 16A and API RP 5C7
construction
• Pressure rating shall comply with the maximum expected wellhead
and selection
pressure.

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Volume-2/Chapter-2: Workover Operations

Features Acceptance criteria

Initial test • Function test after installation.
and • Low- and high pressure leak test after initial installation.
verification • Leak test to maximum expected WHP on following runs.
Length of lubricators shall at all time allow space for BHA above
Use
well closing device including items pulled from well.
Monitoring Visual periodic inspection.
Impairment Leak through body or connections.
Table 1.7: Acceptance & verification criteria for Wireline lubricator as a barrier

1.8 Wireline BOP

Features Acceptance criteria
This element consists of a BOP body with rams and riser/lubricator
Description
connections
• The function of the wire line BOP is to prevent flow from the wellbore in
case leakage in stuffing box / grease head or lubricator system above
Function the BOP.
• The element is a back-up element to the stuffing box / grease head in
the primary barrier.
• The wire line BOP shall be constructed in accordance with ADCO
standards
• The BOP shall exceed the maximum well design pressure including a
margin for killing operations.
Design,
construction
• The cable ram shall be able to provide a seal on the selected cable size.
and selection • For slick line operations in live wells a minimum of one cable ram shall
be installed.
• For braided line operations in live wells a minimum of two cable rams
shall be installed, with the lower ram capable of holding pressure from
above. A system for pumping grease between rams shall be included.
Initial test • Function test after installation.
and • Low- and high pressure leak test after initial installation.
verification • Leak test to maximum expected WHP on following runs.

Use • The wire line cable rams shall be activated as described in the well
control action procedures (contingency procedures).
• Periodic visual inspection for external leaks.
Monitoring • Periodic leak-and functional test, minimum each 14 days when in
operation.
• Leak in any of the elements, body or connections.
Impairment • Leak in hydraulic operating system.
• Unable to operate or malfunction.
Table 1.8: Acceptance & verification criteria for Wireline BOP as a barrier

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Date Issued: 30/03/2009 Last Revision:
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Volume-2/Chapter-2: Workover Operations

1.9 Xmas Tree

Features Acceptance Criteria
This element consists of a housing with bores that are fitted with swab,
Description
master valve, kill and flow wing valves.
Its function is to;
• Provide a flow conduit for hydrocarbons from the tubing into the surface
lines with the ability to stop the flow by closing the flow valve and/or the
master valve.
Function • Provide monitoring and pressure adjustment.
• Provide vertical tool access through the swab valve.
• Provide an access point where kill fluid can be pumped into the tubing.

1. The X-mas tree shall be equipped with;

• One master valve and one wing valve in the main flow direction of
the well.
• If the production tree has side outlets, these shall be equipped with
Design, automatic fail-safe valves.
construction • One manual swab valve for each bore at a level above any side
and selection outlets.
• Isolation valves on downhole control lines which penetrates the
production tree block.
2. All connections, block etc. that can be exposed to the hydrocarbons
shall be fire-resistant.
Initial test • The valves shall be tested with both low and high differential pressure in
and the direction of flow. The low-pressure test shall be 500 psi.
verification • It shall be tested as per API 6A at manufacturing site.

Use • Beware of equalization during opening and closing of valves.

The valves acting as barriers in the xmas tree shall be tested at regular
intervals as follows:
• Test duration shall be 15 mins.
• Monthly, until three consecutive qualified tests have been
performed, thereafter -
Monitoring • Every three months, until three consecutive qualified tests have
been performed, thereafter -
• Every six months.
If the leak rate can not be measured directly, indirect measurement by
pressure monitoring of an enclosed volume downstream of the valve shall
be performed.
Failure to pass the regular test.
Impairment
During rig move due to extra risk involved of hitting / dropping objects
Table 1.9: Acceptance & verification criteria for Xmas tree valves as a barrier

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Volume-2/Chapter-2: Workover Operations

1.10 Completion String Component

Features Acceptance criteria
These elements consist of a housing with a bore. The element may
Description have a side mounted feature or a valve providing communication
between tubing and annulus.
Its purpose may be to provide support to the functionality of the
Function completion, i.e. gas-lift or side pocket mandrels with valves or dummies,
nipple profiles, gauge carriers, Flow coupling etc.
1. The components (pipe and threads) shall be gas tight.
2. Minimum acceptable design factors shall be defined. Estimated
effects of temperature, corrosion, wear; fatigue and buckling shall
be included in the design factors.
3. The component should be designed/selected with respect to
• Tensile, compression and torsional load exposure.
Design, • OD clearance and fishing restrictions.
Construction • Tubing (and annular) flow rates, also including erosion effects.
and • Metallurgical composition in relation to exposure to formation or
selection injection fluid.
• Odd shaped assemblies in casting material shall be subject to finite
element analysis.
• Strength reduction due to temperatures effects.
4. For gas lift valves to qualify as a barrier there shall be a qualification
test demonstrating the valves ability to be gas tight over number of
cycles. The valve shall be subject to frequent testing with acceptable
results similar to testing of SCSSSVs
Initial test
and Pressure testing to Maximum Expected Temperature & Pressure.
verification
Running of intervention tools shall not accidentally shift a functionality of
Use
the tool.
Monitoring Pressure integrity is monitored by independence of the annulus pressure.
Impairment Inability to maintain a pressure seal.

Table 1.10: Acceptance & verification criteria Completion string components as a barrier

1.11 Completion String

Features Acceptance criteria
Description This element consists of tubular pipe.

The purpose of the completion string as barrier element is to provide a

Function
conduit for formation fluid from the reservoir to surface or vice versa.

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Features Acceptance criteria

1. All components in the completion string (pipe/housings and threads)
shall have gas tight connections, unless the well is used for water
injectors, disposal, source water production, or mud/cuttings/liquid
disposal.
2. Dimensioning load cases shall be defined and documented.
3. The weakest point(s) in the string shall be identified.
4. Minimum acceptable design factors shall be defined. Estimated effects
Design, of temperature, corrosion, wear; fatigue and buckling shall be included
construction in the design factors.
and selection 5. The tubing should be selected with respect to
• Tensile, compression and torsional load exposure.
• Tool joint clearance and fishing restrictions.
• Tubing and annular flow rates.
• Abrasive formations.
• Buckling resistance.
• Metallurgical composition in relation to exposure to formation or
injection fluid.

Initial test and

Pressure testing to Maximum Expected Temperature & Pressure (METP).
verification
Stab-in safety valve and one way check valve for all type of connections
Use
exposed at the drill floor shall be readily available.

Monitoring Pressure integrity is monitored by independence of the annulus pressure.

Impairment Leak to or from the annulus.

Table 1.11: Acceptance & verification criteria for completion string as a barrier

1.12 Mechanical Tubular Plugs

Features Acceptance criteria
This is a mechanical plug set anywhere inside steel conduits
Description
(casing/tubular).
The purpose of the element (plug) is to prevent flow of formation
Function
fluids and resist pressure from above or below, inside tubulars.
1. The plug shall be designed for the highest differential pressure and
highest downhole temperature expected. Installation and test loads
shall also be considered.
2. Down hole fluids and conditions (temperature, H2S, CO2, etc.)shall be
considered in estimating the life time of the plug.
3. The plug shall be designed such that pressure can be equalized
Design,
across the plug, if removed mechanically or by drilling out.
construction
4. The plug is not accepted as a barrier element alone in permanent
and selection
plugging of wells or branches of wells, where design integrity in an
eternal perspective is required.
5. To ensure the barrier integrity in using the plug, it shall only be
installed in a tubular section of the well, which is cemented, or supported
by sufficient wall thickness to withstand radial loads from the plug.

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Features Acceptance criteria

1. If possible the plug shall be inflow tested (from below), else it shall be
pressure tested from above.
Initial test and 2. Test pressure shall be minimum ~1000 psi above measured formation
verification strength below casing/ potential leak path, or minimum ~500 psi for
surface casing. Test pressure shall not exceed casing pressure test,
which ever is lower.
Inadvertent release of the plug by mechanical motion/ impact shall
Use
not be possible.
Pressure integrity shall be monitored through recording of the
Monitoring
pressure above the plug.
Impairmen Inability to maintain a pressure seal.

Table 1.12: Acceptance & verification criteria for Mechanical tubular plugs as a barrier

1.13 Tubing Hanger

Features Acceptance criteria
This element consists of body, seals and a bore which may have a tubing
Description
hanger plug profile.
Its function is to
• support the weight of the tubing,
• prevent flow from the bore and to the annulus,
• provide a seal in annulus space between itself and the wellhead,
Function
• provide a stab-in connection point for bore communication with the
production tree.
• provide a profile to receive a BPV or plug to be used for nippling
down the BOP and nippling up the production tree.
Design,
Construction Fire resistant seals should be used.
and Selection
• The primary seal shall be tested in the flow direction.
Initial Test • The hanger seal can be tested against the flow direction.
and • If only single seals are used in the tubing hanger, annulus is to be
Verification tested. In the case of double seal, an in-between seal test shall be
performed.
Use None.
Monitoring Continuous monitoring of annulus pressure.
Impairment Leak past seals.
Table 1.13: Acceptance & verification criteria for Tubing hanger seal as annulus barrier

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Volume-2/Chapter-2: Workover Operations

1.14 Tubing Hanger Plug

Features Acceptance criteria
This element consists of an equalising plug with a locking device and a
Description
seal between the bore of the tubing hanger and the body of the plug.

Its function is to provide a pressure barrier in the bore through the tubing
Function
hanger.

• Fire resistant seals should be used.

Design,
construction • It shall only be classified as a barrier element during BOP or x-tree
and selection disconnect, providing the plug (and prong) does not extend up above the
tubing hanger body.
Initial test
and The tubing hanger plug shall be tested in the flow direction.
verification
Monitoring Regular monitoring of pressure above plug or by visual observation.
Impairment Non-compliance with above mentioned requirements.
Table 1.14: Acceptance & verification criteria for Tubing hanger plug as a barrier

1.15 Production Packer

Features Acceptance criteria

This is element consists of a body with an anchoring mechanism to the

Description
casing/liner, and an annular sealing element which is to be activated.

Its purpose is to provide

• a seal between the completion string and the casing/liner, to
prevent
communication between the formation and the A-annulus above the
Function
production packer.
• prevent flow from the inside of the body element located above the
packer element to the A-annulus(tubing to production casing).

1. The packer shall be set (meaning that it shall not release by up or

downward forces), with ability to sustain all known loads.
2. The seal element shall withstand Maximum Expected Differential
Pressure, which should be based on the highest of;
• pressure testing of tubing hanger seals,
Design,
• reservoir-, formation fracture- or injection pressures less hydrostatic
construction pressure of fluid in annulus above the packer,
and selection • shut-in tubing pressure plus hydrostatic pressure of fluid in
• annulus above the packer less reservoir pressure,
• evacuated tubing with pressure in annulus.
3. It shall be qualification tested in accordance with recognized standards,
which shall be conducted in unsupported, non-cemented casing.

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Volume-2/Chapter-2: Workover Operations

Features Acceptance criteria

• It shall by preference be leak tested to the maximum expected differential

pressure in the direction of flow.
Initial test
& verification • Alternatively, it shall be inflow tested or leak tested in the opposite
direction to the maximum expected differential pressure, providing that
ability to seal both directions can be documented.

Running of intervention tools shall not impair its ability to seal nor
Use
inadvertedly cause it to be released.

Sealing performance shall be monitored through continuous recording of

Monitoring
the annulus pressure measured at wellhead level.

Impairment Inability to maintain a pressure seal.

Table 1.15: Acceptence & verfication criteria for Production packer as a barrier

1.16 Liner Top Packer

Features Acceptance criteria
This is a mechanical plug, consisting of a tubular body with an external
Description
seal element, set in the liner lap between casing and liner.
Its purpose is to provide a hydraulic seal in the annulus between the casing
Function and liner, to prevent flow of formation fluids, and resist
pressures from above or below.
1. The packer shall be designed for the highest differential pressure and
highest downhole temperature expected during installation,
acceptance testing and throughout its service life. Other down hole
conditions, such as formation fluids, H2S, CO2,etc. shall also be
Design, considered in estimating the lifetime of the packer.
construction 2. The risk of sealing failure due to variable downhole temperatures/cyclic
and selection loading shall be evaluated.
3. It shall be able to seal in oval, worn or scored casing.
4. It shall not need the support of cement in the liner annulus to seal.
5. It shall be designed to avoid prematurely setting and allow rotation
before set.
It shall be pressure tested from above and inflow tested, if practicably
Initial test possible. The pressure shall;
and (a) be minimum ~1000 psi above measured formation strength
verification below casing/ potential leak path,
(b) not exceed casing pressure test which ever is lower.
It is not accepted as a barrier element in permanently abandoned wells or
Use
well bores.
Monitoring None
Impairment Inability to maintain a pressure seal.
Table 1.16: Acceptence & verfication criteria for liner top packer

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Volume-2/Chapter-2: Workover Operations

1.17 Casing Cement

Features Acceptance criteria

This element consists of cement in solid state located in the annulus

Description
between the casing/liner and the formation.

The purpose of the element is to provide a continuous, permanent and

impermeable hydraulic seal along hole in the casing annulus or between
Function
casing strings, to prevent flow of formation fluids, resist pressures from
above or below, and support casing or liner strings structurally.
1. A design and installation specification (cementing program) shall be
issued for each primary casing cementing job.
2. The in-situ compressive strength of the cement shall be higher than
the estimated formation strength of the cemented formation.
3. Cement slurries that will be exposed to permeable and abnormally
pressured hydrocarbon bearing zones should be designed to prevent
gas migration, when the cement sets.
4. The cement placement technique applied should ensure a job that
meets requirements whilst at the same time imposing minimum
overbalance on weak formations. ECD and the risk of lost returns during
cementing shall be assessed and mitigated.
5. Cement height in casing annulus (TOC):
(a) General: TOC shall be minimum 350 ft above a casing shoe,
where the cement column in consecutive operations is pressure
Design, tested / the casing shoe is drilled out.
construction (b) Conductor: Cemented conductor is not defined as a barrier
and selection element.
(c) Surface Casing: TOC Shall be defined based on load conditions
from wellhead equipment and future operations. TOC should be
inside conductor or to surface.
(d) Casing through hydrocarbon bearing formations: TOC shall be
defined based on requirements for zonal isolation. Cement should
cover potential cross-flow interval between different reservoir
zones. For cemented casing strings which are not drilled out, the
height above a point of potential inflow/ leakage point / permeable
formation with hydrocarbons, shall be 650 ft, or to previous casing
shoe, whichever is less.
6. Temperature exposure, cyclic or development over time, shall not
lead to reduction in strength.
7. Requirements to achieve the along hole pressure integrity in slant
wells to be identified.
1. It shall be pressure tested if the casing shoe is drilled out. Note, in
cases where this may break down formation, the verification may be
Initial test and through exposing the cement column for differential pressure from fluid
column above cement in annulus. In the later case the pressure
verification integrity acceptance criteria and verification requirements shall be
defined.
2. The verification requirements for having obtained the minimum cement

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Features Acceptance criteria

height shall be described, which can be;
• verification by logs (cement bond, temperature, LWD sonic) or
• estimation on the basis of records from the cement operation
(volumes pumped, returns during cementing, etc.).
3. The strength development of the cement shall be verified through
observation of representative surface samples from the mixing.
Use None

• The annuli pressure above the cement barrier shall be monitored

regularly when access to this annulus exists.
Monitoring
• Surface casing by conductor annulus outlet to be visually observed
regularly.

• Non-compliance with any of the above mentioned requirements

Impairment Pressure build-up in annulus as a result of e.g. micro-annulus,
channeling in the cement column, etc.

Table 1.17: Acceptance & verification criteria for Casing cement as a barrier

1.18 Cement plug

Features Acceptance criteria

This element consists of cement in solid state that forms a plug in the
Description
wellbore

The purpose of the plug is to prevent flow of formation fluids inside a

Function wellbore between formation zones and/or to surface, resist pressures
from above or below.

1. The in-situ compressive strength of the cement plug shall be higher than
estimated formation strength at the depth where plug is installed.
2. Cement slurries that will be exposed to permeable and abnormally
pressured hydrocarbon bearing zones should be designed to prevent
gas migration, when the cement sets.
3. Permanent cement plugs should be designed for minimal strength
reduction and no shrinkage caused by thermal exposure and cyclic
Design, loading
construction 4. It shall be designed for the highest differential pressure and highest
and selection downhole temperature expected, inclusive installation and test loads.
5. A minimum cement batch volume shall be defined for the plug in
order that homogenous slurry can be made, to account for
contamination on surface, downhole and whilst spotting downhole.
6. The firm plug shall extend minimum 50ft MD above any source of
outflow/ leakage point. A plug in transition from open hole to casing
should extend at least 150ft MD below casing shoe.
7. If it is set inside casing and with a mechanical plug as a foundation,

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Features Acceptance criteria

the minimum length shall be 20 ft MD.
8. A casing/ liner with shoe installed in permeable formations should
have a 10 ft MD shoe track plug.
1. Cased hole plugs should be tested either in the direction of flow or
from above.
2. The strength development of the slurry should be verified through
observation of representative surface samples from the mixing.
3. The plug installation shall be verified through documentation of job
performance; records of cement operation (volumes pumped, returns
during cementing, etc.).
4. In case of Open hole Its position shall be verified, by means of,
Initial test and Tagging, or measure to confirm depth of firm plug.

verification 5. In case of Cased hole Its position shall be verified, by means of,
• Tagging, or measure to confirm depth of firm plug
• Pressure test, which shall be 1000 psi above estimated formation
strength below casing/ potential leak path, or ~500 psi for surface
casing plugs, and not exceed casing pressure test less casing wear
factor which ever is lower (but never lower than leak-off/fracture
pressure).
• If a mechanical plug is used as a foundation for the cement plug & this
is tagged & pressure tested, the cement plug does not have to be
verified.

Use Ageing test may be required to document long term integrity.

For temporary suspended wells: The fluid level/ pressure above the
Monitoring
shallowest set plug shall be monitored regularly when access to the bore exists.
Non-compliance with above mentioned requirements and the following:
Impairment a. Loss or gain in fluid column above plug.
b. Pressure build-up in a conduit, which should be protected by the plug.

Table 1.18: Acceptance & verification criteria for Casing cement as a barrier

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Volume-2/Chapter-2: Workover Operations

SECTION 2

WELL CONTROL IN WORKOVER OPERATIONS

1. Introduction
Well control procedures for workover operations are significantly different than those
used when drilling. Though basic pressure considerations are the same,
implementation methods vary greatly due to well conditions, which are often unique
to individual wells. These conditions include the type of completion, formation
pressures exposed to the wellbore, and the reasons for performing the workover.

Routine workover operations often require the implementation of various well control
procedures. An understanding of the principle of killing operations and the effect of
routine operations on well control is essential for the Drilling Supervisor.

Killing a producing well is often the first step in a workover operation. Prior to
performing this step; certain actions must be taken to ensure the kill is performed in
the safest and most efficient manner. In this section, the principles and the
procedures for killing different types of completion and wells are discussed.

2. Checking Well Integrity and Installing Pressure Barriers

Prior to start killing a well:-

• Review casing and cementing operations including any mechanical problem

encountered during drilling the well.
• Inspect surface casing, and review the possibility of N/U BOP’s and applying
pressure on well integrity.
• Conduct the required remedial operations such as wellhead scaffolding and
adding extra valves.

• Well head survey should be conducted prior to rig move to verify the condition of
wellhead
• Apply ADCO pressure barrier policy.

3. Un-plugging the Well and Checking Wellhead Pressure

Prior to unplugging the well, the rig must be fully operational and capable of handling
any well control situation that may occur as consequences to unplugging the well
• A minimum of 500 bbls of workover fluid should be available in the tanks prior to
unplugging the well.

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• Kill and choke lines must be connected to the wellhead and choke manifold and
tested to the X-Mas tree working pressure prior to unplugging the well. Flare lines
shall be also flushed and tested.

• Test lubricator to the wellhead working pressure.

• Retrieve plugs from tubing hanger.

• After retrieving all plugs or mechanical barrier from Tubing Hanger, Tubing Spool,
SC-SSSV and Tubing String, wait for pressure to stabilize (Bleeding off gas cap
is not allowed).

• Record pressures of tubing strings, tubing/ casing annulus, and casing/casing

annulus.

• Check X-Mas tree valves against well pressure

4. Killing the Well

4.1 General Guidelines
Many considerations must be given to selecting the proper method of killing a
normally pressured well. The generic well kill guidelines are summarized
below

• Install kill and choke lines and test against the wing valves to the wellhead
working pressure.

• Rig up and test the wireline lubricator to wellhead working pressure.

• Retrieve SC-SSSV and any other wireline plug set inside the string.

• Monitor and record wellhead pressure.

• Kill well using one or more of the following methods:

O Bullheading
O Coiled Tubing Killing
O Lubrication
O Punch the tubing and circulating.
O Reverse circulation
O Killing annulus
O Through tubing kill with hole in the tubing or leak in the packer
• Observe the other string or annulus for communication.

• Observe well for loss or gain.

• Observe well static prior to N/Down X-Mas tree.

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• Use LCM Pill to cure losses if needed.

• Install SC-SSSV if not installed.

• Install NRV(s), N/D X-Mas tree and plug control line port(s).

• Check tubing hanger thread

• N/U BOP, remove NRV after confirming no pressure below, install plug
and test BOP.

• Remove plug, make up landing joint w/ safety valve on top.

• Retrieve SC-SSSV.

• Retract lock down screws.

• POH with completion string.

Note:
O Tubing string must be secured with safety and circulating valve during
stinging out or releasing the hydraulic packer.
O Rig floor must be ready with contingency plan to handle strong U tube.

4.2 Equipment required for kill operations

• Wellhead fittings and x-overs required for killing operations.

• Kill line, choke line and choke manifold.

• Pumping Unit.

• Killing fluid.

• Flare lines.

• Coil tubing unit (if required).

• Wireline unite and tools (if required).

• Electric wireline unit (if required) with required tools i.e punching, cutting.
Selection of equipment required for well killing must be decided on case by
case basis.

4.3 Killing Methods

The kill method that is most suitable for a particular completion string and
formation pressure / fluid will primarily depend on whether the completion
string is in communication with the annulus or not.

The text that will follow discuss the most common kill methods, highlighting
the factors that must be taken into account while using each method.
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4.3.1 Bullheading

Bullheading is a term used to describe the pumping of the fluids into

the formation. In the case of well control, the objective is to pump a
workover fluid down the tubing and drive the formation fluids out of the
tubing, through perforations and back into the formation.

A pumping schedule shall be available to avoid fracturing the

formation while the killing fluid is descending downhole. The schedule
shale be designed to consider the initial shut in pressure and fracture
pressure so that the bottom hole pressure is always below the fracture
pressure.

It is important to note that pressures should decrease as the kill fluid is

pumped into the well since the hydrostatic pressure of the kill fluid is
greater than the formation fluid. If this occurrence is not observed to
the extent expected in the field operations, either the formation's ability
to accept the fluid is decreasing (plugging) or gas is migrating upward.
It should also be noted that as the low density formation fluids are
displaced by greater density killing fluids, the maximum allowable
surface pressure decrease.

Upward migration of low density fluids through higher density fluids

may be a serious problem in workover operations, particularly when
bullheading techniques are used. Factors affecting migration rates
include: Fluid densities and viscosities, hole geometry, and influx size.

In the cases of formations with characteristics that only allow low

pump-in rates, upward gas migration rates may equal or exceed the
pump rates and result in negating the advantages of bullheading. The
addition of viscosifiers to the workover fluid has been found to be a
practical field-proven method to reduce migration rates.

Formation fluids often affect the feasibility of bullheading procedures.

Low viscosity fluids such as gas will flow back through the formation at
rates sufficiently greater than oil or water. In addition, gas will have a
reduced tendency to plug the formation as it reverses flow.

4.3.2 Coiled Tubing Killing

Coiled Tubing is often used for killing a producing well. The objective
is to circulate killing fluid down the coiled tubing and up the coiled
tubing / production tubing annulus. A primary application for coiled
tubing is in cases where the well can not be killed by bullheading
because the wellbore is plugged.

Applications for coiled tubing may be restricted in deep wells due to

strength limitations of the tubing. In some cases, in gas wells, field
experience has shown that a coiled tubing section filled with killing
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fluid will exceed the tensile strength of the pipe. This is not usually the
case in oil wells because the buoyancy provided by the oil reduces the
overall tubing load.

The following are general guidance procedures when killing a well

using coiled tubing:-

• De-pressurize X-tree.

• R/U and pressure test C/T BOP and injector head.

• RIH with the following basic tool string configuration

O Circulating nozzle
O Two check or flapper valves
O Straight bar
O Release joint
O Tubing connector.
• Test weight indicator before running coiled tubing into the well.

• Standard running speed should be 50 ft/min, this speeds must be

reduced when running through the riser, X-Mas tree, SC-SSSV
and any other downhole restrictions.

• Run coiled tubing below perforations depth.

• Displace completion string with kill fluid. Keep pumping until clean
fluid returns.

• Observe pressure and record losses.

• Report results to town.

• Pull out of the hole while circulating kill fluid until the tubing end
connector tags the stripper, don’t exceed 4000 lb overpull.

• Close the well master and swab valves.

• Bleed off pressure in the coiled tubing and surface lines through
the closed line drain in case of any hydrocarbon discharge.

• Rig down the coiled tubing and associated equipments.

Notes:

O DS and RM must be alert during killing operations while coiled

tubing downhole.
O Contingency plan to handle any well control incident must be in
place.
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O Returns must be routed through choke manifold.

O Flaring oil or gas is not allowed without management approval.
O Gas detectors, breathing apparatus must be ready in place prior to
commenceing killing operations.
O Check SC-SSSV ID compared to C/T OD prior to rigging up C/T.
For more details about coiled tubing operations refer to Coiled Tubing
Manual (the manual is electronically available at ADCO Drilling
Website.

4.3.3 Lubrication

Lubrication is occasionally used for killing wells during workover

operations. It is a process that alternately pumps a kill fluid into the
tubing or annulus, and then a volume of gas is allowed to escape from
the well until the kill fluid begins to escape through the choke. At this
point, brine water or other fluids are pumped into the tubing or
annulus, and the cycle is restarted. As each volume of brine is
pumped into the tubing, the Shut-In Tubing Pressure should decrease
by a calculated value until the well is eventually killed. Caution must
be exercised to insure that large volumes of kill fluids are not allowed
to escape from the well during the bleeding phase.

The lubrication and bleed method is often employed to kill high

pressure wells where kill pressures would approach the rated
pressure of the wellhead or tubing and in wells that have a plugged
wellbore or perforations and will not allow bullheading. Lubrication
procedures can be employed to kill the well without necessitating the
use of coil tubing. It should be apparent, however, that lubrication is a
time consuming process.

A certain amount of time is required for the gas to migrate upward

through the falling kill fluid after the pumping ceases. Gas migrates
upward at 17-35 ft/min; therefore after pumping, it is important to wait
several minutes before bleeding gas from the well to prevent bleeding
the kill fluid through the choke.

Refer to Chapter-3 in Volume-1 for more details.

4.3.4 Perforating the Tubing / Stinging out and Circulating

Perforating the tubing and circulating a kill fluid is another primary

method of killing producing wells. The method will allow direct
circulation or reverse circulation of brine water. This method requires
that the packer fluid in the annulus be in circulable condition and not
severely gelled.

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Careful attention must be given to the selection of a perforation tool. It

is important that the tool be capable of perforating the tubing without
damaging the adjacent casing, should the tubing be in close proximity
to the casing. In addition, oriented perforating becomes a serious
consideration in cases of dual completion to avoid perforating the
other string.

Tubing punch is normally carried out above the most top packer, in
the middle of a tubing joint , far from wireline nipples, blast joint, travel
joint…etc

In case of pulling the tubing out of the packer, circulating a kill fluid out
of the bottom of the tubing is a kill option involves lifting the tubing a
sufficient height to pull the seal assembly from the packer. The
disadvantage of this method is that the X-Mas tree must be removed,
and BOP’s installed in order to pick up the tubing.

Some types of completions such as Tandem Dual Completions are

not suitable for this method of well killing.

4.3.5 Reverse Circulation

Reverse circulation involves pumping kill fluids down the annulus and
displacing the formation fluids up the tubing. This procedure requires
that a choke is placed in the standpipe or that the surface equipment
can be arranged in such a manner that conducts the formation fluids
through the standpipe to the choke. The reverse circulation method
utilizes the pumping casing pressure to monitor the kill operation. The
standpipe choke is used to adjust the pumping casing pressure to the
required values.

Reverse circulation offers several advantages and disadvantages

relative to normal circulation. The advantages include

(1) A significant reduction in the time required to circulate the

formation fluid from the well.

The disadvantages of the reverse circulation procedure include

(1) Possible plugging when attempting to reverse flow if circulating

ports are in the work string

(2) The slow circulating rates used in the reverse procedure may
allow gas to migrate up the annulus at a rate greater than the
downward flow rate.

(3) It is not suitable method for high pressures

Reverse circulation kills are not as often used as normal circulation.

However, During Workover operations the well is usually fully cased
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and the pressure of the exposed reservoir is known. The workover

fluid is, therefore, probably already of sufficient density to control the
formation. In these cases, the kick will usually be the result of an
effective underbalance created by swabbing. Thus, the workover fluid
need not to be weighted up as long as the tubing is sufficiently close
to bottom. The kill method used is then equivalent to the Drillers
Method; with the exception that only one circulation is required since
the "weight up" is unnecessary.

4.3.6 Killing Annulus

A separate annular kill is sometimes required because of a loss of

integrity in the tubing string resulting from a hole or leak. In these
cases, killing the tubing by lubricating or snubbing will not necessarily
kill the annulus. It is therefore necessary to perform kill techniques on
the annulus using one of the previously described methods. These
include bullheading, circulating or reverse circulating. Gas Migration
can be a serious consideration when pumping down the annulus.

In all methods of well killing, it is important to maintain a constant

pump speed along with the required casing or tubing pressure. If the
pump speed is allowed to change or the proper surface pressure not
used, bottomhole pressure will be either too high or too low and either
loss of circulation or additional influx will occur. If the kill rate must be
changed, a new tubing pressure schedule which accounts for a
change in the circulating pressure losses must be followed.

4.3.7 Through Tubing Kill with Hole in the Tubing or Leaking

A through tubing kill with a hole in the tubing or a packer leak requires
additional considerations. The primary concern is determining the
location of the hole or leak. Additional concerns include (1) the effect
of the annulus pressure exposed on the casing and (2) the kill
procedure that will be most effective in each case.

Determining the location of the tubing hole generally requires an on-

site evaluation of the situation. The hole or leak will be indicated by
pressure on the casing string(s). The most common method of
locating the leak is by pumping a volume of colored brine water until it
is returned to the choke on the annulus. This volume can be used to
calculate the location of the hole.

Deep holes will generally allow the well to be killed in a conventional

circulation manner. Shallow to medium depth holes will require
snubbing coil tubing or jointed pipe or lubrication. Bullheading can be
attempted only if the dynamic pressures do not exceed the casing
burst pressures.

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5. Testing Wellhead

• Test between primary and secondary seals through T.H.S testing port to either
60% of the collapse pressure of the casing string exposed or to 1500 psi
whatever is less.

• Always observe other side’s ports during testing.

• Check injectivity down annulus if requested in the drilling program, do not exceed
500 psi, maximum injection pressure is to be decided on case-by-case basis.
Town approval is required.

• Remedial cementation at this stage must be considered.

6. Checking for Trapped Pressure and Bleed off Procedures

After kill operation and when checking the trapped pressure, the following good
practices should be followed:

• Bleed off pressure from the casing side only. The reasons are (1) the primary
choke is generally located on the casing side, (2) to avoid contamination of the
mud (or brine water) in the tubing.

• Use the tubing pressure as a guide since it is a direct bottomhole pressure

indicator.
• Bleed small amounts (1/4 to 1/2 barrels) of mud at a time. Close the choke after
bleeding and observe the pressure on the tubing or annulus.
• Continue to alternate the bleeding and subsequent pressure observation
procedures as long as the shut-in tubing pressure is continuously decreasing.
When the pressure ceases to fall, stop bleeding and record the true SITP and
SICP.

• If the SITP decrease to zero during this procedure, continue to bleed and check
pressures on the casing side as long as the casing pressure decreases.
• These bleeding procedures can be implemented at any time. However, it is
advisable to check for trapped pressure when the tubing string is displaced with a
clean kill fluid if any pressure remains on the work string.

7. Nippling down X-Mas Tree & Nippling up BOP

• Refer to in section 1 of this chapter for pressure barriers requirements when

removing X-Mas tree.

• Observe well static (1 hour for oil wells and 2 hours for gas wells)

• Install downhole plug (if applicable).

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• Close SC-SSSV (if applicable).

• Install NRV(s) (use DRN in gas wells), Nipple down X-Mas tree and plug control
line port(s).

• Install BOP with adequate pipe rams (same criteria applied to drilling); remove
NRV after confirming no pressure below NRV. Refer to volume-1, chapter-3 “Well
Control” and Chapter-1 “Policies” for BOP requirements.

• Install plugs (2 way check valve) in tubing hanger and test blind/shear rams.

• Remove plugs, make up landing joint with safety joint on tubing hanger and test
Annular Preventer and remaining BOP components as per procedures in ADM,
volume – 1, Chapter-3 “Well Control”.
Note:
Before N/U the BOP, the DS must ensure that the BOP is cleaned from any
cuttings or debris that may drop and accumulate on top of the NRV during the
BOP pressure test. Check tubing hanger threads are clean.

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SECTION 3

RECOVERING OLD COMPLETION STRINGS

1. General
The following must be taken into account when planning for recovering old
completion:

• Review downhole well status including tubing dimensions, strength and

capacities of each item in the string.

• Identify the point of the weakest tensile strength in the string.

• Know fluid density and type in the annulus and inside tubing.

• Inspect tubing hanger after removing X-Mas tree and prior to installing BOP’s
o Tubing Hanger thread type and conditions.
o Pack off design and retrieving mechanism
o Lock down screws condition
o Control line fittings
• Consider special surface arrangement for handling U-tube.

• Retrieve SC-SSSV prior to pulling the tubing hanger to surface.

• All subs and x/overs (with safety valves) required to shut in the well must be
ready on rig floor for any emergency.
• Calculate overpull required to release the tubing from the packer or to shear the
pin for releasing the hydraulic packer.

• Contingency planning must be in place should well control incident occurred

• Be aware of the design and mechanism of the downhole completion equipment

such as packers, SC-SSSV, Travel Joints,…..etc.
• The landing joint that required for pulling on the completion string must be
inspected in particular the minimum ID required to allow free passage of wireline
tools.

2. Recovering Completion - General Procedure

The follows are general guidelines for recovering old completion:-

• Check for trapped pressure below NRV. Do that by filling little water on top of the
NRV, observing water passing the NRV down the string. Push the NRV spring by

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NRV retrieving tool and watch pressure. If pressure exists, bullhead string with
clean kill fluid.
During killing operation, trapped pressure below NRV can be due to over
charging the formation. This pressure can be released without having extra influx
from formation. To bleed-off trapped pressure, follow up the procedures
mentioned in the previous section.

Pressure that might be exist below the SC-SSSV could pass across, especially
at low pressures

• When well is safe. i.e. wellhead pressure is zero and static losses is less than 20
Bbls/hr, proceed to recover the completion

• Retrieve SC-SSSV, observe well

• Make up landing joint (with safety valve) to the tubing hanger. Connect surface
lines and valves that allow flexible change between normal circulation and
reverse circulation.
Note:
landing joint must be checked with the proper gauge cutter and cleaned from
scale.

• Retract Tubing Hanger lock down screws.

• Calculate maximum allowable pull on completion string(s) that is required to do

the following:
o Retrieve tubing hanger
o Open travel joint
o Release hydraulic packer or snap out the tubing
• Pull on the string in gradual increase, retrieve tubing hanger from tubing head
spool, open travel joint and work string, as applicable, to sting out seal units /
snap latch or to release the hydraulic packer.

• Maximum allowable pull on tubing is:

o For new tubing 85% of the tensile strength of the weakest component
o For old tubing 75% of the tensile strength of the weakest component
• Once packer is unset (wait 30 min. to allow packer element to deflate), or tubing
string is snapped out of the packer, start circulating slowly. Circulate one cycle
using workover fluid.

• If unable to recover the completion by direct pull, consider other options such as
cutting / milling and fishing operations

• Ensure no flow and the static loss is less than 20 BPH. Use HVP or LCM if
needed.
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• POH lay down old completion, install pin and box thread protectors

• Reserve samples of corroded or scaled sections of tubing marked with depth for
inspection.
Note:
o Pull slowly inside 7” liner to avoid swabbing action.
o Observe hole on top of liner, when string is half way out of the hole and at
1000 ft
o Consider using variable ram to suit different completion sizes.
o Have “Kick Joint” ready on V. door to shut in tubing string at any stage while
pulling out of the hole.

3. Releasing Hydraulic Packers

The following are general guidelines for releasing dual hydraulic packer:-

• R/Up tubular equipment for pulling completion string in tandem

• Define packer setting / releasing side, L.S or S.S. (Assume L.S for this example)

• Calculate the minimum pull required to shear releasing pin.

• Calculate the maximum allowable pull on the weakest point in L.S.

• Make up landing joint (with safety valve) on both strings.

• Install circulating valve on both sides.

• Retract lock down screws.

• Pull S.S, Retrieve TH segment from THS, watch opening travel joint. Apply
10,000 lb over string weight, and set SS on slips.
• Cut S.S above dual packer, circulate and POOH with S.S (ADCO procedure is
not to pull completion in tandem)
• Pull LS, retrieve TH segment from THS, observe opening travel joint.

• Record string weight below and above travel joint.

• Pull on L.S to release dual hydraulic packer, Appling gradual increments of 5000
lb. Refer to the tables in the next page for information about the packers currently
used in ADCO operations

• Work string up and down repeatedly to help shearing the releasing pins

• Fluid density inside tubing and below packer must be equal or less than that in
the annulus.

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Rev-00/09 Drilling Operation -B 2-31
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• If unable to release the packer, proceed to cut and fish completion strings as
described in step 4.1 of this section.

S.G. ADM Volume-2 Page

Date Issued: 30/03/2009 Last Revision:
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Volume-2/Chapter-2: Workover Operations

Table 2-5: Hydraulic Packers Specifications

Baker Packers
Pressure Tension
Packer Packer Casing Casing
Packer Setting Setting Shear
Type OD Bore ID Size in Weight Service
Model Method Min. Release
in in Lb /ft
psi lb
4 ½" Packers
Retrievable 3.771 -- 4.5 9.5-13.5 Hydrostatic 2000 30000 Sour
FH
Retrievable 4.5 9.5-13.5 Hydrostatic --- 30000 Sour
4 ½ ", 5"
& 6.5/8" 5" Packers
Single FH Retrievable 4.125 1.978 5 15-18 Hydrostatic 1500 30000 H2S
Hydraulic
6.5/8" Packers
Packers
FH Retrievable 5.603 2.374 6 5/8 24-28 Hydrostatic 1530 40000 Sour
Retrievable -- -- 7 26-29 Hydrostatic Sour
Retrievable -- -- 7 26-29 Hydrostatic -- -- --
FH
Retrievable 5.968 2.370 7 Hydrostatic 1440 40000 Sour
7" Single
Hydraulic Retrievable -- -- 7 20-26 Hydrostatic 1520 40000 Sour
Packers Retrievable 6.080 2.377 7 23-26 Hydraulic 1800 40000 H2S
HS Retrievable 5.910 2.373 7 26-29 Hydraulic 2500 40000 H2S
Retrievable 5.910 2.356 7 23-32 Hydraulic 1800 40000 H2S
Retrievable 7 26-29
7" Single FHL
Retrievable 5.983 2.992 7 Hydrostatic 1530 40000 Sour
Hydraulic
Packers HS Retrievable 5.910 2.919 7 23-29 Hydraulic 2500 40000 H2S
Retrievable 8.218 -- 9 5/8 47-53.5 Hydrostatic 1500 40000 Sour
FH Retrievable 8.218 --- 9 5/8 Hydrostatic 1500 40000 Sour
9 ⅝” Retrievable 9 5/8 40-47 Hydrostatic 1500 40000 Sour
Hydraulic Retrievable 8.310 2.919 9 5/8 40-53.5 Hydraulic 1800 40000 H2S
Packers
HS Retrievable 9 5/8 40-53.5
Retrievable 8.310 2.919 9 5/8 40-53.5 Hydraulic 2500 40000 H2S
Retrievable 7 26-32

7" Dual GT Retrievable 5.937 7 26-32 Hydraulic 2100 30000 H2S

Hydraulic Retrievable 5.937 7 26-32 Hydraulic 2100 30000 H2S
Retrievable 7 23-32 Hydraulic
Packers A-5
Retrievable 5.942 1.937 7 Hydraulic 1750 30000 H2S
AL-5 Retrievable 7 Hydraulic
Retrievable 9 5/8 40-47
GT
9 ⅝” Dual Retrievable 8.500 9 5/8 Hydraulic 2150 40000 H2S
Hydraulic Retrievable 9 5/8 40-47
Packer A-5
Retrievable 8.510 2.968 9 5/8 40-47 Hydraulic 1500 40000 H2S
ESP Retrievable 9 5/8 40-43.5 Hydraulic 50000
Twin
Seal

S.G. ADM Volume-2 Page

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Pressure Tension
Packer Packer Casing Casing
Packer Setting Setting Shear
Type OD Bore ID Size in Weight Service
Model Method Min. Release
in in Lb /ft
psi lb
4 ½" Packers
Retrievable 3.771 -- 4.5 9.5-13.5 Hydrostatic 2000 30000 Sour
4 ½", 5" FH
Retrievable 4.5 9.5-13.5 Hydrostatic --- 30000 Sour
& 6.5/8"
Single 5" Packers
Hydraulic FH Retrievable 4.125 1.978 5 15-18 Hydrostatic 1500 30000 H2S
Packers
6.5/8" Packers
FH Retrievable 5.603 2.374 6 5/8 24-28 Hydrostatic 1530 40000 Sour
Retrievable -- -- 7 26-29 Hydrostatic Sour
7" Single Retrievable -- -- 7 26-29 Hydrostatic -- -- --
Hydraulic FH
Packers Retrievable 5.968 2.370 7 Hydrostatic 1440 40000 Sour
Retrievable -- -- 7 20-26 Hydrostatic 1520 40000 Sour
4 ½" Packers
PHL Retrievable 3.76 1.917 4.500 9.5-13.5 Hydraulic 3500 32000 H2S
4 ½", 5" & 5” Packers
6.5/8" Retrievable 5.00 15-18 Hydraulic 2000 24000 H2S
4.83 1.925
Single RH
Hydraulic Retrievable 4.83 1.925 5.00 15-18 Hydraulic 2000 24000 H2S
Packers 6.5/8” Packers
RH Retrievable 5.520 2.360 6.5/8 24-32 Hydraulic 2000 43000 H2S
PHL Retrievable 5.610 2.360 6.5/8 24-28 Hydraulic 3500 41000
Retrievable -- --- 7.00 23-32 Hydraulic -- -- --
7" Single Retrievable 5.880 2.360 7.00 23-32 Hydraulic 2000 -- H2S
Hydraulic RH Retrievable -- -- 7.00 26-32 Hydraulic --- --- ---
Packers Retrievable 7.00 Hydraulic 2000 40000 H2S /
5.880 2.360 26-32
CO2

Halliburton

Pressure Tension
Packer Packer Casing Casing
Packer Setting Setting Shear
Type OD Bore ID Size in Weight Service
Model Method Min. Release
in in Lb /ft
psi lb
Retrievable 6 7.00 23-29 Hydraulic 2000 32000 H2S
7" Single
Retrievable 7.00 23-29 Hydraulic 3000 40950 H2S
Hydraulic PHL 5.980 2.360
Packers
Retrievable 5.980 2.885 7.00 23-29 Hydraulic 3000 40950 H2S
9 ⅝” Single Retrievable 8.31 9 5/8 40-47 Hydraulic 2000 40000 H2S
Hydraulic RH
Retrievable 8.31 9 5/8 40-47 Hydraulic 2000 40000 H2S
Packers
PHL Retrievable 8.45 9 5/8 40-47 Hydraulic 3500 41300 H2S
7" Dual RDH Retrievable 7 26-32 Hydraulic

S.G. ADM Volume-2 Page

Date Issued: 30/03/2009 Last Revision:
Rev-00/09 Drilling Operation -B 2-34
Printed on: 19/08/2008
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Pressure Tension
Packer Packer Casing Casing
Packer Setting Setting Shear
Type OD Bore ID Size in Weight Service
Model Method Min. Release
in in Lb /ft
psi lb
Hydraulic Retrievable 5.940 7 26-32 Hydraulic 2000 30000 Sour
Retrievable 7 26-29 Hydraulic
Packers BHD
Retrievable 6.015 7 26-29 Hydraulic 4000 30000 H2S
43.5-53.5
RDH
Retrievable 8.340 9 5/8 43.5-53.5 Hydraulic 2000 40000 Sour
9 ⅝” Dual
Hydraulic Retrievable 9 5/8 43.5-53.5 Hydraulic
RDH
Packers Retrievable 8.340 9 5/8 43.5-53.5 Hydraulic 2000 40000 H2S
43.5-47
BHD
Retrievable 8.475 9 5/8 43.5-47 Hydraulic 3000 40000 H2S

Weatherford

Packer Packer Casing Casing Setting Pressure Tension Service

Packer OD Bore ID Size In Weight Method Setting Shear
Type
Model in in Lb /ft Min. Release
psi lb
7" Dual
Hydraulic
Hydraulic Hydro-II Retrievable 5.938 7 23-32 2000 30000 H2S
Packers

Arrow

Packer Packer Casing Casing Setting Pressure Tension Service

Packer OD Bore ID Size In Weight Method Setting Shear
Type
Model in in Lb /ft Min. Release
psi lb
9 ⅝” Dual Hydro-II Retrievable H2S /
8.50 9 5/8 47 - 53.5 Hydraulic 2000 30000
Hydraulic CO2
Packers Hydro-II Retrievable 8.5 9 5/8 47 - 53.5 Hydraulic 2500 40000 H2S
Hydro-II Retrievable 8.5 9 5/8 40 - 47 2500 40000 H2S

NODECO

Packer Packer Casing Casing Setting Pressure Tension Service

Packer OD Bore ID Size In Weight Method Setting Shear
Type
Model in in Lb /ft Min. Release
psi lb
9 ⅝”
Dual
RR (ESP) Retrievable 9 5/8 40-47 Hydraulic 1500 50000 H2S
Hydraulic
Packers

S.G. ADM Volume-2 Page

Date Issued: 30/03/2009 Last Revision:
Rev-00/09 Drilling Operation -B 2-35
Printed on: 19/08/2008
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Volume-2/Chapter-2: Workover Operations

4. Recovering Dual Completion

4.1 Recovering dual completion with Stuck Dual Retrievable
Packer
The following procedures describes steps to recover dual completion and
assume that after recovery of S.S, the dual packer can not be released by
pulling on L.S, If unable to release dual hydraulic packer by direct pull,
proceed as follows:-
Step-1: - Cutting short string above dual hydraulic packer
• Make up landing joint (with safety valve) on short string tubing hanger.

• Apply 10,000 Ibs tension on SS and land on slips.

• Rig up electric wireline BOP on S.S side and test to 3000 psi.

• RIH with chemical cutter, cut S.S at +/-5 ft above dual hydraulic packer.
POH and rig down electric wire line, circulate hole.

Cut L.S 15 ft
above dual
Cut S.S 5 ft packer
above dual
packer
Dual Packer

Short String

Long String

Cut L.S at
middle
joint above
blast joints
Blast Joints

Single Packer

Figure 2-2: Step-1 Cut Short string Figure 2-3: Step-2 Cut Long Figure 2-4: Step -3 Cut Long
String below Dual Packer String above Dual Packer

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ADCO
ADM Volume-2
Rev-00/09 Drilling Operation -B
Date Issued: 30/03/2009 Last Revision:
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DRILLING MANUAL
Volume-2/Chapter-2: Workover Operations

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• POH and lay down S.S.

• Make up landing joint (with safety valve) on LS tubing hanger. Pull up to

75% of the tension strength of the weakest component and attempt to
release dual hydraulic packer and sting out of permanent packer.

• If packer releases, circulate hole. Observe well, and POH, laying down
completion strings.
• If 75% of the yield strength of the weakest components of LS was not
enough to release the packers, proceed to Step–2 to cut L.S below dual
packer as follows:-
Step – 2: - Cutting long string below dual hydraulic packer
• R/U wireline on L.S. and run with chemical cutter, cut L.S between single
and dual packer at the middle of the joint above all blast joints.
• Try again to unset the dual hydraulic packer if not succeeded; proceed to
step-3 to cut L.S above the dual packer as follows:
Step – 3: - Cutting long string above dual hydraulic packer
• RIH with chemical cutter and cut LS at +/-15 ft above dual hydraulic
packer), POH and R/Down electric wire line, circulate hole.

• POH and lay down L.S.

• Change top pipe ram (if needed), test BOP’s and install wear bushing

• RIH with overshot on drill pipe. (See section-4 of this chapter for BHA
configuration).
• Latch onto L.S side, Try again to unset the dual hydraulic packer. If not
succeeded; proceed to step-4 to mill and fish the dual packer as follow:
Step – 4: - Milling and fishing dual Hydraulic packer
• RIH with washover assembly, washover dual packer until it became free.

• RIH with overshot and fishing assembly engage and catch LS. POH and
lay down dual packer.
Step – 5: - Stinging the seal units out of the permanent single packer
• If seal units still stuck inside the permanent single packer, RIH with
overshot to top of LS, engage and workout to pull the seal units out of the
permanent packer. POH and lay down fish. If unable to pull the seal unit,
proceed as per step-6.
Note:-
In case if single hydraulic packer is retrievable, try to release the packer by
direct pull using overshot otherwise wash over the Packer till it become free.
Run with overshot, engage fish and POH.
S.G. ADM Volume-2 Page
Date Issued: 30/03/2009 Last Revision:
Rev-00/09 Drilling Operation -B 2-37
Printed on: 19/08/2008
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Volume-2/Chapter-2: Workover Operations

For fishing assemblies and tools refer to section-4 of this chapter.

Step–6:- Washing over permanent single packer and recovering seal
units
If unable to sting out from the permanent packer, proceed as follows:
• Run wash over shoe with enough extension, wash over the permanent
packer until it becomes free. If stick up above permanent packer is long
(long section of blast joints), consider cutting below blast joint, noting that
washing over long section of tubing across deviated section is not
operationally easy

• Run overshot with proper size of basket garble, engage top of tubing.
POH and L/Down fish.
• If seal units were recovered earlier by direct pull, proceed as per step -7 to
mill and recover the permanent packer

Step–7:- Milling and recovering permanent packer

For milling and retrieving permanent packers use HE packer milling and
retrieving tool. The tool consists of the following components:

• Packer Retrieving Spear

Designed for removal of drillable full bore packers from the well. During
the milling operation it will remain in the catching position at all times to
engage the lower end of the packer. It consist of three parts, top coupling,
mandrel slip and bull plug or mill head at the bottom.
The Packer Retrieving Spear dressed with the proper size slip (grapple)
for the bore of the packer is made up on sufficient extensions to allow the
spear to be below the packer or extension(if any) during milling operation.
The spear can be run in hole with slip in catch or release position.
As the spear enters the bore of the packer, the slip is forced to move up
on the mandrel in an area where the OD is reduced enough to allow
passage through the packer. As the slip clears, it automatically drops to
catch position.
The Packer Retrieving Spear can be released by applying slight overpull
and right hand rotation. Also, it can be engaged into the packer by merely
lowering through the packer.

• Extension
Sufficient extensions to be made to have the Packer Retrieving Spear
below the bottom of the packer or seal bore extension (if any) during
milling operation.
Extensions is equipped with special locked joint connections which
prevent any possibility of whip-off during the milling operation.

S.G. ADM Volume-2 Page

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• Milling Head
The packer milling head has an API connection up and an extension
connection down.

Recover permanent packer with short seal bore extension (<10 ft)
If the permanent packer is connected with short seal bore extension (less
than 10 ft), the following procedures are to be followed:-
• Make up The Packer Retrieving Spear with slips suitable for the packer
bore (which is to be milled), Extension and mill head, lock the connections
of the extension to avoid back-off during milling operation.

• Lower the entire milling assembly to the top of the packer. Circulate and
check weight of string up and down with and without circulation. Stop the
pump.

• Lower the milling assembly until the Packer Retrieving Spear passes
through the bore of the packer.
• Check that the Packer Retrieving Spear has engaged the packer by
applying 10,000 lbs over pull.
• Start milling the upper slips and packing element of the packer.

• Push the packer down (~ 50') pump Hi-Vis-Pill and circulate bottom up.

• POH the milling tool and remainder of packer.

S.G. ADM Volume-2 Page

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Rev-00/09 Drilling Operation -B 2-39
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Assuming that: Dual Yes

• Well is killed and fluids equalized. packer
• Unable to release S.S from dual Released?
Pkr.

No (*See Note.1)

Washover dual packer,

Cut S.S. above dual packer, run overshot assy,
circulate and POH with S.S. latch onto L.S, POH
with dual packer.

Pull 75% of the yield strength of the

weakest component of the LS Run overshot assy, latch
onto seal assy above
permanent packer.

Dual Packer Yes

Released?

Seal assy Yes POH and

Released? L/D seal
assy.
No

Cut L.S. below dual packer and pull

on dual packer. No

Washover permanent
packer using packer
Circulate
milling & retrieving tool,
and POH
Dual Packer Yes and POH fish.
with L.S.
Released? OR
and dual
Washover with milling
packer
tool, run overshot, POH
with fish
No

*Note.1:
Cut L.S. above dual packer,
Consider to terminate the Fishing
circulate and POH with L.S.
operations in special cases as mentioned
in Clause-5.

Run overshot assy, latch onto L.S. to

unset dual packer.

Figure 2-5: Recovering Dual Completion Flowchart

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S.G. Page
ADCO
ADM Volume-2
Rev-00/09 Drilling Operation -B
Date Issued: 30/03/2009 Last Revision:
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Volume-2/Chapter-2: Workover Operations

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 ADCO
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Note:
As an alternative, packers with seal bore extension (millout extension or with
x-over and tail pipe attached to the bottom of the packer can be milled and
retrieved in one trip by utilizing the Pioneer slick bore packer milling and
retrieving tool.

5. Abandoning Completion Tail and Packer(s)

Fishing operation of Completion tail & Packer(s) shall be terminated if these
conditions are met.

• Effective zonal isolation between different zones can be achieved.

• Abandonment is economically feasible compared to the fishing and milling option.

• Abandoning completion tail & packer(s) will not have negative impact on the new
well target, quality or integrity.
• Continuing milling / fishing may result in loosing the chance to achieve zonal
isolation due to plugging of String/Perforations.
Note: Refer to Chapter-4, Section-6 (Well Abandonment) for details on well
abandonment and zonal isolation.

6. Recovering 7" scab liner

Scab liners were set in old dump injection wells to isolate the perforated aquifers.
During workover operations, the corroded scab liner is replaced by cemented casing
string to surface.

Most of the scab liners in ADCO consist of:

• 194-75-60 FA-1 Baker Permanent packer at bottom.

• 190-75, K-22 Anchor seal assembly.

• 7" casing enough to cover the aquifer perforation.

• 194-60, FB-1 Baker Permanent packer at top.

The bottom packer was set on electric wireline while the upper packer together with
casing was run and set on DP.

6.1 Retrieving Procedure

• RIH 8.1/2" X 7.1/16" rotary shoe, wash over FB-1 PKR until it becomes
free. POH.

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• RIH with 7" casing spear and hydraulic jar. Latch into 7" casing. Release
K-22 Anchor Seal by jarring and rotating ± 20 turns to right while applying
overpull equal to 20% of the liners weight.

• POH and L/D 7" scab liner marking same to carry out corrosion inspection
prior to milling/retrieving bottom FA-1 packer with milling retrieving tool.
Notes:

a) If K-22 anchor seal will not released, release the spear, POH and
proceed to next step.
b) RIH with internal casing cutter. Cut 7" casing at ± 5' above scab
liner bottom.
c) POH with casing cutter, RIH with 7" casing spear to recover the 7"
scab liner.
d) If casing is parted, attempt to recover the rest with spear and, if no
success, proceed to step b and c above.

• RIH with 7" casing releasing spear and hydraulic jar. Latch into 7" casing.
POH and L/D 7" scab liner numbering same for corrosion inspection.
O RIH with 8.1/2" X 7.1/16" rotary shoe on 30'X8.1/2" washover pipe.
O Washover FA-1 packer until same drops down.
O RIH with 7" casing spear to recover the rest of casing and bottom
packer.
Notes:

Have available on location 8.3/8" short catch overshot with 7" spiral grapple to
be used if spear fails.

S.G. ADM Volume-2 Page

Date Issued: 30/03/2009 Last Revision:
Rev-00/09 Drilling Operation -B 2-42
Printed on: 19/08/2008
 ADCO
DRILLING MANUAL
Volume-2/Chapter-2: Workover Operations

SECTION 4

FISHING GENERAL GUIDANCE

This section describes the fishing tools and assemblies used in workover operations and
highlight the factors and concerns that must be taken into account when using each tool.

1. Standard Fishing Assembly

• The standard fishing assembly consists of the following:

O Fishing tool
O Jar and Bumper Sub
O Accelerator
O Drill Collars
O Heavy Weight Drill Pipe
O Drill Pipe
• A Safety Joint should not be run. Since the Safety Joint will not transmit left hand
torque, it would not be possible to back-off below it using a string shot. However,
a Safety Joint could be run between the catching tool and the jar when a non
releasing tool such as taper tap is being employed.

• Avoid any restrictions in the bore of tools run above the catching tool, which
would prevent the use of a cutting tool or the back-off shot within the fish.
• Where losses or plugging are expected the use of a Circulation Sub in the fishing
assembly should be considered.

2. Overshot

• Plan the operation taking into account the following factors:

O The catching action of the tool will stress the fish neck inwards.
O A regular, smooth shape of the fish neck is necessary for a successful
operation.
O Jarring is only possible using “The Jarring type overshot”.
O If the fish diameter is near the maximum catch or size of basket grapple, a
spiral grapple is recommended. On the other hand, if the fish diameter is
considerably below the maximum catch size, a basket grapple is preferable.
O If the hole is enlarged, use an oversize guide.
O When the fish has been milled over, if possible, run an overshot extension to
avoid catching the fish by the milled part.
S.G. ADM Volume-2 Page
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Rev-00/09 Drilling Operation -B 2-43
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• Run the fishing assembly, space out as required, and make up the Kelly.

• Lower the overshot to just above the fish and circulate for a few minutes to clean
the top of the fish.
• Prior to engaging the fish, record the weight of fishing string (up, down and
rotating) with and without circulation.
• To engage a fish, the fishing string is lowered and rotated to the right very slowly,
pumping at minimum rate. During the engaging operation, continuously monitor
the weight indicator and stand pipe pressure.

• As the fish is engaged, allow the right hand torque to slack out and pull on the
fish picking up rapidly the fishing string 5 to 8ft. Drop the string 2 to 4ft and catch
it in the brake to make sure that there is a firm grip.

• If possible, consideration should be given to circulating bottoms up through the

fish before pulling out of hole.

• When tripping out of the hole with the fish, the string must not be rotated; pipe
Spinner should be used.

• If pulling out of the hole wet, flow checks shall be carried out frequently.

3. Releasing Spear

• Plan this operation taking into account the following factors:

O The fish will be stressed outwards due to the catching action of the tool.
O A regular, smooth shape of the fish is essential for a successful operation.
O To allow unlatching of the spear, the use of a bumper sub is recommended.
O Use the fishing jar If jarring is required. In this case the use of a Spear Stop is
required. Check the Spear Stop OD when it is used in open hole and use the
stop only if hole condition permits.

• Perform the fishing job as per overshot procedure.

4. Taper Tap / Pin Tap

• Plan this operation taking into account the following factors:

O The size of the taper tool should be selected in order to engage the fish with
the middle of the tapered point.
O The taper taps do not allow free passage of the back-off tool.
O Excessive torque can damage the tapered thread and swell the top of the
fish.

S.G. ADM Volume-2 Page

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O It is very difficult to impossible to release the tool once engaged. For this
reason its use has to be considered the last resort.
• Run the fishing assembly, complete with safety joint, space out as required and
make up the Kelly.

• Lower the catching tool to just above the fish and circulate a few minutes to clean
the top of the fish. Do not circulate excessively as this may enlarge the hole.
• To engage the fish, apply right hand torque. A gradual increase of back torque is
an indication of successful operation.

• Spin the pipe out of hole with the fish.

5. Reverse Circulation Junk Basket

• This procedure is more successful in soft formations.

• Use the following parameters:

O WOB = 4000 to 8000 Lbs
O Rotary = 45 RPM
O Low Pump Rate (half of pumping rate while drilling).
• Core approximately 1 foot. Pick up to allow the junk on the side of the basket to
fall into the pilot hole, and then proceed coring a further +/-2 feet.

• Pull the junk basket out of the hole

6. Fishing Magnet
Magnets can be successfully used but only in hard formations to retrieve small steel
objects such as bit cones, bearings, slips, tong dies and milling cuttings.

To avoid sticking the fish in the hole, weight must not be applied.

Fishing magnets may be run on wireline or on drillpipe. Wireline run have the
advantage of speed and economy. Drillpipe run has the great advantage of utilizing
the circulation to remove cuttings settling above the fish.

7. Milling Tools
The following are general guidelines for the use of milling tools:

• Milled cuttings are much heavier than drilling cuttings. Therefore, mud yield
should be increased or high viscosity pills should be pumped to help in carrying
the steel cuttings out of the hole.

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• Oil based mud has poor carrying capabilities and should be avoided whenever
possible. Polymer mud is most suitable for milling.

• Never mill faster than it is possible to remove the cuttings.

• Magnets placed in the flow line will help in removing metal particles from drilling
mud. Removal of mill cuttings and debris reduces the wear on mud pumps and
other equipment.

• A junk sub placed in the string above the mill can aid in catching the larger
cuttings.
• Always start rotating, with low RPM for about 3 ft above the top of fish. Lower
onto the fish and adjust the weight and the rotary speed to obtain satisfactory
progress.

• Generally the most efficient milling rates are obtained by running the rotary at 80
to 100 RPM. Milling with washover shoes is an exception and are usually more
efficient at speeds of 60 to 80 RPM.

• Continuously monitor the torque indicator during milling operations.

• The type and stability of the fish (cemented or not) together with the hardness of
the fish and/or cement are factors that affect milling rates.

There is a wide variety of mills specifically designed for various applications. Two
basic categories are available:

8. Hydraulically Activated Mills

8.1 Section Mill
Section mill is a hydraulically actuated tool and is used to mill out a complete
section of casing. Downhole section milling of casing, is generally done for
the following reasons:

• To mill a section of casing that permits sidetracking in any direction.

• To mill the perforated zone in a production casing string or to expose

cased-off formations. The formations may be then under-reamed and
gravel packed past the original completion.

9. Fixed Milling Tools

The most commonly used Fixed Mills are:

9.1 Junk Mills

Used to mill all types of junk, including rock bit cones, reamers cutters, items
dropped through the rotary, cemented tubing, etc.
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9.2 Pilot Mills

Designed to mill casing, tubing, wash pipe, safety joint, swaged casing, etc.

9.3 Taper Mills

Generally used to eliminate restrictions or to mill through collapsed casing.

9.4 Washover Shoes

Designed to mill away formation or tool obstructions such as stabilizer blades,
reamer cutters, expanded packers and bit bodies which may be holding the
drill or tubing string in the hole

10. Special Mills

Window mills, Watermelon mills, etc. for casing sidetracking systems (See
Sidetracking Section -5 of this Chapter).

11. Fishing of Radio-Active Wireline Tools

11.1 Caution
Radioactive Source containers release, if broken, very harmful materials that
are dangerous to human lives and contaminate the field as these materials
migrate in the formation. Therefore, every precaution MUST be taken to avoid
breaking these containers while fishing.

11.2 Preparation
The whole operation needs good communication and co-ordination between
Driller, Derrickman, Floormen and the Wireline Contactor Operator.
Therefore, the DS will arrange a pre-job safety meeting.

11.3 Operations
• When stuck, determine if the tool or the cable is stuck by using the stretch
charts provided by the Wireline Contractor.
• Do not break the cable or the weak point. Chances to recover the tool are
reduced by doing either of them.
• Prepare the overshot using the correct grapple to suit the cable head in
use and the guide shoe to suit the hole size. Screw the assembly into the
sub to be made up between the overshot and the drill pipe.

• Pull up 2000 lbs over normal cable tension.

• Secure the cable with the special T-Clamp, slack off and cut the cable 5-7
feet above the Rotary table.

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• Lower the block with the upper sheave wheel and fix the top sheave as
high as possible in the derrick, at a position where the Derrickman can
easily reach the cable.

• Use the Wireline Contractor’s tension device on the lower sheave.

• Feed the "hole" end of the cable through the overshot assembly and
prepare the male type quick connection.

• Prepare the "Unit" end of the cable with the female type quick connection.
Make up sufficient sinker bars on this end to overcome the cable weight
while lowering the quick connection through the drillpipe.
• Pick up the first stand of drillpipe and lower the quick connection through
the pipe.
• Engage the quick connections and pull up until the cable is slightly under
tension.
• Make up the overshot assembly to the drill pipe, chain tong tight.

• Pull up the cable until the T-Clamp is hanging free. Disconnect T-Clamp.

• Make the overshot assembly to the drillpipe tong tight

• Lower the stand until the pin end of the quick connection is completely
clean of the pipe.
• Drop in the Rotary slips, place C-Plate into the groove of the quick
connection and slack off cable tension.
• Release the quick connection, pick up the next stand of drillpipe and
repeat operation until approaching the fish.

• Stop one stand above the torpedo and install the circulating sub.

• Circulate slowly to clean the overshot and note the number of strokes and
pressure. While circulating, there is every possibility that a cable loop will
be formed at the bottom of the overshot. Therefore, Do Not Lower or
Rotate the string while circulating.
• Disconnect circulating sub and continue the approach until the cable
tension is increasing. Do Not Rotate The Pine At Any Time.
• After engaging the tool into the overshot, circulate again at the same
stroke as in above. The pressure should be higher now.

• Connect clamp and use the traveling block to pull the weak point.

• Cut off quick connections and make a square knot with the cable ends.

• Pull out and spool the cable on the drum.

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• Pull out the fishing string slowly. Do Not Rotate.

• Disconnect the tool from the head and break overshot connections with
the tongs.

Notes:

To avoid accidental damage of the containers during fishing and to know as

soon as possible if the container is broken:

− Monitor permanently mud return with a gamma-ray tool at the shale

shakers while circulating.
− Never rotate with the drilling string at any stage.
− Minimize the people working on the rig floor when the tool containing the
source is pulled out of the hole.
− If all efforts fail to fish the source and it is decided to abandon the same, it
must be protected by a cement plug.
− A gamma-ray log will be taken after the cement job to check that there is
no contamination and that the source was not dragged up the hole during
the cementing process.
− If at any stage position of the source is not clear, a gamma-ray log will be
taken to trace it.
− It must be ensured that the abandonment of such source with exact
details as per the depth, date…etc are clearly recorded in the Daily
Drilling Report by the Drilling Supervisor on the rig and properly
documented in the respective well file by the relevant Drilling Engineer in
the office.

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SECTION 5

SIDETRACKING OPERATIONS

Sidetracking is creating an exit through openhole or casing to allow a new lateral section to
be drilled.

1. Sidetracking in Open hole

Sidetracking through openhole can be done using different techniques as follow

1.1 Cement Plug Method

• Select the formation which gives the best chance of sidetracking success.
This is normally done by analysis of the ROP log. The ideal formation is
normally a consolidated formation at the place of best ROP.

• The minimum distance between the TOF to the Kick-off Point (KOP) is
100 feet and between casing shoe and KOP is 30 ft.

• Sidetracking in Shale formation is not recommended, because of the high

risk of caving.

• Prior to start any sidetrack operation, ensure first that drill string is in good
condition and does not require a tubular inspection, especially after any
fishing job.

• Run in hole with 1000 feet of 2 ⅞" or 3 ½” open ended tubing on drill pipe
to the top of fish.
• Set high compressive strength balanced cement plug on top of fish to
cover the distance between the top of fish up to 150 feet above the
selected kick-off point depth (KOP). The recipe of the cement slurry
should be made such as to obtain very hard cement.

• In case of losses at the bottom of the hole, several cement plugs may be
necessary. In this case, all efforts should be made to cover at least the
distance between 150 feet above the KOP down to 100 feet below the
KOP with one same cement plug such as to obtain uniform cement plug
homogeneity.
• While waiting on cement, run in hole with milltooth bit and dress TOC to
30 feet above the KOP and circulate hole clean.
• Test the hardness of the cement by applying 50,000 lbs WOB without
rotating the pipe but with a maximum of pumping rate. If no penetration is
obtained in such condition, the cement is probably hard enough. If any
penetration, WOC a further 8 hours and repeat the cement hardness test.

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• In both cases, when the cement is hard enough, drill the remaining
cement to the KOP required, circulate hole clean, and take a survey with
bit as close to bottom as possible and pull out of hole.
Note:
In case directional control is required during the sidetracking, RIH enough
non-MAG DCs to allow taking a survey prior to POH for sidetracking.

• RIH the following sidetrack assembly:

1. Tricone bit.
2. Mud motor.
3. Bent Sub (1.1/2° to 2.1/2° depending on hole size).
4. Orienting Sub (In case directional control is required)
5. 1 or 2 non-mag drill collar (In case directional control is required-
Length NMDC' Model depends on angle of hole and direction)
6. Enough HWDP to allow a maximum of 20,000 lbs WOB.
• Run in hole last 30 feet with low circulation and RPM (Adjust the string
length such as to have a full kelly above the RT with the bit on bottom).
• If directional control is required, orient the tool face in the required
direction and start sidetracking.
• If the well is already a deviated hole the easiest optimum direction for the
sidetrack would be on the "Low side" of the hole.
• If no directional control is required, lock the rotary table and do not allow
the string to rotate any more until the kick off is completed.

• With the rotary table locked and marked, and constant circulation
pressure, drill the first 15 feet in 12 hours time at a rate of 1 inch each 4
minutes. Check percentage of cement and formation on the shale shaker.

• Drill the next 15 feet in 6 hours time at a rate of 1 inch each 2 minutes.
Check percentage of cement and formation on the shale shaker.
• Make the connection carefully ensuring that the string is not rotating. Re-
adjust the pump rates as for above.
• Continue sidetracking another 30 feet in 6 hours at a rate of 1 inch per
minute. Check the percentage of cement and formation on the shale
shaker. As soon as 100% of formation is obtained on the shale shaker,
increase the WOB to normal drilling condition.

• Make another connection as previously and drill the next 30 feet normally.

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Shoe to KOP
= Min 60 ft
KOP to TOF = Min 100 ft

Cement Plug

Fish

Figure 2- 6: Openhole sidetracking cement Plug

Note:
The KOP where the first foot of sidetracked hole is drilled is the depth which
must be considered for lost hole calculation.
• Take a survey after a total of 90 feet are sidetracked and compare this
survey with the survey taken previously.

• Continue sidetracking until a total of 5° change of hole angle is obtained,

or a total departure from the original hole of 5 feet, whichever comes first.
Take a final survey and continue drilling sidetrack hole as per plan.
Note:
It is important to ensure always the same pump pressure during the sidetrack
operation in order to have always the same "reactive torque" on the drill
string. The rotary table being locked during the sidetrack would allow the tool
face of the bit to change every time the circulation pressure changes.
• In case of a vertical hole where the direction of the sidetrack is not critical,
RIH with the standard pendulum BHA and drill ahead in normal condition,
taking a survey every 90 ft. at the beginning to ensure the hole angle is
dropping off. Thereafter only normal surveys are required.
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• In case the sidetracked hole direction is critical, or in case of deviated

sidetracked wells, the required BHA for continuing drilling must be
selected according to the hole conditions and the target position.
Note:
Remember that a conventional rotary drilling assembly has normally a "right-
hand roll off" tendency during drilling (tendency to turn the well direction to
the right) while turbo-drilling has a "left-hand roll off". This can be considered
to help in reaching the target of the deviated hole.

1.2 Openhole Whipstock (Cement Whipstock Method)

1.2.1 General Notes

• The Cement Type Whipstock although set in open hole conditions,

should be set on some type of bottom (i.e., formation, fish, etc.) to
prevent it from moving downhole when setting.

• If required, the cement type whipstock can be oriented to a specific

direction.

• Enough cement is pumped and applied generously around the

whipstock and at least 100 feet above the whipstock.

1.2.2 Bottom Hole Assembly

• Cement Type Whipstock

• Setting Tool

• Universal Bottom Hole Orientation Sub (UBHO)

• Drill pipe joint

• Pup joints (for space-out if necessary)

Note:

The UBHO Sub is required only when orientation is necessary.

1.2.3 Procedure

• Pick up a single joint of drill pipe and make up the whipstock

Setting Tool to the bottom connection.

• If required, make up the UBHO sub to the top of the drill pipe.

• Make up the Setting Tool to the whipstock concave by sliding the

Setting Tool’s tube over the cementing tube extending through the
whipstock’s concave.
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• Run the whipstock into the hole at a slow, steady rate, 2 to 3

minutes per stand. Fill the drill string every 10 to 15 stands to
ensure that the tubes on the whipstock do not plug.
Caution:
Do not include drill collars in the drill pipe string when setting a
cement type whipstock. The small ID of drill collars may cause
“flash” setting of the cement.

• Circulate through the drill pipe string.

• At 10 ft from bottom, run survey tools on wireline to the UBHO sub,

take survey readings and correct direction of whipstock.
• Pull the wireline from the drill pipe string and lower the whipstock
assembly until it rests on the bottom.

• Connect the cementing line to the drill string.

Note:
The cementing tube is rated to 3,500 psi. Pump cement at no
more than 2 bpm to prevent bursting the tube.

• Pump the cement to a level approximately 100 feet above the

whipstock (see Figure 2-8).
• Disconnect the cementing line immediately after the cementing
procedure is complete.

• Pick up to the string weight.

• Pick up 5 to 10 feet and then quickly lower back to the bottom to

shear loose from the concave.

• Once shearing has been verified, pick up the drill pipe string 10
stands (see Figure 2-9).

• Pull out of the hole, circulating on the way out.

• Wait on cement to set.

• Use a drill bit to drill through the cement, above the whipstock
down the whipstock’s concave and into the new formation (see
Figure 2-10).

• This run should include a flexible assembly as follows (from top to

bottom):
1. Drill pipe string
2. One joint drill pipe

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3. Bit Sub (Minimum length, bored for the float assembly)

4. Drill Bit (Usually PDC or short tooth rotary bit)
Caution:

Do not rotate stabilizers on the whipstock's concave; this action

could cause damage to the whipstock orientation.

Figure 2- 7: Cementing O.H. Whipstock Figure 2- 8: Releasing Whipstock Figure 2- 9: Sidetracking

2. Sidetracking Inside Casing

For sidetracking inside casing, two different methods are available:

• To cut a section of the casing over its complete circumference and continue with
a conventional open hole side- tracking procedure.

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• To set a Whipstock assembly inside the casing and cut a window in the side of
the casing through which the sidetrack is made.
Both the above methods are efficient but the final selection of which to use must be
made on the hole condition, as described hereunder.

2.1 Sidetracking through a cut section of casing

This method of sidetracking should be used when the casing across the KOP
is in poor cemented and/or mechanical conditions, which would not permit the
setting of a Whipstock in safe condition.

2.1.1 Standard measures

• As for sidetracking in open hole, the optimum formation behind the

casing should be selected for better chance of success.
• The very minimum distance of casing to be cut is 60 ft, from which
the top 40 feet are reserved for "getting out" of the old hole.
• The optimum length of cut casing is 75 feet.

• Distance between the top of fish and the bottom of the cut section
of casing is minimum 50 ft.

2.1.2 Section mill description

The section mill cuts through casing with three cutter blades working
like single-point tools and then mills the casing with six blades at a
speed of up to 8 ft/hr.

The mill features is a piston actuated cam that locks the cutting blades
open during operation and automatically closes them when pump
pressure is removed.

When cut out is complete, annular flow through the tool is more than
doubled resulting in a pressure drop of about 200 psi and a noticeable
increase in pump strokes.

2.1.3 Cutting section (window) in casing

• Run in hole with section mill to the desired depth, filling string
every 10 stands.
• Rig up slickline.

• RIH with 1.11/16" GR/CCL and correlate driller depth.

• Pull out of hole and rig down slickline.

• Rotate section mill at 60 RPM without pump pressure.

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• Turn pump on and build up pressure to 1500-2000 psi. Record

pressure and pump speed and hold pressure as even as possible
during cut out.

• Cut the distance of casing required. During this operation, as

casing joints are normally 40 feet long, a maximum of 1 casing
collar is to be cut. POOH.

• When the cut out is completed, a pressure drop of about 200-250

psi will be noticed and the pump speed will increase.

• After the cut out is made, allow the tool to rotate for about 10
minutes to clean up the cut.

• Increase RPM to 100-125.

• Gradually apply 4000-8000 lb/ft weight.

• Maintain an even weight while milling rather than allowing the

weight to "drill off" before adding more weight.

• After casing has been milled, reduce weight to 2000 lb/ft.

• Turn the pump off.

• Rotate 2 to 5 minutes and stop rotation.

• Pull into casing slowly and continue POOH.

• RIH with 600 feet of 2 ⅞" or 3 ½" open ended tubing on 3 ½” DP

down to at least 30 feet below the base of the cut casing section.
The ideal would be to set the base of the cement plug right at the
top of the fish.

• Set a balanced cement plug.

• Clean out to top of cement as; the KOP will be 10 feet below the
upper section of the casing cut.
• For controlled azimuth side tracks the survey to be taken will
require a single shot Gyro tool or continues Gyro tool due to the
magnetic interference from the casing string.

• Proceed with the same sequences as described above in “Cement

Plug Method” including all notes and remarks.

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Cut window = 75 ft Optimum

(60 ft minimum)

Cut Window
Bottom of window
to TOF = 50 ft

Fish

Figure 2-10: Cut window in casing with section mill

2.1.4 Mud conditioning for milling

• Minimum annular velocity of 120 ft/min.

• Turbulent flow is required to clear the cuttings and avoid the

chance to "bird nest" in the wrong place such as above DCs.

• If well conditions permit, use water based drilling fluid.

• Increase the yield point of the mud with a moderate increase in

viscosity.

• Keep a minimum of 60-70 cp viscosity.

2.1.5 Removal of cuttings

• Make sure that all tubulars run with the section mill are full bore
because restrictions can cause fluid volumes problems preventing
cutting removal and could affect the hydraulically operated section
mill.

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• Additional nozzles may be installed, pointing up the hole, directly

above the section mill.

• Have a magnet on the flow line.

• Surface arrangement should be available for flushing flow line to

avoid plugging.

2.2 Sidetracking in casing with Conventional Whipstock

This method of sidetracking should be used when the casing across the KOP
is in good cemented and mechanical conditions (only 20 to 30 feet of good
casing are required to allow a safe setting of the Whipstock).

2.2.1 Standard measures

• The optimum formation behind the casing should be selected for

better chances of success.
• The minimum distance required "to get out of the old hole" is 30
feet.
• There is no need for a special distance between the top of fish
(TOF) and the setting depth of the bridge plug.
• This sidetrack CAN NOT GO WRONG, even if the sidetrack is
made through two strings of casing (which is not always the case
in open hole technique sidetracks).

2.2.2 Whipstock mills

• Starting Mill: Used to lower the whipstock into the setting position
and to cut the initial window.
• Watermelon Mills: Typically run above the window Mill and drill
pipe to assist in opening the window.

• Window Mill: Used for cutting windows as a follow-up to the

Starting Mill.
• String Mills: Used on the final run above the Window Mill on a drill
collar.
• Tapered Mill: Used when problems (such as flattened, split, or
bent casing) are encountered; not used to cut the formation.

2.2.3 Procedure

• Make a round trip with scraper across the packer setting area.

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• In case of directional holes which require azimuth control of the

side track, the Whipstock packer has to be set on DP to allow
orientation of the Whipstock by means of an orienting tool.

• In this case the BHA would be:

O Permanent Bridge Plug (with aligning pins for the Whipstock).
O Hydraulic setting tool (with ball installed on the seat as the ball
will not pass the orienting sub above it).
O Orienting sub (with mule shoe guide).
O HWDP and DP.
• The setting procedure will be as follows:
O Run in hole with above BHA to packer setting depth.
O Fill string every 10 stands.
O Orient the packer into the required direction using single shot
gyro instrument.
O Set the permanent packer by applying pressure.
O Release the setting tool by pull shearing the release pin.
O Pull out of hole.
• In wells where directional control of the well is not required, the
packer can be set on DP as said above, but without having to
orient the string, or can be set on electric wireline.
Note:
It is advisable to set the packer about 10 feet above a casing collar
such as having the Whipstock (the later window) in smooth casing.

• With the permanent packer set, run in hole with Whipstock

assembly # 1 as follows:
1. Casing Whipstock with its latching device assembly at bottom.
2. Starting mill shear pinned to the Whipstock.
3. HWDP and DP.
• Fill the string every 10 stands.

• When this assembly is on top of the permanent packer, the

Whipstock is latched/secured automatically onto the packer. In
case of required directional control, the Whipstock is automatically
oriented by means of the aligning key which is in the permanent
packer, prior to being latched / secured. DO NOT ROTATE THE
PIPE in any attempt to help the alignment.
• The shear pin connecting the nose of the "starting mill" is then
sheared-off by applying weight (normally 12,000 lbs).
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• Cutting the window is made by normal rotation of the mill and

slacking-off the string at a rate of one inch every 15 minutes over a
distance of 2 to 3 feet (observe the RT torque carefully). The
tapered shape of the "starting mill" by "sliding down the slope of
the Whipstock, is pushing the cutting edge of the mill against the
casing wall. Cutting will progress until the bottom nose of the
starting mill touches the wall of the casing. The string is pulled out
when the starting mill begins to take weight.
Note:
A magnet should be installed in the mud ditch such as to collect
steel cuttings and evaluate the volume of casing wall cut-off.
Check also for cement and formation cuttings.

• The BHA # 2 to be as follows:

1. Diamond mill.
2. Watermelon mill.
3. 15 joints of HWDP.
Note:
The reason for the 5" HWDP is because a flexible BHA is required.

• At the top of the Whipstock, start reaming at approximately 90

RPM. Ream the "starting cut" made previously maintaining
smooth cutting and acceptable Rotary torque. When the torque
has disappeared the diamond mill starts to cut its own window.
Increase RPM to 130 and adjust WOB for smooth torque until 10
to 15 feet of formation is drilled. POOH.

• Run in hole the following reaming assembly # 3:

1. Taper mill
2. String mill.
3. Watermelon mill.
4. Normal size DCs (use non-mag in case of directional control).
• Continue drilling until 5° inclination is obtained or 5 to 10 feet
departure from the old hole is obtained, whichever comes first, and
POOH.

• RIH building-up assembly consisting of Rock bit, N.B. stabilizer,

and DC's.

• Drill 70-100 ft. Take survey and if 5° inclination is achieved POH,

otherwise drill more to get 5° inclination or + 10 ft departure from
old hole. POOH.

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• RIH with drop off assembly consisting of rock bit and string stab at
60 ft above bit and resume normal drilling operation.
• In case of azimuth control, remember that magnetic interferences
of the string of casing (and the fish) will require the use of the
single shot gyro surveying instrument until approximately 40 feet
distance is reached.

2.3 Sidetracking in casing with Single-Trip Whipstock

The single-trip whipstock is hydraulically set in the casing, eliminating the
need for a false bottom. This system enables setting, orienting the whipstock,
detach the milling assembly, mill a full-size window, and drill a pilot hole all in
a single trip.

2.3.1 Milling fluids

• Utilize the mud which will be used to drill the next hole section.
The fluid properties planned for the next section are usually
adequate for hole cleaning during milling.
• Consider the fracture gradient at the previous shoe if there is a risk
of milling into an un-cemented annulus.

2.3.2 Wellbore preparation

• Make a round trip with scraper and full gauge, rough outer
diameter string mill to ensure that the wellbore is clean/free of
debris.

• In deviated holes or in special drift casing strings, scraper plus two

full gauge mills spaced out with short DC is recommended.

• Pump viscous pill and work scraper at the whipstock setting depth.
If there is a lot of cement to be drilled, consider using adequate
scraper. Check the string mill gauge when out of the hole, if there
is evidence of junk in hole when this assembly is pulled, an
additional cleanout run including junk basket is recommended.
• Be sure that casing across whipstock’s setting depth is in good
cemented and mechanical conditions (only 20 to 30 feet of good
casing are required to allow a safe setting of the Whipstock).

• The whipstock should be positioned so that the window is milled

through the wall of the casing joint, and not across a casing collar.
This milling practice will help avoid the possibility of parting the
casing string if the cement behind the casing is poorly set and
unconsolidated, if a CBL is available, avoid centralizers.

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• The optimum formation behind the casing should be selected for

better chances of success.

• There is no need for a special distance between the top of fish (if
any) and the whipstock setting depth. However all precautions
should be made to get as far from the original hole as possible.

2.3.3 Bottom hole assembly

• Lead mill.

• Full gauge string mill.

• One joint of drill pipe

• Orienting sub or MWD.

• Drill collar or HWDP.

• Concave.

• Hydraulic Anchor and Hydraulic Packer (packer is optional).

2.3.4 Running in hole

• The whipstock engineer must be on rig floor while making up and

running the system in hole.

• Make certain that the hole is full of fluid prior to tripping.

• Slowly lower the system into the hole ensuring that whipstock and
milling BHA do not hang up on the Blowout Preventer or casing
top.

• Run in hole slowly. The maximum speed for running in the hole
with the system is two minutes per stand.

• Fill the string every 10 stands while RIH.

• Use back-up tongs properly while making up the drillstring. If the

drillstring turns sharply below the drill floor, this can fatigue the
shear screws resulting in premature shear between the milling
BHA and the whipstock.

• Set down and pick up easy on the slips, any jolting pipe movement
will fatigue the shear attachment bolt.

• Should circulation need to be established at any time while running

in hole, monitor the flow rate as not to accidentally set the
Whipstock (whipstock engineer must be on rig floor)

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• Run in hole slowly until approximately 30 feet of setting depth.

• Move the drillstring up and down 5 to 20 feet, recording accurate

string weights and removing torque from the drillstring.

• Place the Whipstock at setting depth.

2.3.5 Orienting

• The Directional Driller should be on rig floor during the entire

process.
• Determine orientation of the whipstock by wireline conveyed Gyro
or flowing through the MWD.
• The whipstock may be oriented using MWD in inclined holes
(greater than ~ 5 degrees), or using a surface readout gyro in
near-vertical holes.

2.3.6 Setting the whipstock

• The whipstock engineer must be on rig floor during the entire

process.
• Slowly increase the pump flow rate and set whipstock as by
manufacturer’s instructions.
• Turn off the pumps and slack off the drillstring. The drillstring
weight will decrease indicating the whipstock is set.
• With the whipstock set, move the drillstring down applying WOB to
shear the milling BHA from the whipstock. Weight in excess of the
shear value may be required to shear the attachment bolt in
deviated wells.

• Once the milling BHA shears from the whipstock, apply an

additional weight (~15,000 lbs) above the recorded shear WOB to
ensure the whipstock is set.

• Lift the drillstring 10 feet above the top of the whipstock in

preparation for milling.

2.3.7 Milling procedures

• Do not commence milling while displacing to a different mud

system. The variations in standpipe pressure can make it difficult
to monitor and control the milling operation.

• Install ditch magnets (two to four magnets) to catch metal junk.

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• Begin rotating the string slowly; increase the RPM to appropriate

milling speed (50 to 70 RPM).

• Reciprocate the string up and down, recording the pick-up and

slack-off string weights, free rotary torque, and pump pressure.
• Lower the string to commence milling. Once the Lead Mill reaches
the top of the whipstock, there will be an immediate increase in
rotary torque.

• Begin milling with approximately 1,000 Ibs WOB down on the Lead
Mill for the first 6 inches of milling depth.

• Slowly bring the RPM up to the recommended range.

• Slowly increase the WOB until a rate of penetration of one to six

feet per hour is achieved. After the Lead Mill passes the bottom of
the concave, a significant increase in ROP should be observed.

• Continue to mill with enough weight to maintain a minimum ROP

of 1 ft/hr. The optimum ROP from this point on is 2 to 4 ft per hour.

• Check the fluid returns frequently for the presence of cement

and/or formation.
• When the casing window has been milled and the Lead Mill is out
into the formation, increase the WOB as necessary to drill the
formation. The optimum milling distance is to mill formation beyond
the end of the concave.
• Make sure that the string mill has completely passed through the
window.
• Once the total milling depth has been reached, the WOB has been
milled off, and "bottoms up" circulation has been achieved, reduce
the pump flow, RPM, and start reaming the window.

• Continue reaming up and down through window, recording torque

and string weights, until torque does not increase while reaming.

• Pump Hi-Vis pill as required and circulate wellbore clean.

• Drill 1 – 1.5 ft extra rat hole to ensure bottom is free of junk.

• Stop pumps and rotary and slowly slide the BHA through the
milled window; there should be no decrease in string weight.
• Pull the Milling BHA out of the hole and gauge mills to verify
window’s condition is acceptable.

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2.3.8 Drilling ahead

• Run in hole with drilling bottom hole assembly.

• The driller must always be aware of whipstock top and bottom

depths and orientation. Post this information clearly.

• Always orient the bit towards window opening when tripping in/out
with directional BHA. Enter the window slowly, watching weight
indicator.

• DO NOT ROTATE BIT (particularly PDC bits) OR STABILIZERS

ACROSS THE WHIPSTOCK FACE. Know the positions of these
items with respect to the whipstock at all times.

• DO NOT CIRCULATE THROUGH MOTOR WHEN BIT IS

ACROSS THE CASING WINDOW.
• Be particularly aware of items in the drill string above the bottom
hole assembly (especially reamers), which are sometimes
forgotten. None of these items should be rotated over the
whipstock, and caution should be used when POOH these items
through the window.
• The Directional Driller must be on site every time these items are
tripped through the window.
• If the bit could not pass easily through the window, run in hole with
dressing assembly.

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Volume-2/Chapter-2: Workover Operations

SECTION 6

REMEDIAL CEMENTATIONS

Remedial cementation during workover operations may be required in the following cases.

• Repair primary cement job.

• Plug back old/watered out holes.

• Well abandonment.

• Directional requirements/sidetracking.

• Casing leaks.

• Abandon non productive or depleted zones.

• Seal off lost circulation zones.

The remedial cementing techniques typically used during workover operations are:
• Balance Plug cementing.

• Cement through EZSV.

• Cementing through coiled tubing.

• Macaroni Tube.

The matrix below presents the different technique that might be used for each application:

Table 2- 6: Techniques used for different remedial applications

Technique
Purpose Balanced Squeeze Coiled Macaroni
Plug with EZSV Tubing Tube
Repair primary cement job-channels X √ X X
Cement Top Job X X X √
Well abandonment √ √ √ X
For directional requirements and sidetracking √ X X X
Casing leaks. √ √ X X
Abandon non productive or depleted zones √ √ √ X
Selective Shut-Off for Water Injection X √ √ X
Shut-off fluid migration into production zone. X √ √ X
Plug back existing perforations √ √ √ X

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1. Balanced Cement Plugs

1.1 General Notes
• Plugs are set by “spotting” cement through tubing tail pipe with a ported
side outlet sub on bottom. Length of tubing tail pipe should be equal to the
plug length plus 30 %.

• 2 ⅞" tubing is used in slim holes of 8½” diameter or smaller. 3½” tubing is
used in larger holes. Coupling OD’s of the tubing must be minimized.

• If no tubing is available, 3½” drillpipe may be considered. The tail length

should be equal to the plug length plus 30%.

• Caution should be taken not to plug the cementing string while RIH.

• The minimum thickening time should be the job time plus 1-2 hours safety
margin.

• Cement slurry should be mixed in a batch mixer. If cement is mixed using

a re-circulating jet mixer, dump the slurry until the correct slurry density is
achieved.
• If a hole is badly washed out, it is better to set 2 short plugs over the
washed-out interval rather than to try to cover the interval in one go with a
large amount of cement. Gauge hole sections are preferred for cement
plugs.

• When setting abandonment plugs in potential loss zones it is better to set

a cement plug in two stages, i.e. first a small one, which acts as a carrier
for the next plug.

• Balance Plug length should not exceed 700 ft.

• Pull the pipe back to at least 500 ft above theoretical top of plug before
commencing reverse circulation. This does not apply if a series of plugs
are to be set continuously.
O Always calculate the loss in hydrostatic pressure before using water or
base oil ahead of a cement plug. Consider gauge hole for calculations.
O Never stab the cement string back into the plug following
displacement.
O Always use spacers ahead and behind the slurry. Use spacer volumes
to give at least 100 ft. linear height in the tubing and annulus.

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1.2 Spotting Procedure

• Make up and run cement string to the bottom of the plug depth and
circulate hole clean.

• Pump a low viscous pill, of the same weight as the mud.

• Pump weighted spacer ahead. The quantity of the spacer depends on

hole size.
• Pump the mixed cement slurry.

• Pump sufficient spacer behind the cement to balance pre-flush.

• Displace with mud to balanced position where level of cement slurry and
spacer inside tubing are the same as annulus.
O Do not over displace.
O Do not reciprocate the pipe during cement displacement.
• Pull back slowly (20 ft/minute) to at least 500 ft above theoretical top of
the plug. Pulled out stands shall be hammered, cleaned and drifted after
lay-down on racks.
• Reverse circulate 2 times string capacity to clean the cement string
(except if tail pipe bottom is below Nahr Umr), Drop two 6” Foam balls
(with minimum 15 bbls of mud spacing) and circulate through string with
maximum allowable pumping rate for 1-1/2 string volume.

• In case if tail pipe bottom is below Nahr Umr, POOH above top of cement
(at least 500 ft), drop two 6” Foam balls (with minimum 15 bbls of mud
spacing) and circulate through string with maximum allowable pumping
rate for two cycles.
O Reverse circulation is not permitted across Nahr Umr to avoid string
plugging by shale cuttings/cavings.
O Reverse circulation may induce losses, or cause differential sticking
of the cementing string.
O 6” foam ball is applicable for all sizes of Drill pipes or Tubing
between 2-7/8” to 5-7/8”.
• Close pipe ram and squeeze cement at a maximum of 0.65 psi/ft, hold
pressure for 6 hours. This step is applicable only if mentioned in the
program.

• Bleed off (if there is any pressure) & POOH. During POOH Hammer every
stand. Lay down, clean & drift if any joint is not cleaned by foam balls.
Inspect, clean & drift all the x-overs used in cement string.

• Wait on Cement as required.

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1.3 Balanced Cement Plugs for Kick-off

Following are general notes for setting balanced cement plugs for kick-off
purpose;
• In soft formation e.g. Zone A or B, use 125 pcf normal G cement as kick-
off plug.
• For kick-off plugs in hard or medium hard formations, Sand cement slurry
with 142 pcf weight or Metallic ribbon reinforced slurry (e.g. Durastone)
with 147 pcf weight shall be used.

• Cement slurry should be mixed properly in the Batch mixer to get the
designed uniform slurry weight.
• In all types of kick-off plugs, a weighted spacer of 90 pcf shall be used
ahead and after of cement and volume shall be calculated as per balance
plug calculations.

• If the plug length is more than 600 ft, cement slurry of 125 pcf shall be
spotted below it as a carrier / foundation for the kick off plug.
• The cement string to be circulated clean by using 2 foam balls spaced by
mud as mentioned in clause 1.2 above.

• For kick-off plugs, cement shall be tagged and dressed as per program.

1.4 Balanced Cement Plug in Deviated Wellbore

A successful cement plugs in a deviated (30º-75º) wellbore require the
following conditions to be met.

• Reduce the density differential between the drilling fluid and cement.

• Increase the yield point or gel strength of the drilling fluid below the
cement plug.
• Place high viscous pill or stable reactive spacer pill between the cement
and the drilling fluid.

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2. Squeeze Cementing
2.1 Cementing through EZSV
Cement squeeze through retainer may be used when circulating cement
behind casing, between two sets of perforations is required.

2.1.1 Cement Squeeze through retainer for high injectivity.

• Rig up W/L BOP on 7" shooting nipple and test to 1000 psi.

• Set EZ-Drill cement retainer between the two sets of perforations

with W/L (avoid setting cement retainer against casing collar or the
final production packer setting depth).

• RIH EZ stinger with 1000 ft. of 2 ⅞" tubing on Drill pipe.

• Sting into EZ cement retainer. Check circulation through retainer,

by repeating volumetric communication test for 15 minutes each
way. If communication is not established as before, inform town.

• Keep stinger in retainer if injection rate is more than 2 BPM at 0.65

psi/ft or 1500 psi surface pressure.

• R/U circulating head and test cement lines to 3000 psi for 15
minutes.
• Mix and pump the designed cement volume and additives as per
cement recipe.

• Circulate ½ volume of cement through retainer at maximum 0.65

psi/ft. (do not squeeze for more than 15 minutes if unable to
circulate the above cement volume).

• Sting out and spot the rest of cement as balanced plug on top of
EZ-Drill retainer. Check for losses during job.
• POH 10 stands or to 50' below top of liner (above all perforations)
whichever is the case. Reverse out at a maximum pressure of 0.65
psi/ft or 1500 psi whichever is less recording any losses. POH one
more stand.

• Close rams and squeeze cement at 0.65 psi/ft or 1500 psi

whichever is less until lock up pressure is reached then increase
pressure to 0.75 psi/ft. or 2000 psi whichever is less. Hold
pressure for 6 hours.

Note:
If lock up pressure is not achieved, release pressure, check for
back flow and POH.

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• Release pressure, check and record back-flow, open rams, POH.

• RIH with appropriate bit and two junk subs, tag top of cement,
clean out to 50 ft. above top perforations.
• After total 24 hours WOC, drill out cement, cement retainer,
cement and RIH to PBTD. Circulated hole clean, POH.
Note:
If cement is still soft after 24 hours, stop DOC, circulate one cycle
and W.O.C. to complete 30 hours prior to clean out to PBTD.
• Trip with bit and scraper to PBTD. Circulate hole clean and
displace with new clean fluid.

• Repeat the communication test.

2.1.2 Cement squeeze through retainer for low Injectivity

Formation

To be made when communication rate is established at more than 0.5

BPM and less than 2 BPM at 0.65 psi/ft or 1500 psi surface pressure.

• Rig up W/L BOP on 7" shooting nipple and test to 1000 psi.

• Set cement retainer.

• RIH with stinger and 1000 ft. of 2 ⅞" tubing on DP.

• Circulate at 10 ft. above retainer for 15 minutes. Record circulation

rate and pressure. Sting into retainer and establish injection rate at
0.65 psi/ft or 1500 psi whichever is less. Record rate of injection
for 15 minutes.

• Sting out of retainer, circulate for 15 minutes.

• R/U circulating head and test cement lines to 3000 psi.

• Mix cement and pump down D/P the following:

O 5 Bbls 15% HCL with additives (this should be done in case of
iniectivity less than 0.5 BPM, otherwise acid is not necessary).
O 5 Bbls fresh water
O Cement with additives as per cement recipe
O 5 Bbls fresh water.
O Displace cement to 5 Bbls inside DP above the drillpipe to
minimize U-tube prior to sting in (use choke manifold if
required to control U-tube effect).

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• Sting into retainer, bullhead by pumping down D/P at 0.65 psi/ft. or

1500 psi whichever is less for a maximum duration of 15 minutes
or 1/2 the cement volume or lock up pressure whichever comes
first.
• Increase surface pressure gradually until reaching to 0.75 psi/ft. if
necessary.
• Sting out of retainer and spot the remainder of cement as
balanced plug of cement above retainer.

3. Cementing Through Coiled Tubing

3.1 Applications
Cementing through coiled tubing has different applications as follows:

• Isolate / Abandon perforations during multi-zone testing.

• Shut off gas or water production zone.

• Squeeze- off perforations riglessly prior to rig move.

• Horizontal hole abandonment

3.2 Slurry Design Criteria

• Low Rheological Values (PV & YP)

• Laboratory mixing energy = Field mixing energy

• Good slurry stability

• Minimum gellation under static downhole condition

• Safe thickening time (Optimized)

3.3 Placement Procedure

• Run with suitable gauge cutter to reconfirm Coiled Tubing accessibility.

• R/U and RIH with Coiled Tubing to the desired plug depth.

• Circulate coiled Tubing while RIH.

• Perform pull test every 3000 ft.

• Slow down Coiled Tubing running speed at any restriction.

• Circulate at the plug setting depth and at the same time observe the well
stability.

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• Pump 5 bbls fresh water followed by 7 bbls weighted spacer ahead of the
cement recipe.

• Pump the designed cement slurry until 2 bbls of cement exit from the
coiled tubing nozzles.
• Pump 5 bbls weighted spacer followed by 5 bbls fresh water.

• POOH w/ Coiled Tubing at a speed maintaining 2 bbls of cement

coverage above C.T nozzle.

• Continue displacing and spotting cement, POOH to 100 ft above the

T.O.C.
• Circulate above the top of cement.

• Wash down to the planned T.O.C.

4. Squeezing Off the Aquifers

Sealing off the aquifers (Dammam, UER and Simsima) with cement is normally done
prior to running and cementing tie-back casing.
The objective of sealing off the aquifers prior to running the tie-back casing is to
protect the casing from the corrosive action of aquifer water, and to avoid the erosion
resulting from the cross flow between the different aquifer perforations of Dammam,
UER and Simsima.

4.1 Procedure
• Isolate the reservoir perforation with either cement plug or Bridge Plug.
• RIH with 1000', 2 ⅞" tbg. tail pipe on 3 ½" DP to 50' below aquifer
perforations.
• Spot 500 SKS class "G" cement with a light weight cement (+ 95 pcf) as
balanced plug. POH 15 stands and flush string with location water.
• POH another 10 stands and W.O.C 6 hours.
• RIH with cementing string with circulation, tag T.O.C and repeat steps
above as required.
• RIH bit and clean out casing down to top of liner or as specified in well
programme.
• DO NOT test the squeezed off perforations. Observe well for losses or
flow.
Note:
If losses are more than 15 BPH, another cement plugs should be spotted as
above to cure losses.

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Volume-2/Chapter-2: Workover Operations

SECTION 7

SETTING INTERNAL CASING PATCH

This technique could be used in some water supply wells to seal off holes in corroded
surface casing to prevent sand entry to well.

A corrugated pipe 1/8" thick and plated with resin was mechanically expanded and set
across the corroded part of casing using special setting tool after the holes being squeezed
of with cement to isolate the aquifer water from contact with the patch.

1. Well Preparation

• RIH with bit and casing scraper. Clean out casing ± 100 ft below expected leak
point.
• Circulate with 54 pcf viscofied emulsion or as specified in well Program and test
casing to 500 psi. If leaking, proceeds to next step .
• Run casing packer and locate leak in casing by selective testing at 500 psi.

• Cure leak with ± 200 sks cement, (volume of cement will be determined based on
injectivity rate). Repeat steps above.

2. Procedure

• Lay out and prepare the casing patch (Welder to weld sections of patch to obtain
the required length).
• Pick up setting tool, extension bar and safety joint assembly.

• Pick up patch with tugger and strip onto extension bar.

• Make up cone, collet, and bullnose assembly, grease liberally.

• Lower patch into well and apply epoxy to outside of liner.

• Make up BHA comprising of:

1. Casing Patch
2. Setting tool
3. Single drill pipe
4. Impact sub
5. Single drill pipe
6. Drill pipe pup joint (master joint if required)
7. Drill pipe to surface
• Run in hole with patch (Medium speed whilst running to depth).

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• Pick up kelly and position patch (Taking up and down string weight).

• Slowly pressure up drill pipe, to set patch, Tool will stroke at approximately 1000
psi. Continue to pressure to 3000 psi, to assure full stroke.

• Bleed to zero pressure and leave bleeder open.

• Pull tool open at string weight. When tool is open, overpull will be encountered.
Continue to pull cone and collect through patch and set some. Overpull will be
approximately 40 klbs to 70 klbs, dependent on the condition of the casing. Pull
out of top of patch.

• Drop bar and shear out impact sub pin.

• Pull out, break and lay down tools.

• Test casing to 500 psi. If OK proceed to well programme.

Important Note:

Setting casing patch will result in reducing the casing inside diameter by more than
0.25 inches. (I.e. 13.3/8 csg patch will reduce the ID of 13.3/8, 68 lbs/ft from 12.415
to 12.115 so that 12.1/4 bit will not pass).

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SECTION 8

SECURING WELL WITH SHALLOW SET CASING PACKER

3. When to Secure the Well

Securing the well with kill string and casing packer hanged at shallow depth is
required prior to performing the following operations.

• Repairing or changing a BOP element which would not allow shutting-in the well
in case of a kick.
• Repairing of the upper casing or tubing spool which would not allow shutting-in
the well in case of a kick, even if the repair does not require any welding or torch
cuttings.

• Changing the upper casing or tubing head spool.

• Any welding or torch cutting on the wellhead, even if the fluid in hole does not
contain hydrocarbons, and the well is overbalanced with drilling fluid
• Any urgent well suspension needs.

4. Minimum Barriers Requirements

It is preferable to carry out the required wellhead repairs immediately after a remedial
cement jobs or liner cementing job. Refer to the table bellow for the minimum barriers
requirements:

Table 2- 6: Techniques used for different remedial applications

Water Injectors Oil Wells Gas Wells

(Except Bab Mid (and Bab Mid Dip Injectors) Producer, Injectors
Dip Injectors)
2 Barriers 3 Barriers 3 Barriers
(1 Mechanical (2 Mechanical & 1 Hydraulic) (2 Mechanical & 1 Hydraulic)
and 1 Hydraulic)
Cemented casing with non drilled shoe track is a Barrier that
can substitute the 2 Mechanical Barriers

5. Safety Precautions
Prior to commencing welding / cutting operations after removing old tubing head
spool, the following safety measures must be considered as minimum:

• Test fire fighting unit prior to the job, keep it ready during the whole job.

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• Clean well cellar and cover with dry sand.

• Displace the top 5 ft inside casing with foam, circulate through wing valves.
Check for any effluents.

• Safety officer (drilling) to confirm the cellar is free of gas prior to any welding.

• Issue hot work permit

6. Securing Well Procedure

This operation must be planned to be carried out during a programmed day time trip
(bit change or POH / RIH open ended pipe after cement job).

• Make up the 9 ⅝” casing packer.

• Make up the SC-SSSV onto the top of casing packer. Ensure that the threaded
joint between the seal mandrel and the upper body of the SC-SSSV is only hand
tight. Check the rating of the safety plug shear pin if rated to 1500 or 3000 psi,
and record same in daily report (Note that the 3.72" size SC-SSSV uses only
1700 psi shear pin).
• Install the DP rubber wiper plug over the string to avoid dropping of foreign matter
on top of the packer and RIH casing packer to approximately 300 feet below
rotary table. Break circulation a few minutes. Record the string handling weight
with and without circulation.

• Set the casing packer and pressure test above the packer to 2000 psi. Slack off
the total string weight of string below packer, after the pressure test.
• The casing packer mandrel must have adequate strength to support the weight of
drill pipe or tubing string. The 9 ⅝” casing tensile and burst capacity must be
strong enough to withstand the addition of the string weight below the packer and
the pressure test load above the packer, even if the casing is not cemented
behind.
• As the SC-SSSV is a combination of safety valve and back-off safety joint:
1. Apply left hand rotation to close the balanced valve inside the SSC tool. At
this stage the SC-SSSV being closed will retain any amount of pressure
from below the packer AND ONLY 1500 or 3000 psi pressure from above
because of limited shear rate capacity of the safety plug inside the SSC
tool.
2. By applying further left hand turns the string will unscrew and release from
the safety joint. A total of 20 turns are required to close and unscrew the
3.72" size SC-SSSV while 22 turns are required for the 4.3/4" and 6 ⅛"
SC-SSSV.
3. Pick up one foot and pressure test the annulus above the packer to 1000
psi to ensure the SC-SSSV is closed. Spot clean viscous mud pill above
S.G. ADM Volume-2 Page
Date Issued: 30/03/2009 Last Revision:
Rev-00/09 Drilling Operation -B 2-78
Printed on: 19/08/2008
 ADCO
the packer (about 25 bbls in case of 9 ⅝” casing). Record the
DRILLING MANUAL
exact backed-off string weight and POOH.
Volume-2/Chapter-2: Workover Operations
• Proceed with the required repairs or other work to be carried out after having
taking all surface safety precautions, like removing/ cleaning all hydrocarbon
fluids from the cellar, issuing Hot Work Permits if welding or torch cutting, etc.
are required, or proceed with well abandonment program after closing the BOP,
if this is the case.
Notes:
O Any welding on wellhead or casing has to be done by Production
Operations
Division's certified welder.
O All welds on casing must be X-rayed and approved by Production
Operations
Division before proceeding further with the job.
O Production Operations Division must be notified 24 hours in advance if
any welding on casing is required.
O If any component of the BOP stack or the wellhead has been removed,
opened, or changed, each of above element must be re-pressure tested
after nippling up.
• When the repairs are completed, or the temporary abandonment is over; RIH
the same backed off string to the top of the SC-SSSV above the casing packer.
Pick up the Kelly and break circulation a few minutes. Engage the mandrel
inside the SC-SSSV without circulation. Use the drill pipe rubber wiper
plug around the string while RIH to prevent dropping of foreign matters down
the hole on top of packer.
O Apply same amount of right hand turns as in disconnecting step to
reconnect and to open the balanced valve inside the SSC tool and equalize
pressure on both sides of the packer.
O Unset the casing packer and circulate bottom up to ensure the hole is safe.
Notes:
O If unable to unset the casing packer because the SC-SSSV is not opened,
so that the pressures above and below the packer are not equalized,
pressure up the string to the shear pin capacity and pump out the safety
plug then unset the packer Circulate bottoms up to ensure hole is safe.
O When necessary to perform wireline operations through the SC-SSSV after
it is re-opened, the safety plug in the bottom of the valve can be knocked
out with a sinker bar, this would provide an unobstructed opening through
the tool. It is also possible to pump out this plug when the valve is closed
as already said in note above.

• POOH casing packer to surface without rotating the string. Lay down SC-
SSSV
and casing packer and proceed with program.

Printed on: 19/08/2008