FM WELL INTERVENTION

CERTIFICATION COURSE

S CHAPTER-1
PRINCIPLES AND PROCEDURES

Chapter 1 Principles & Procedures

TOPICS

Barrier Principles
ª
Well Integrity
ª
Valve Operation in Flowing Wells
ª
Pressure Control Methods
ª
Problems
ª
Pressure Control Management
ª

Page....1
 Barriers

ª
Any devices, fluids or substance that prevent flow of wellbore fluid.

ª
Two Types of barrier used to prevent well flow are Mechanical and
Fluid.

ª
At least TWO independent, tested barriers to prevent undesired flows
of hydrocarbons from the well to surface.

ª
Artificial lift well needs to have same minimum barriers as natural
flow well.

ª
Barrier should be tested in the direction of flow of the well.

ª
Three main Categories of Barrier in term of their systematic operation:
Primary, secondary and tertiary barriers.

ª
During operations, there must always to have more than one barrier
[can combine two types of Barrier in same well].

ª
Two barriers are required between the well and the external
environment.

Page....2
 Mechanical Barriers

ª
Cemented liner/casing

ª
Completion string

ª
Tubing hanger

ª
Xmas tree

ª
Cement plugs

ª
Mechanical plugs (many things)

ª
Mechanical barriers prevent well flow by closing off the flow path

ª
Can be installed by wireline, coiled tubing, snubbing, and freeze
(ice plug) method
[last way out when X/mas tree & BOP were removed or removing jammed equipments
from Tree/BOP]

ª
Wireline plug and pump through plug are installed by intervention
methods

ª
BOPs and Xmas tree valves are considered as closeable barriers
[Closeable - can be opened or closed by hand or remotely control]

Page....3
 Mechanical Barriers

Fluid Barriers
Common Fluids used as a Barrier are;

Drilling Mud, Brine, inhibited Sea Water and Fresh water

ª
Correct specification (desired weight)
ª
Testing [monitoring when fluid is being weighted and pumped that
should be consistency]
ª
Observation [monitoring for a period that pumped fluid is
stabilizing or kill the well]

Classed as a primary barrier

[being as primary barrier when it balance the well pressure or a well is killed]

Page....4
 Barriers Envelops
Contain well pressure
ª Production Casing
ª Production Tubing
ª Production Packer
ª Tubing hanger with check valve (if installed)
ª Xmas Trees

Prevent annulus flow

ª Production Casing
ª Production Packer
ª Completion Fluid
ª Tubing hanger/hanger spool
ª Casing spool outlet valves

Page....5
Barriers Envelops
Drawing beside, identify the
barrier elements (envelope)
Xmas free
that;
Tubing hanger with check valve
(Inside Tbg)
Tubing hanger well head (outside) Contain Well Pressure
Wellhead with annular

Production string
1.
DHSV
2.
3.
Casing 4.
well fluid 5.
Completion fluid

Production Packer
Prevent flow from Annulus
1.
Perforations 2.
3.
4.
5.

From the production well

schematic, identify the barrier
(envelop) that prevent Annulus
flow?
(pick up 5 answers)

1.
2.
3.
4.
5.

Page....6
 Barriers Envelops
From the production well
schematic, identify the barrier
(envelop) that contain well
pressure?
(pick up 5 answers)

1.
2.
3.
4.
5.

Barrier Philosophy
Two primary Barriers
Between inside and
external Environment

First contain/maintain pressure or flow

[first line of the defense from an uncontrolled well flow]
= Primary Barrier
Page....7
Barrier Philosophy

Well was killed with Kill Fluid (fluid barrier)

First prevent flow of well = Primary Barrier

Page....8
 Barrier Philosophy
Wireline Operation
First preventing flow of well
Primary Barrier = Stuffing Box

Pressure
Hydrostatic Pressure

The hydrostatic pressure of a column of fluid is determined on the basis

of that fluid density and vertical height of that fluid column.

API Unit
Pressure (psi) = 0.052 x Fluid Density (ppg) x TVD (ft) Formula-3

Pressure Gradient (psi/ft) = 0.052 x Fluid Density (ppg) Formula-1

Fluid Density (ppg) = Pressure (psi)

[0.052 x TVD (ft)]
Formula-2
Page....9
 Pressure
Formation Pressure
When the well had been shut in, static well head pressure (SIWHP) was
stabilized. Formation Pressure can be determined as follows;-

API Unit Formula-4

Formation Pressure (psi) = Hydrostatic Pressure (psi) + SIWHP (psi)

When well was shut in fluids and gas in production string will separate out
due to gravitational forces thus hydrostatic pressure will be equal to sum of
hydrostatic pressure of fluids and gas columns in the production string.

Formation Pressure Determination

Formation Pressure
= HSP of Producing Fluid + SITHP

SITHP
SAMPLE: (Oil Well)

SITHP = 2,500 psl

Oil Density = 7.0. ppg

Depth of top Perforation = 9,500 Ft. (TVD)

FP = (0.052 x 7 x 9500) + 2500

= 5,958 psi

Page....10
Over Balance & Under Balance Pressure
Overbalance (psi)
= Bottom Hole Pressure - Formation Pressure

Over Balance Pressure is;

Mud Wt
20.4 ppg [0.052 x 10.4 x 10000] - 5200 = 208 psi
Static BHP=5,408 psi
Over Balancing Formation
Pressure by 208 psi

In opposite;
If Formation Pressure > Bottom Hole Pressure
10,000 ft TVD

Well is under balance

Pressure
Pressure

Basic Hydrostatic Pressure

Shut in Pressure Calculation

Page....11
 Testing Barriers
Barriers should be tested for its integrity

There are two types of testing;

• Inflow test - reducing the pressure on the upper side of the barrier to detect
any leaks

• Pressure testing - increasing the pressure to a value higher than the lower
side of the barrier to detect any leaks

INFLOW TEST

Reduce Pressure at the upper side of

Barrier then observe for certain period
of time in order to detect for any leaks.

PRESSURE TEST

Increase Pressure at the upper side of

Barrier then observe for certain period
of time in order to detect for any leaks.

Page....12
 Testing Barriers
The Testing Barrier will depend on which phase of the well life;
•Drilling
•Completion
•Production
•Well Intervention
SAMPLE OF TESTING BARRIERS OF VARIOUS
MECHANICAL & FLIUD BARRIERS

Cement Plug (P & A):

Pressure test to verify for
the future leakages

Cased hole well:

• Pressure test with mud or water
• Inflow test by displacing mud with
sea water (washing)

The Testing Barrier will depend on which phase of the well life;
• Drilling
SAMPLE OF TESTING BARRIERS OF VARIOUS
• Completion
MECHANICAL & FLIUD BARRIERS
• Production
• Well Intervention

X/Mas Tree & Well Head:

• Pressure Test by pumping
• Inflow test of valves and
connections with well pressure
Deep Plug with Perforated Liner:
• Inflow test by reducing pressure at
top of plug
• Pressure test to verify its integrity

Page....13
 Testing Barriers
The Testing Barrier will depend on which phase of the well life;
• Drilling
• Completion SAMPLE OF TESTING BARRIERS OF VARIOUS
• Production MECHANICAL & FLIUD BARRIERS
• Well Intervention

Production Packer Production Packer with

without perforation: perforation:
Pressure test from Pressure test from Annulus
Underside
Tubing Hanger:
Inflow/pressure test by
pumping from annulus and
check for leakages

Casing:
Pressure test annulus

ª
Positive plug prevents the flow from either direction

ª
If it is not possible to perform inflow test for installed plug, then it should
be pressure tested from above (except the dead well can not perform
inflow test)

ª
Test of SSD above top packer after closingiDy pressure test the annulus
(Tubing open to the Perforations, alternatively set plug at tailpipe before
testing)

Page....14
Design Test Pressures
API's pressure classes are based on working pressures of 2M, 3M, 5M, 10M,
15M and 20M. Where M = 1,000 psi (test before deployment)

ª
2 times working pressure up to and including 5M equipment

ª
1.5 times working pressure for 10M and 15M equipment

ª
1.25 times working pressure for_20M equipment

ª
When equipment is being installed and during the operation phase, it is
leak tested to the given working pressure (test to maximum anticipate
working pressure that equipment withstands, i.e. BOP, plugs , e.t.c)

Valve Operation in Flowing Wells

ª
Before conducting well intervention, pressure (leak) test Xmas tree
valves

ª
Opening the valve under pressure can damage other equipment and
need to equalize pressure before opening

ª
Open the closed valve while having pressure on the father side may
cause damage to the valve and equipment downstream of the valve
(due to great differential pressure)

ª
DHSJ is the last valve to be closed during the emergency
shut-in

Page....15
 Shutting in Well at Xmas Tree
ª
Valves can be damaged if they are closed on a tool string

ª
Use the upper master valve if there is nothing in the hole (shut in when
well kicks)

ª
Some Master valves can close and cut the wireline

ª
The lower master valve is not normally used

ª
Counting the turns while operating the valve

ª
After closing, a manual valve should be backed out a part of turn

Volume Calculation
String Pipe Capacity and Displacement

Page....16
Volume Calculation
Closed End String Displacement

Annular Capacity

Page....17
Volume Calculation
Capacity of Production Tubing
= ¶ x (ID)2 x L
4
Tubing Capacity (bbl/ft) = (ID)2
1029.4

Capacity of Annulus
= ¶ x (IDcasing)2 - (ODtubinq)2x L
4

Annular Capacity (bbl/ft) = (IDcsq)2 - (ODtbq)2

1029.4
(where OD and ID in Inches, Capacity in bbl/ft)
WELL INTERVENTION

Given Capacity in
bbl/ft. (API) l/m. (Metric)
Volume Calculation

API Unit Formula-7

Strokes to Displace (strokes)

Tubing = Tubing Capacity (bbl/ft) x MP (ft)

Pump output (bbl/stroke)

Annulus = Annulus Capacity (bbl/ft) x MP (ft)

Pump output (bbl/stroke)

Metric Unit

Capacity = l/m.
Pump output = l/stroke

Page....18
Volume Calculation
API Unit Formula-6

Time to Pump (minutes)

Tubing = Tubing Capacity (bbl/ft) x MP (ft)

Pump rate (bbl/min.)

Annulus = Annulus Capacity (bbl/ft) x MP (ft)

Pump rate (bbl/min.)

Metric Unit
Capacity = 1/m.
Pump rate = 1/min.

API unit
Sample:
Casing - 7", 32 lb/ft, 6.094" ID, set @ 11,436 ft. (MD/TVD)
Tubing- 2-7/8", 7.9 lb/ft, 2.265" ID -
End of Tubing - 11,300 ft. (MD/TVD)
Packer - set @ 11,290 ft. SSD - set @ 11,190 ft. (MD/TVD) -,
Pump output - 0.1044 bb/stk.
-Perforations - top 11,353 ft. bottom 11,393 ft. (MD/TVD)

1. Annulus capacity - Kfi.094)z - (2.875)'] + 1029.4 = 0.028 bbl/ft

2. Tubing capacity -X^^)2 + 1029.4 - 0.0050 bbl/ft

3. Casing capacity - ($.094)2 + 1029.4 - 0.0361 bbl/ft4.

4.Total Barrels in Annulus above Packer = 0.028 x 11.290 = 316.6 bbls

5. Total Barrels and Strokes to Reverse circulation through SSD

Barrels in Annulus - 0.028 x 11,190 = 313.35 bbls
Barrels in Tubing - 0.0050 x.11,190 - 55.95 bbls
Total barrels for reverse circulation - 313.35 + 55.95 - 369.3 bbls
Total strokes for reverse circulation » 369.3 * 0.1044 - 3537.4 stks

6. Total barrels to bullhead down the tubing to the top perforation

with 2 barrels over displacement and surface volume Is 2 barrels:-
Volume in tubing - 0.0050 x 11,300.- 56.50 bbls
Volume in casing below tubing - top Perf. - 0.0361 x 53 - 1.91 bbls
Total volume for bullheading - 56.50 + 1.91 + 2 + 2 = 62.4 bbls
Total strokes for bullheading - 62.4 + 0.1044 - 598 stks

Page....19
 Key Practices for
Reverse Circulation & Bullheading
Reverse Circulation
ª Calculate volume both in Tubing and Annulus based on SSD
depth. When Completion Fluid (Brine) is fully filled in Tubing,
Some overbalance pressure required during reversely circulating
until kill fluid entering the Tubing via SSD, The tubing head
pressure is allowed to drop to zero.

Bullheading
ª Calculate tubing volume from surface down to the end of tubing
plus volume in casing below tubing until top and bottom
perforation if requested.
ª Total volume include tubing volume + volume below tubing plus
volume of surface lines and "upfront" kill fluid (acid/sea water)
which to be injected into the formation for minor fracturing
purposes if the formation is dense

Note: Formation pressure always calculated based on top of

perforation depth.

Kill Fluid
ª
Compatibility with formation and formation fluids (drilling fluid not need)

ª
Appropriate weight to kill well and avoid too much weight causing excessive over pressure

Kill Fluid Density = Formation Pressure

0.052 x TVD (ft)

Kill Fluid Density (ppg)

= Original Fluid Density (ppg) + SIWHP (psi)

0.052 x Top of Perofration in feet (TVD)

Page....20
 Well Killing Methods
ª
Forward circulation (drilling preferred method)

ª
Reverse circulation

ª
Bull Heading (through tubing)

ª
Bleed-off/Lubrication (through tubing)

Reverse Circulation
Preferred method in planned well kill operations (kill faster)

Main advantages:
ª All wells can normally be killed

ª
Both tubing and annulus end up with comparable kill fluid

ª
Surface pressure is low

ª
Less danger of formation damage

ª
Lift solid more easily when in a large hole

Page....21
 Bull Heading

ª
Used in emergency during a well intervention operation and it
becomes necessary to kill the well

ª
Failed DHSV

ª
Cannot establish circulation (in the wen that SSD win not open)

ª
Insufficient information to calculate a reverse Circulation kill (volume
& Weight)

ª
When speed (emergency) is important

ª
Can only be performed when perforation is opened

ª
Can plug formation with scales or solids from inside the completion
string

ª
Limit by working pressure rating of surface equipment

ª
Burst limit of completion

ª
Formation permeability

ª
Fracture of the formation

Page....22
 Bleed off and Lubricating
ª
Can be performed when emergency and not possible to bullhead

ª
Repeatedly bleed off small well pressure and pump small
amount of fluid while maintaining BHP constant

ª
It is a killing method, which consume more time.

Pressure behavior while in Killing Operation

Page....23
Pressure behavior while in Killing Operation

Well Killing Methods

Killing Graphs

Page....24
 Problems
ª
Free gas in the well

ª
Swab and surge pressure

ª
Thief zone

ª
String washout

ª
Blockages in the well

ª
Hydrates

Example of Problems
(Gas Cap) Thief zone)
ª
Shut in the well and pressure slowly build up due to gas cap
(Bullheading Gas) forming in well bore (stabilized fairly
quick)

ª
Thief zone can limit circulation back to Surface (depleted
more than other zones)

ª
Cleaning the sand and scale problem in well with thief zone
would need to use LCM to stop any losses into the thief zone
(especially in the long Perforation zones which few zone is a
Thief zone)

Page....25
Free Gas in the Well
ª
Bleeding off gas (Joule-Thomson)
(decrease in Temp, due to Freezing after across valve i.e. gas
pressure fall thus expands and losses energy) :Brittle fracture
in pipe (stainless steel), valves and e.t.c.

ª
Gas migration (gas migrate up to surface in connection with
uninhibited seawater if used as a displaced fluid in well, will
form hydrate)

ª
Bullheading gas (well shut-in with gas on top)

ª
Hydrates (gas + water = crystalline)

Hydrates
ª
Can damage well bore and intervention
equipment (due to crystalline compound of Hydrate)

ª
Can cause damage if they becomes free at high differential
pressure

ª
Can only form in the presence of free water

ª
Likely to form at high pressures than low pressure well (high
differential pressure potential)

ª
Likely to form downstream of chokes or at pressure relief
valves or emergency blow-down line

Page....26
 Hydrates
ª
Can also be prevented or removed by injecting chemicals or
raising the temperature of equipment used

ª
Injecting methanol, glycol or brine can reduce formation of
hydrates (Inhibitors)

ª
Injecting distilled water cannot prevent the hydrates because
of containing free water

Surge & Swab Pressure

Surge = Piston power
Swab = Suction power

Surge and Swab are function of:-

ª The clearance of well wall and downhole equipments
ª Type of fluid (completion fluid has higher pressure)
ª Trip/run speed
ª Length of components with has a large diameter
ª Acceleration / retardation speed (high speed high
pressure)

Swab will be maximum when we trip out intervention

equipments close to the reservoir

Page....27
 String Washout
ª
Snubbing String Washout

ª
Coiled tubing fracture at surface (especially at the goose
neck, related shut-in procedure, see CT section)

ª
Coiled tubing break in the well (kill the well first before
pulling out the coil)

ª
Blockage the well (sand, scale, mechanical. See methods to
remove the blocks; mechanical & chemical)

Management of Operations
Planning

ª
Start-up meeting
ª
System of communication
ª
Well program
ª
Emergency procedures
ª
Organization - well killing

Abnormal Operations

ª
See details in manual

Page....28
Management of Operations
Conditions necessary for work to conduct safely:

ª
Using tested, inspected and well maintained equipment

ª
Hold pre-job safety meeting before start working

ª
Have crew properly trained in what to do when equipment
failed

ª
Organize meeting to discuss plan, get feed back, make
changes and get everyone to agree and understand
(Tool Box meeting)

ª
Document for responsibility of concerned party in
emergency case

ª
Intervention Equipment Operator to shut in the well when
pressure control problem arise during well intervention
operations

Page....29
Management of Operations
Abnormal conditions occurred during well intervention operation
which are not fully understood:

The well must be;

1. Shut in and secured then need to

2. Analyze the problem and seek out solutions, state the problems
on paper, gives possible causes, invite offshore team to
comment, state action to be taken, then ask onshore support
team to comment on action and get permission.

Note:
In some oil companies, not only well intervention operator who is
in charge to Shut in well. The person designated in the Joint
Operations Manual can also the shut in well in Emergency
situation.

Document for responsibility of concerned party in emergency

case:-

Due to the Well Intervention Operations are carried out by many

involved parties

The Joint Operations Manual must be clearly stated for the Well
operations Intervention Team in order to effectively control of a
well control incident and should be available on site for immediate
actions in emergency case.

ª
Categories of personnel responsible for well Intervention
Emergency duties (i.e. who will shut in well)
ª
Make the Flow Charts (discuss who is a 24 hrs. on duty)
ª
Regular on-site exercises and Tool Box meeting

Page....30