8/27/99 page 5-1 SAUDI ARAMCO Coiled Tubing Manualctes.nov.com/Documentation/manuals/CTManual/download... · Web viewHydrostatic test data including test fluid, pressure, duration

Sample Specificationsfor

Coiled Tubing (CT) Operations

November 2000

Sample Specificationsfor

Coiled Tubing (CT) Operations

Table of Contents

1. Introduction...............................................................................................................12. CT String Specifications............................................................................................13. CT Units Specifications.............................................................................................3

3.1. General Specifications for CT Units...................................................................33.2. CT Work Reel....................................................................................................43.3. Injector Head.....................................................................................................43.4. CT Unit Operator’s Control Cabin......................................................................53.5. CT Weight Sensor(s).........................................................................................53.6. CT Depth Counter(s).........................................................................................63.7. Data Acquisition System (DAS).........................................................................6

4. Pressure Control Equipment Specifications..............................................................64.1. Primary Components.........................................................................................74.2. Ancillary Well Control Equipment.......................................................................74.3. Secondary Components....................................................................................74.4. Pressure Control Equipment Logbook...............................................................84.5. Spare Parts........................................................................................................8

5. Bottom Hole Assembly (BHA) Specifications............................................................96. Auxiliary Equipment Specifications...........................................................................9

6.1. Power pack......................................................................................................106.2. Fluid/Nitrogen Pumping Unit(s)........................................................................106.3. Chicksan Connections.....................................................................................106.4. Chemical/Nitrogen Tanks.................................................................................106.5. Mixing Tanks....................................................................................................106.6. Downhole Motors.............................................................................................10

7. CT Simulators Specifications..................................................................................107.1. CT String Selection..........................................................................................117.2. Parametric Sensitivity......................................................................................117.3. CT Simulator Output........................................................................................11

8. CONTRACTOR Personnel Specifications..............................................................118.1. Minimum CONTRACTOR Personnel Qualifications........................................128.2. Training............................................................................................................12

9. CONTRACTOR Job Proposal.................................................................................1210. Preparation and Testing of CT Equipment..........................................................14

10.1. Equipment Preparation.................................................................................1410.2. Pressure Testing..........................................................................................16

11. General CT Operations Procedures....................................................................1611.1. Rig Up..........................................................................................................16

11.2. Well-Site Pressure Testing...........................................................................1711.3. General Operating Requirements................................................................1711.4. Safety Equipment Specifications..................................................................1811.5. Safety Procedures........................................................................................18

12. Post-Job Reporting Requirements......................................................................1913. CT Services General Requirements....................................................................20

Minimum Acceptable CT SpecificationsSAMPLE

1. IntroductionCOMPANY plans to drill 33 production wells offshore. These wells will typically reach to a measured depth of 15,000 ft, have maximum wellhead pressure of 3250 psi, and have long tangent sections with inclination up to 75º.

The successful CONTRACTOR shall provide one (1) fully-equipped, skid-mounted CT unit capable of operating with 15,000 of 1.75-in and 2.00-in OD CT, ancillary equipment and tools, and associated operating personnel on a call-out basis for COMPANY’S WORK program.

This document provides minimum acceptable specifications for equipping, planning, and conducting COMPANY’s CT operations in the development project.

2. CT String Specifications1. CONTRACTOR shall use a CT simulator (see Section 7) to determine the OD,

wall thickness (taper), and material yield strength of the CT string(s) required for the proposed operation. The minimum design criteria for each CT string are:1.1. OD at least 1.75 in1.2. Adequate mechanical strength such that:

Maximum von Mises equivalent (VME) stress in the CT string is less than 80% of the material yield strength ( VME < 0.8Y )

Calculated collapse pressure (Pc) at the maximum expected tension is greater than 125% of the maximum possible wellhead pressure (Pc > 1.25 x WHPmax)

1.3. Maximum accumulated fatigue in the CT string at the end of the proposed operation will be less than 80% of its predicted working life.

2. All CT strings offered by CONTRACTOR for the first of COMPANY’s proposed work shall be less than 12 months out of the mill and unused for any other job.

3. The CT strings contracted to perform the CT operations shall be capable of performing all aspects of the proposed work to the full measured depth of the well without splicing separate, shorter strings.

4. Each CT string shall have a mill certificate or other appropriate documentation containing the following information, as a minimum:4.1. Manufacturer’s name 4.2. Date and location of manufacture4.3. Manufacturer’s serial number or other inventory control number4.4. Total length of the string and length(s) of each wall thickness section4.5. Master coil and heat numbers for each strip in the string4.6. Mechanical properties of each strip in the string

4.6.1. Thickness4.6.2. Yield strength (Y)4.6.3. Ultimate tensile strength4.6.4. Percent elongation in 2-in gage length

CTES, L.C. November 2000 Page 1 of 21


4.6.5. Hardness4.7. Chemical analysis of each strip in the string4.8. Location of each bias weld4.9. Results of X-ray analysis on each bias weld4.10. Hydrostatic test data including test fluid, pressure, duration of test4.11. Procedure used to dry out the CT prior to storage/shipment

5. The combined lifting weight of any CT string and its reel shall not exceed 45,000 tonnes, or CONTRACTOR shall present detailed plans for supplying the length of CT necessary and the method for delivering it to a work reel for the proposed job.

6. CONTRACTOR shall create and maintain a logbook or file for each CT string. Each entry in the log shall be approved and signed by CONTRACTOR’s Quality Assurance Manager. The log shall contain the following records, as a minimum:6.1. Inspections, non destructive tests, and hydrostatic tests6.2. Repairs and welds with results of non destructive tests and/or certification

of fitness for service6.3. Each job performed with a cross reference to appropriate files from CT

unit DAS (see Section 3.7)6.4. Exposure to corrosive fluids and gasses

6.4.1. Duration of exposure6.4.2. Composition of the corrosive environment6.4.3. Temperature and pressure of the corrosive environment6.4.4. Steps taken to protect CT against corrosion before a job and to

neutralize corrosion after the job6.5. Accumulated fatigue for each 10-ft section of the string at the end of each

job6.6. Maximum tension and depth of occurrence for each job6.7. Maximum pressure and depth of occurrence for each job6.8. Fluid(s) pumped and volume(s) pumped for each job6.9. Procedure for drying the CT string prior to storage6.10. Method, location, and duration of storage since last use

7. The length of the CT string must be at least 1000 ft greater than the maximum target depth (TD) planned for the job.

8. The tubing connection to the CT reel plumbing shall be a welded fitting. The weld must conform to the CT manufacturer’s weld procedure specification and successfully pass magnetic particle and dye penetrate inspections.

9. Advanced CT life monitoring software is the only acceptable method for tracking the working life of CT strings for COMPANY’s CT operations.

10. CONTRACTOR shall retire strings from CT operations upon any portion of the string reaching 80% of its predicted working life.

11. Contractor shall derate the fatigue life of butt welds in CT work strings by at least 50% compared to the fatigue life of virgin tube.

12. CONTRACTOR shall remove a CT string from further consideration for CT operations if any section of the string no longer has adequate mechanical strength per Section 2, Item1.2 for the expected operating conditions.

13. Spare parts



13.1. 2 tubing connectors for each different threaded connection for the BHAs planned for the job (see Section 5 for the connector requirements)

13.2. 2 tube-to-tube connectors to temporarily splice the CT between the guide arch and CT reel. Temporary connectors shall be spoolable and able to hold securely to the CT with a minimum of 5000 lbs tension.

3. CT Units SpecificationsEach CT unit contracted to perform the CT operations shall be capable of carrying out all aspects of the proposed work. The CT unit shall be rated for Operating Zone II.

3.1. General Specifications for CT Units1. Each CT unit shall include a CT work reel incorporating:

1.1. The reel (see Section 3.2)1.2. Reel support structure or cradle1.3. Reel drive/brake mechanism1.4. Swivel and piping manifold with electronic pressure sensor1.5. Level wind1.6. Depth counter(s) (see Section 3.6)

Note: An additional depth counter can be mounted on injector head2. Each CT unit shall include an injector head incorporating:

2.1. Injector (see Section 3.3)2.2. Injector support stand, jacking frame, or wellhead connector2.3. Gooseneck or guide arch2.4. Side-door type stripper (see Section 4.1)2.5. Weight sensor (see Section 3.5)2.6. Depth counter(s) (see Section 3.6)

Note: Depth measurement at the injector head is optional.3. Each CT unit shall include an operator’s control cabin incorporating:

3.1. Power pack remote controls3.2. Injector head controls3.3. Work reel controls3.4. Blowout Preventer (BOP) and stripper controls

Note: The BOP controls shall have a means of preventing accidental operation of the BOP rams.

3.5. Displays (gages) of key operating parameters (see Section 3.4)3.6. Data Acquisition System (DAS) (see Section 3.7)3.7. Air conditioning unit capable of maintaining the cabin temperature at 32 ºC

with ambient temperature of 40 ºC and relative humidity of 100%.3.8. Adequate overhead lighting

4. The CT unit shall be skid-mounted for offshore operation.5. The CT unit shall be capable of functioning continuously at its rated capacity with

ambient temperature of 40 ºC and relative humidity of 100%.



6. The lifting weight of the CT unit shall not exceed 45,000 tonnes, or CONTRACTOR shall present detailed plans for separating the CT unit into modules that weigh less than this limit.

7. CONTRACTOR shall create and maintain a logbook or file for each CT unit. Each entry in the log shall be approved and signed by CONTRACTOR’s Quality Assurance Manager. The log shall contain the following records, as a minimum:7.1. Inspections, calibrations, hydrostatic tests7.2. Repairs and routine maintenance with certification of fitness for service7.3. Each job performed with a cross reference to appropriate files from the

DAS

3.2. CT Work ReelThe CT work reel offered for the proposed work shall meet the following minimum requirements.1. Capacity for any CT string required for the proposed work.2. Depth counter(s) (see Section 3.6)3. Minimum core diameter to CT OD ratio of 40:1 (e.g., the minimum core diameter

for 1.75-in CT is 70 in).4. All plumbing (piping) components installed on the reel shall be the integral type

with a maximum allowable working pressure of at least 10,000 psi. 5. The work reel shall have an electronic pressure sensor at the reel inlet accurate

to plus (+) and minus (-) 5% of actual pressure.6. The work reel shall incorporate or accommodate an electrical connector or slip-

ring assembly for CT with internal E-line.7. The spare parts kit on location for reel assemblies shall include the following

items:7.1. Packing kit for the high pressure swivel7.2. Depth counter head assembly 7.3. Drive pawl for the level wind assembly7.4. 2 rollers for the level wind head, sized for the CT string being run7.5. 1 spare pressure sensor for the reel inlet

3.3. Injector Head The injector head offered for the proposed work shall meet the following minimum requirements.1. Capacity for CT OD of 1.75 in and 2.00 in2. Minimum performance capability of 60,000 lbs pull and 12,000 lbs push

(snubbing)Note: Performance based on 1.75-in OD x 0.156-in wall CT with Y = 80,000 psi and WHP = 3500 psi. In the absence of pressure, the tensile force to yield the CT is 62,500 lbs. At 3500 psi, the pressure area force is 8,420 lbs. Assuming 3000 lbs of drag force at the stripper, the snubbing force would be about 11,500 lbs.3. Capability to move the CT string at a speed of 150 ft/min in each direction4. Bi-directional (tension and compression) weight sensor(s) (see Section 3.5)



5. Depth counter(s) - optional8. Minimum guide arch radius of 48 times the CT OD (e.g., the minimum radius for

1.75-in CT is 84 in).9. The system for gripping the CT shall not slip on the CT nor damage the CT at the

maximum rated pull and push. Note: Damage to the CT is any mechanical gouging or increase in ovality that reduces the collapse rating of the tubing by more than 5% compared to undamaged tubing as calculated by the method of Timoshenko or API RP 5C7.10. CONTRACTOR shall post a plot of applied tension and applied compression

force vs. skate ram pressure for the injector used for the job in the CT unit control cab.

11. The injector head hydraulic system or motors shall incorporate pressure relief valves or other means of positively limiting the maximum pulling force to a predetermined value.

12. The spare parts kit on location for the injector head shall include the following items:12.1. 1 spare pressure sensor or electronic load cell for CT weight 12.2. 1 depth counter, if so equipped12.3. 1 set of guide arch rollers or wear shoes for the CT size used for the job12.4. 1 hydraulic skate ram

3.4. CT Unit Operator’s Control CabinThe CT operator’s control cabin shall contain displays (gages) to present the following information to the operator, as a minimum:1. CT depth2. CT weight3. CT running speed4. CT reel inlet pressure5. Wellhead pressure (WHP)6. Stripper pressure7. Injector skate pressure or gripping force8. Injector chain tension9. Reel back tension10. Hydraulic system pressure11. Power pack engine RPM

3.5. CT Weight Sensor(s) 1. The weight sensor(s) shall be capable of measuring the full range of snubbing

(compressive) and pulling (tensile) forces applied by the injector head to the CT.2. The sensor(s) shall provide an electronic signal proportional to the CT weight that

can be recorded by the DAS and displayed in the CT unit control cab.3. The sensor(s) shall have an accuracy of ±5% of the reading.



3.6. CT Depth Counter(s) 1. The depth counter(s) shall be capable of measuring the full length of the CT

string.2. At least one counter shall provide an electronic signal proportional to the length

of CT passing through the counter that can be recorded by the DAS and displayed in the CT unit control cab.

3. At least one counter shall be a mechanical type.4. The counter(s) shall have a display resolution of ±1 ft.5. At least one spare mechanical counter and a spare electronic encoder shall be

on location during the job.

3.7. Data Acquisition System (DAS) 1. The DAS shall be a computer-based system capable of recording and displaying

the following data:1.1. Time1.2. CT depth1.3. CT weight1.4. CT reel inlet pressure1.5. Wellhead pressure (WHP)1.6. Stripper hydraulic pressure1.7. Fluid flow rate into the CT

2. Pressure, flow rate, and volume measurements shall have an accuracy of at least ±5% of the reading.

3. The DAS shall provide real-time digital displays, trend (historical) records of the data, and alarms for operating data outside preset limits.

4. The DAS shall provide the CT operator with a real-time indication of VME stress in the wall of the CT (at a specific location) relative to the yield strength of the material and/or safe operating limit.

5. The DAS shall be capable of comparing the current CT weight with planned values at any point in the operation.

6. The DAS shall present a real-time display of fatigue accumulation in the CT string and provide the operator with a means to rapidly determine the status of the remaining working life for the string.

7. The DAS shall be capable of creating a data file for each job in a format that can be read with commonly available software such as MS Excel or MS Word.

8. The spare parts kit on location for the DAS shall include 1 spare pressure sensor for the wellhead.

4. Pressure Control Equipment Specifications1. The pressure control equipment stack shall consist of the following sections, from

the top down:1.1. Primary1.2. Ancillary, if so equipped1.3. Secondary



2. All pressure control equipment shall have a maximum allowable working pressure of at least 10,000 psi.

3. Minimum bore diameter shall be 3.06 in4. All connections shall be flanged or quick-connects. No threaded connections are

acceptable for COMPANY’s CT operations.5. All pipe and pipe/slip combination rams shall have equalization capabilities.6. CONTRACTOR shall post a detailed schematic of the pressure control

equipment stack at the CT unit control cab

4.1. Primary Components1. The primary pressure control equipment shall consist of a side-door stripper

(typically mounted on the injector head)2. Stripper packing elements and anti-extrusion rings

2.1. Shall be OEM supplied (except per item 2.2 immediately below)2.2. Products from non-OEM suppliers are acceptable only if physical test data

demonstrates that their performance meets or exceeds the performance of the corresponding OEM product.

2.3. Rated for 5000 psi and at 150 ºF

4.2. Ancillary Well Control EquipmentRiser sections for accommodating long BHA assemblies shall be installed between the primary and secondary pressure control components. Ancillary well control equipment shall have the same materials requirements and pressure ratings as the other pressure control equipment.

4.3. Secondary Components1. The secondary pressure control equipment shall consist of a quad blowout

preventer (BOP) with the following configuration, as a minimum, from the top down:1.1. Blind rams1.2. Shear rams1.3. Side outlet port1.4. Slip rams1.5. Pipe rams

Note: Combination rams can be used in place of single function rams if the BOP body will accommodate them.2. BOP elastomers and seals

2.1. Shall be OEM supplied (except per item 2.2 immediately below)2.2. Products from non-OEM suppliers are acceptable only if physical test data

demonstrates that their performance meets or exceeds the performance of the corresponding OEM product.

2.3. Rated for 5000 psi and at 150 ºF



3. The BOP rams shall operate from accumulators. The hydraulic accumulator system shall have sufficient volume, with the hydraulic charge pump inoperative, to perform the following BOP operations:3.1. Close the slip rams3.2. Close the pipe rams3.3. Close the shear rams and shear the CT3.4. Close the blind rams3.5. Open all well control stack rams3.6. Close all well control stack rams

4. The accumulator system must have the capability of performing the operations described in item 3 immediately above at a WHP of 3500 psi.

5. The BOP ram operating controls shall prevent accidental operation of the shear and blind rams.

6. The BOP ram operating mechanisms shall be capable of locking in “closed” position.

7. Slip rams shall be capable of securely holding the CT against:7.1. A downward force that would yield the tubing7.2. An upward force of 10,000 lbs

8. Shear rams shall be capable of efficiently severing the thickest wall section of the CT string used for the job. If wireline is installed in the tubing, the shear rams must be capable of efficiently severing both the CT and the wireline.

4.4. Pressure Control Equipment LogbookCONTRACTOR shall create and maintain a logbook or file for each component of pressure control equipment. Each entry in the log shall be approved and signed by CONTRACTOR’s Quality Assurance Manager. The log shall contain the following records, as a minimum:1. Inspections, non destructive tests, hydrostatic tests2. Repairs, parts replacements, and routine maintenance with certification of fitness

for service3. Each job performed with a cross reference to appropriate files from the DAS4. Any operation of BOP pipe rams or shear rams where rams contacted the CT5. Exposure to corrosive fluids and gasses

5.1. Duration of exposure5.2. Composition of the corrosive environment5.3. Temperature and pressure of the corrosive environment5.4. Steps taken to protect pressure control equipment from corrosion before

job and to neutralize corrosion after job

4.5. Spare PartsThe spare parts kit on location for the pressure control equipment shall include the following items:1. Primary equipment

1.1. 5 stripper/energizer elements for the stripper used



1.2. 2 sets of anti-extrusion rings for the stripper used1.3. 1 complete set of wear bushings for the packoff assembly on the stripper

used.2. Secondary equipment

2.1. 2 sets of blind ram inserts 2.2. 2 sets of pipe ram inserts 2.3. 1 set of shear rams 2.4. 1 set of slip rams 2.5. 1 set of bonnet seals and o-ring redress kit for each ram 2.6. 2 redress kits for the equalizing valves

3. Connections - 1 full set of replacement seals for each connection

5. Bottom Hole Assembly (BHA) Specifications1. All BHAs for COMPANY’s CT operations shall include a dual flapper-type check

valve assembly. The seals (elastomer or metallic) used in the check valves must be rated for the bottom hole temperature and the fluids pumped through the CT.

2. The tubing connector used to attach the BHA to the CT shall be capable of withstanding a tensile force equivalent to the product of the cross sectional area of the CT times the lesser of 3500 psi or 125% of the maximum WHP.

3. Disconnect (release tool)3.1. Any BHA required to apply an axial force during operation shall include a

means of disconnecting the tool from the BHA.3.2. The BHA shall include a hydraulic or electrical disconnect whenever the

predicted maximum overpull available at the maximum expected TD is less than the force required to operate a mechanical disconnect.

3.3. The disconnect shall allow pressure testing of the BHA during rig up without separating the tool.

4. CONTRACTOR shall prepare detailed fishing diagrams prior to running any BHA into the wellbore.

6. Auxiliary Equipment Specifications1. All auxiliary equipment shall be rated for Operating Zone II.2. The lifting weight of any auxiliary equipment shall not exceed 45,000 lbs, or

CONTRACTOR shall present detailed plans for separating the auxiliary equipment into modules that weigh less than this limit.

3. CONTRACTOR shall create and maintain a logbook or file for each component of auxiliary equipment. Each entry in the log shall be approved and signed by CONTRACTOR’s Quality Assurance Manager. The log shall contain the following records, as a minimum:3.1. Inspections, non destructive tests, hydrostatic tests3.2. Repairs, parts replacements, and routine maintenance with certification of

fitness for service3.3. Each job performed with a cross reference to appropriate files from the

DAS



6.1. Power packThe CT unit power pack shall have the following capabilities:1. Continuous operation at full power2. Supply hydraulic fluid simultaneously to the attached equipment3. Emergency shut-down from inside the CT unit control cab

6.2. Fluid/Nitrogen Pumping Unit(s)1. Each pumping unit designated for the job shall conform to the requirements of

the COMPANY’s Job Program.2. All pumping units shall have a properly certified pressure relief device installed.

6.3. Chicksan ConnectionsAll chicksan connections shall be rated for 3500 psi at 150 ºF.

6.4. Chemical/Nitrogen Tanks1. Each chemical and nitrogen tank designated for the job shall conform to the

requirements of the COMPANY’s Job Program. 2. All chemical and nitrogen tanks shall meet COMPANY’s requirements for the

following tests:2.1. Vacuum2.2. Pressure relief valve opening pressure2.3. Piping and valves pressure integrity

6.5. Mixing TanksEach mixing tank designated for the job shall conform to the requirements of the COMPANY’s Job Program.

6.6. Downhole MotorsEach downhole motor designated for the job shall conform to the requirements of the COMPANY’s Job Program.

7. CT Simulators SpecificationsCONTRACTOR shall have engineering support in Angola equipped with a CT simulator used for modeling proposed CT operations. The CT simulator shall be capable of providing the following results, as a minimum:

1. The forces and stresses for each segment in a CT string 2. The buckling condition for each segment in a CT string 3. Safe mechanical operating limits for the CT 4. The pressure distribution around the fluid flow path for a given flow rate or an

estimate of the flow rate for given pump pressure 5. The accumulated fatigue damage in each segment of the CT string prior to and

after the proposed job



7.1. CT String SelectionCONTRACTOR shall use a CT simulator to determine what CT string(s) will have adequate mechanical strength and fatigue life to perform the proposed operation(s). CONTRACTOR shall model the operation(s) with a CT simulator to determine suitable outside diameter (OD), wall thickness, and material strength for the CT string.

7.2. Parametric SensitivityCONTRACTOR shall use a CT simulator to determine the ranges of operating conditions that pose the lowest risk of failure. As a minimum, CONTRACTOR shall determine the sensitivity of the proposed CT operation to:

1. CT buoyancy (affects drag and buckling)2. Friction coefficient (Cf) versus depth (affects drag)3. Axial force applied at the BHA

3.1. Set down weight (SDW) - affects lockup3.2. Overpull - affects mechanical limits

4. Wellhead pressure (WHP) - affects collapse

7.3. CT Simulator OutputThe following CT simulator results are required for each CT operation:

1. Predicted CT weight indicator reading versus depth during running into hole (RIH) and pulling out of hole (POOH)

2. The distribution of axial forces acting on the CT string when it is static at a given depth

3. The distribution of stresses in the CT string when it is static at a given depth4. The maximum SDW and overpull available at a given depth5. Working life remaining in each segment of the CT string after the proposed

operation plus contingency trips6. For hydraulic operations at a given depth, the maximum flow rate possible for a

given pump pressure7. For hydraulic operations, the relationship between pump pressure and flow rate

versus depth

8. CONTRACTOR Personnel SpecificationsCONTRACTOR shall provide the qualifications for personnel offered for the proposed work. CONTRACTOR shall include the CV of the following personnel:

Manager for Operations in Angola Lead Supervisor for Operations in Angola Shop Supervisor Base Manager Manager for Engineering Manager for Quality Assurance and Maintenance



Manager for Training

8.1. Minimum CONTRACTOR Personnel Qualifications

1. CONTRACTOR engineering support personnel shall have a minimum of five (5) years experience with CT operations, be proficient with CT job planning, and be capable of performing computer-aided job design and evaluation as described in Section

2. The CONTRACTOR operations supervisor on location shall meet the following minimum requirements:2.1. Ten (10) years experience with CT operations 2.2. Two (2) years previous supervisory experience2.3. Ability to operate all of the CT equipment listed in Section 32.4. A working knowledge of all aspects of the computer simulations and the

DAS used for the job3. CONTRACTOR CT operators at the work site shall have a minimum of (5) years

experience with CT operations 4. In the event a CONTRACTOR REPRESENTATIVE at the work site is unable to

perform his/her duties adequately, CONTRACTOR shall replace that person or remedy the situation to COMPANY’s satisfaction at the sole expense of CONTRACTOR.

8.2. Training1. CONTRACTOR personnel on location shall be properly trained to:

1.1. Perform their required duties1.2. Operate the well control equipment (supervisors)1.3. Safely handle all treatment fluids planned for the job1.4. Operate any safety equipment required for their job1.5. Speak and read English fluently enough to understand the job procedures

and safety procedures2. Well control training for workover operations from a source accredited by the

IADC or approved by COMPANY is required for:2.1. CONTRACTOR supervisor on location2.2. Any CONTRACTOR personnel authorized by their company to operate

well control equipment3. Basic first aid training from a source approved by COMPANY is required for the

CONTRACTOR supervisor on location.

9. CONTRACTOR Job ProposalAs part of the planning process for each COMPANY CT operation, the CONTRACTOR shall submit a job proposal for COMPANY’s approval that includes the following elements:

1. CT simulator input and results



2. Surface equipment proposed for the job2.1. CT string 2.2. CT reel2.3. Injector head and guide arch2.4. CT weight sensor(s) 2.5. CT depth counter(s) 2.6. Pressure control equipment2.7. Data acquisition system (DAS) 2.8. Power pack2.9. Auxiliary equipment

2.9.1. pumps2.9.2. compressors2.9.3. tanks2.9.4. special tools

3. BHA specifications (include a drawing)3.1. Function3.2. Components3.3. Dimensions3.4. Weight3.5. Operating characteristics

3.5.1. mechanical3.5.2. hydraulic

3.6. Forces generated by the BHA3.6.1. lateral - arms, centralizers, or pads3.6.2. axial – jars, setting tools3.6.3. torque – motor, indexing tool, orientor

3.7. Required axial forces – SDW and overpull4. Treatment fluid(s)

4.1. Density4.2. Viscosity4.3. Composition4.4. Hazards to personnel and equipment

5. Chronological list of major events (a detailed procedure)6. Data acquisition and real-time monitoring 7. Safety issues and precautions

7.1. Well control7.2. Treatment fluid(s)7.3. Equipment hazards

8. Risk analysis for their operations8.1. Potential problems and risk (based on previous experience and the CT

simulator results)8.2. Contingency plans8.3. Emergency procedures

9. Environmental safeguards10. QA plan for the job



11. Manpower requirements12. Cost estimate

10. Preparation and Testing of CT Equipment CONTRACTOR shall provide the detailed specifications for preparation and testing of CT equipment offered for the proposed work. Preparation and testing shall meet the following minimum requirements.

10.1. Equipment PreparationThis section presents COMPANY’s minimum requirements for preparing and testing equipment proposed for COMPANY’s CT operations. The CONTRACTOR shall prepare and test all equipment in accordance with these requirements prior to mobilizing the equipment to the job location. Record all inspections and tests results in the log for that equipment.

1. Verify that the CT string’s fatigue history is current. If it cannot be made current, then reject the CT string for the planned operation.

2. Conduct routine maintenance on the CT reel per manufacturers' specifications. 3. Injector Head

3.1. Inspect the equipment and conduct routine maintenance per manufacturer's specifications. Use only OEM replacement parts or their equivalent approved by COMPANY.

3.2. Ensure that all gripper blocks are the correct size and in good condition.3.3. Operate the injector head and ensure it performs all required functions.3.4. Verify proper operation of the weight indicators in both pipe light and pipe

heavy modes with the DAS operating3.5. Stripper

3.5.1. Replace stripper elements as necessary. 3.5.2. Verify that the stripper element material is suitable for the

application. 3.5.3. Replace the backup rings, bushings, and other components as

necessary. 4. BOP Stack

4.1. Inspect the BOPs and conduct routine maintenance per manufacturer's specifications. Use only OEM replacement parts or their equivalent approved by COMPANY.

4.2. Operate the BOP and ensure that each set of rams functions properly achieving full travel in each direction.

4.3. Verify that the shear rams are capable of shearing the thickest wall section of the CT string selected for the job. The best approach is to actually shear a sample of the CT. A shear test is mandatory:4.3.1. For CT containing an electric cable 4.3.2. After rebuilding or servicing the hydraulic cylinders



Note: After each shear test, inspect the blades for damage and replace them as necessary.

4.4. Ensure that each ram position indicator functions properly.4.5. Ensure that each ram manual lock functions properly.4.6. Pressure test the BOP body per Section 10.2.4.7. Close and lock the blind rams and pressure test them from below. Record

the results in the equipment log. Equalize the pressure across the blind rams before opening them.

4.8. Insert a test bar through the pipe and slip rams, close and lock both sets of rams, and pressure test the pipe rams from below. Record the results in the equipment log. Equalize the pressure across the pipe rams before opening them.

5. DAS5.1. Configure the DAS displays to show the expected data with proper scaling5.2. Set the operating limits per the COMPANY Job Program.5.3. Verify that the annunciators (alarms) are functioning.

6. BHA6.1. Inspect equipment and conduct routine maintenance per manufacturers'

specifications.6.2. Whenever possible, operate the BHA components and ensure they

perform all required functions.6.3. Check all connectors and crossovers for compatibility with mating

components.6.4. Confirm that all flow paths and nozzles are open.6.5. Verify that the disconnect, if so equipped, has the correct internal

components properly installed and will separate in the manner prescribed by the COMPANY Job Program.

6.6. Verify that the check valves operate freely.7. Power Packs

7.1. Inspect equipment and conduct routine maintenance per manufacturers' specifications.

7.2. Operate the power pack and ensure it performs all required functions.7.3. Verify that the shutdown systems operate properly.

8. Fluid/Nitrogen Pumping Unit(s)8.1. Inspect equipment and conduct routine maintenance per manufacturers'

specifications. 8.2. Operate each pumping unit and ensure it performs all required functions.8.3. Verify that each pumping unit has a properly certified pressure relief

device installed.9. Chicksan Connections

9.1. Inspect all chicksan components and replace joint seals as required.9.2. Inspect all tie-down equipment and repair it as needed.

10. Chemical/Nitrogen TanksInspect equipment and conduct routine maintenance per manufacturers' specifications. 11. Mixing Tanks



11.1. Inspect equipment and conduct routine maintenance per manufacturers' specifications.

11.2. Operate the mixing equipment and ensure it performs all required functions.

11.3. Remove drain plug(s), inspect, and clean each tank. Make necessary repairs.

11.4. Replace drain plug(s), fill each tank with water, and note any leaks.11.5. Remove drain plug(s) and repair any leaks.

12. Downhole MotorsVerify that each downhole motor designated for the job operates within the manufacturer's specifications.

10.2. Pressure TestingThe CONTRACTOR shall conduct pressure tests according to the following criteria.1. Conduct all pressure tests with water to the lesser of 5000 psi (±250 psi) or 120%

of the maximum possible WHP for the planned CT operation.2. Test pressure must remain stable for at least 15 minutes.3. A successful pressure test meets both of the following criteria:

3.1. No visible leaks3.2. Pressure decrease less than 5% after 15 minutes at the test pressure

4. When pressure testing BOP rams, always equalize the pressure across the rams before opening them.

5. Record all pressure tests with at least one of the following:5.1. Chart recorder scaled so that the test pressure is between 25% and 75%

of full scale on the chart. Use a separate chart for each pressure test.5.2. DAS

6. Measure pressure with a pressure sensor accurate to at least ±1% of reading.7. Record test results in the logbook for the equipment being tested.

7.1. Date, time, and location of test7.2. Serial number of pressure sensor and chart recorder7.3. Signature of person conducting test7.4. Stable test pressure and duration7.5. Tracking number or filing code for the test data

8. Keep each pressure test record on file for at least 12 months from the date of the pressure test.

11. General CT Operations ProceduresThe following section provides minimum requirements for general operations procedures that apply to every COMPANY CT job.

11.1. Rig Up1. All equipment delivered to the location shall meet the minimum requirements in

Sections 2-6 and the requirements of the COMPANY Job Program.



2. Position vent lines from pressure relief valves to discharge safely away from any personnel

3. Injector head3.1. Stabilize and securely anchor the injector support platform, if so provided,

before installing the injector head. 3.2. Position the injector head so that the CT will pass through the center of

the BOP stack.Note: The centerline (longitudinal axis) of the CT must be aligned with the vertical centerline of the BOP stack.

3.3. Remove the transport clamps from the injector head before testing the weight sensors

3.4. Verify proper operation of the injector head before installing it on the BOPs.

4. Do not start the job until the DAS, all sensors, and all displays are fully operational.

5. For nitrogen operations over steel decking, support all tanks and cryogenic hoses with wooden planks covered with tarps or rubber mats

11.2. Well-Site Pressure Testing1. Conduct all well-site pressure tests according to Section 10.2, unless instructed

otherwise in the COMPANY Job Program. 2. Use a clean fluid pump for pressure testing all components connected to the CT.3. Replace or repair any component that fails its pressure test.4. Pressure test the surface lines against the CT reel inlet valve and the top kill

valve (TKV).5. Open the TKV and pressure test the the quad blind rams against the hydraulic

master valve (HMV) and the inboard hydraulic wing valve (IBHWV).6. Insert the CT into the injector head and stripper, install the BHA, and assemble

the pressure control stack.7. Pressure test the connections, stripper, quad pipe rams, and BHA check valves

against the HMV and IBHWV while holding the CT with the injector head.Note: Ensure that the gripping force applied to the CT by the injector head is adequate to hold the CT against the pressure (snubbing) force.

11.3. General Operating Requirements1. Operate the DAS at all times the BHA is below the BOPs and monitor the real-

time operations data.2. Monitor the VME stress in the CT wall relative to the working limit prescribed by

the job program. Do not exceed the CT working limit without prior approval from the COMPANY supervisor.

3. Monitor the trend in the CT weight compared to the predicted values. Advise the COMPANY supervisor if the comparison becomes unfavorable.

4. Monitor the remaining working life in the CT string. Do not exceed 80% of CT working life without prior approval from the COMPANY supervisor.



5. Do not use the slip rams during normal operations. If they are used, inspect the surface of the CT contacted by the rams for signs of damage before continuing operations. Do not run damaged CT below the BOPs.

6. Pump liquid through the CT during POOH until the end of the BHA is above the crown valve unless nitrogen was the last fluid pumped before POOH.

14. Do not pressure test CT strings with nitrogen or any other gas on location.15. Reverse circulation or allowing wellbore fluids to flow back (up) through the CT is

not acceptable practice for COMPANY’s CT operations.16. Each CONTRACTOR REPRESENTATIVE at the work site shall have a minimum

of 12 hours rest between work periods.17. Each CONTRACTOR REPRESENTATIVE at the work site shall have all

manuals and equipment required to adequately perform their portion of the Job program to COMPANY’s satisfaction.

11.4. Safety Equipment SpecificationsCONTRACTOR’s safety equipment for the proposed CT operations shall meet the following minimum requirements.1. Appropriate personal safety gear for CONTRACTOR’s personnel2. An emergency response and first aid site located at least 200 ft upwind from the

wellhead. This site shall be equipped with the following items, as a minimum:2.1. Fire extinguishers suitable for flammable liquids2.2. First aid kit2.3. Eye wash kit2.4. Stretcher

3. Emergency kill equipment shall consist of the following components, as a minimum:3.1. Kill line3.2. Remotely controlled, hydraulically activated fail closed gate valve installed

in the kill line between the tubing kill valve (TKV) and the pump.3.3. Pumping unit3.4. Kill fluid storage tanks3.5. Appropriate kill fluid

4. CONTRACTOR shall provide each work area involving acid or other hazardous chemicals the means to:4.1. Rapidly wash (flush) with water the hazardous substance off personnel

and affected surfaces4.2. Neutralize the hazardous substance or minimize its effects

11.5. Safety ProceduresCONTRACTOR shall include the following safety procedures in its detailed safety plan for the proposed CT operations.1. Prominently display a detailed equipment layout drawing around the location

noting the locations of hazards and escape routes.



2. Only COMPANY personnel shall operate wellhead valves and associated equipment belonging to COMPANY.

3. Prominently display large, weather-proof safety signs around the location whenever hazardous materials are in use. As a minimum, these signs shall proclaim the following information:3.1. Types of chemicals in use and their constituents3.2. Relevant safety precautions for each chemical3.3. Emergency actions in event of chemical spill3.4. First aid treatment in case a person comes in contact with nitrogen or a

hazardous chemical3.5. Emergency telephone number(s) for additional information.

4. Support the injector head on a work platform or from overhead with a crane whenever personnel are working on or near the injector head.

5. Before any person climbs onto or works on the injector head:5.1. Stop the drive chains5.2. Shut down the power pack5.3. Attach a warning tag to each injector head control

6. Hold a safety meeting with all personnel on location prior to RIH6.1. Summarize the planned operations6.2. Discuss the results of the risk analyses6.3. Describe contingency plans and emergency procedures6.4. Demonstrate special safety equipment6.5. Assign responsibilities6.6. Identify communications procedures

12. Post-Job Reporting RequirementsCONTRACTOR shall submit to COMPANY a comprehensive and detailed report on each CT operation. Each post-job report shall be approved and signed by CONTRACTOR’s Operations Manager and Quality Assurance Manager. The report shall contain the following information as a minimum:

1. Chronology of major events2. Comparison between the planned and actual operations3. Conclusions and recommendations4. Data from the DAS

4.1. Processed data - plots, tables, etc.4.2. Raw data in electronic form4.3. Interpretation of the data4.4. Comparison of the data with CT simulator results

5. Description of problems (if any)6. Description of the equipment used

6.1. CT string6.1.1. OD6.1.2. wall thickness (taper)6.1.3. material properties – yield stress and modulus of elasticity



6.1.4. accumulated fatigue in each 10 ft of the CT string6.2. CT weight sensor(s) 6.3. Depth counter(s) 6.4. DAS6.5. Injector head 6.6. Pressure control equipment 6.7. Guide arch radius6.8. CT reel diameter6.9. CT disconnect(s)6.10. BHA description (include a drawing)

6.10.1. components6.10.2. dimensions6.10.3. weight

6.11. Pressure sensors – wellhead and reel inlet6.12. Power pack6.13. Auxiliary equipment

6.13.1. pumps6.13.2. compressors6.13.3. tanks

6.14. Special tools

13. CT Services General RequirementsCONTRACTOR shall provide the detailed specifications for CT services offered for the proposed work. CT services shall meet the following minimum requirements.

1. CONTRACTOR shall prepare and test all equipment in accordance with Section 10 prior to mobilization of equipment for COMPANY operations.

2. CONTRACTOR shall obtain in writing from COMPANY any waivers or concessions to these specifications.

3. CONTRACTOR shall ensure that all equipment supplied for COMPANY operations complies with applicable statutory regulations.

4. CONTRACTOR shall develop and maintain the following written documentation, approved and signed by CONTRACTOR’s Quality Assurance Manager, as a minimum: 4.1. Quality Assurance (QA) plan4.2. Maintenance program plan4.3. Log for each CT string4.4. Log for each component of a CT unit4.5. Log for each item of auxiliary equipment4.6. Hazardous chemical safety bulletins

5. CONTRACTOR shall calibrate all sensors, measuring equipment, and recording devices at least every three (3) months against standards certified by appropriate regulatory agencies.

6. CONTRACTOR shall ensure that all documentation is correct and presented in a manner acceptable to COMPANY and certifying authorities.



7. CONTRACTOR’s representative shall hand-deliver to the COMPANY supervisor at the work site a complete set of documentation (see Section 2) for the CT string designated for the proposed work.

8. CONTRACTOR shall have a maintenance facility/support base in Angola, capable of supporting the proposed CT operations.

9. CONTRACTOR shall maintain an inventory of spare parts sufficient to repair/rebuild/replace each component on the CT unit and auxiliary equipment.

10. CONTRACTOR shall provide for every job an enclosed, weatherproof container equipped with all spare parts, hand and power tools, BHA components, connectors, safety equipment, etc. required to sustain the proposed work.

11. All equipment, tools, spare parts, and consumables shall be preslung or containerized before shipping to or from the work site. Each pallet and container shall be properly marked and inventoried prior to shipment. CONTRACTOR shall properly secure and protect all equipment for safe transportation.

12. Shipping containers and skips shall be certified to fully comply with local statutory requirements.

13. CONTRACTOR shall transport hazardous chemicals in accordance with statutory requirements and with warning signs prominently displayed.

14. CONTRACTOR’s REPRESENTATIVE shall ensure that all materials and equipment necessary for the performance of the CT operations are present at the work site and are in good working order.

15. CONTRACTOR’s REPRESENTATIVE shall ensure that all personnel affected by the COMPANY’s Job Program know and understand it.

16. CONTRACTOR shall not attempt the proposed work without the CT unit DAS fully operational. CONTRACTOR shall not deviate from this rule without expressed permission of the COMPANY supervisor.


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8/27/99 page 5-1 SAUDI ARAMCO Coiled Tubing Manualctes.nov.com/Documentation/manuals/CTManual/download... · Web viewHydrostatic test data including test fluid, pressure, duration