Workover Opertions

CHAPTER-1
Workover Rig And Equipment
1.0 INTRODUCTION:
About 80 on land workover rigs (60 owned by ONGC + 20 Charter hired)
of different make, type and capacity are presently operating in ONGC. All
the workover rigs are mobile, mounted on wheeled carrier, with or
without prime mover, which can be driven to the well site with all
necessary hoisting equipment, engines and special telescopic mast as one
complete unit.
Workover rigs can broadly be divided in two categories namely rotary
type and non-rotary type. In well servicing often drilling of cement/sand
plug, milling of bridge plug/ packer/ fish etc are performed which
requires rotation of string. This requirement necessitates the need of
rotary rigs in well servicing operations. In rotary type, inbuilt rotary table
does rotation of workstring. Non-rotary type do not have rotary table but
rotation of workstring may be achieved by some external equipments like
power swivel. Drilling of cement/ sand can also be accomplished by
mounting dynadrill with work-string. Circulating workover fluid at
certain rate rotates these tools and not the workstring.
Overall cost and success of a workover job depends upon selection of
workover rig. The selection of suitable workover rig to perform a
particular job depends on depth of the well and load capacity. Rig
capacities are commonly spoken of in terms of depth rating with
particular size tubing, usually 2 7/8”. Rig capacity depends upon a
number of factors namely braking capacity, derrick capacity and draw
works horsepower. Braking capacity is the prime consideration in rig
selection as considerable energy is developed in lowering pipe in the hole.
This energy is converted into heat energy in the braking system and must
be effectively dissipated from the system.
ONGC - SOP Workover Operations - Onshore | 1

1.1 BASIC COMPONENTS OF AN ONSHORE WORKOVER
RIG AND EQUIPMENT
A rig is a combination of mechanical equipment powered by diesel/ gas /
electric engine. Transmission of power to various parts of the rig namely
draw work, rotary table etc. Is achieved mechanically. Rig and equipment
causes major safety hazards due to dynamic, instantaneous and fatigue
loading; continuous wear and tear and hazardous environment and
corrosive fluids.
1.1.1 COMPONENTS OF AN ONSHORE WORKOVER RIG
A. Rig Engine or Prime Movers
Most of the rigs operating in ONGC are powered by diesel engine. Both
number and sizes of the engines required depend on the capacity of the
rig. Rig engine power varies from 200 HP to 750 HP.
B. Derrick / Mast
The function of derrick is to provide the vertical clearance necessary for
raising and lowering of the workstring into and out of the hole during
workover operations. It should be of sound construction, maintained in
safe working order, adequate strength, sufficient height and should be
adequately secured to prevent it from overturning because of wind
velocity and dynamic loading. Guy ropes should be anchored properly as
per the recommendations of the manufacturer.
The mast in mobile workover rigs is generally telescopic. Drill pipes/
tubing are accommodated on a racking platform (monkey board) during
tripping.
C. Derrick Floor / Sub-Structure
It takes over mast, rotary table, draw works and other loads generated
during rig operations and transmit them to sub base. It also resists forces/
loads during mast raising and lowering. It is also designed to resist the
loads coming in addition to above due to storage of drill pipes, drill
collars and tubing. It consists of a structured framing system of trusses,
beams and girders connected to columns. The height of sub-structure
must be sufficient to house and afford access to the blowout preventer
stack.
2 |ONGC - SOP Workover Operations - Onshore

D. Hoisting System
D.1 Draw works: The draw works enable tubular/ downhole equipment to
run in and out of the hole and also provide power for making and
breaking the pipe joints. It is important that the Draw works control are
designed, installed and maintained in such manner as to provide the
operator at his control panel, complete visibility, rapid control of hoisting
operations and adequate protection against moving equipment.
The main components of draw works is hoisting drum, whereon casing
line is spooled and vertical movement is derived from the rotation of the
hoisting drum. Hoisting drum is equipped with braking system (main
brakes and auxiliary brakes). The drum of the draw-works should have
suitable guards.
The draw-works particularly its brakes, linkage and brake rims should
invariable be examined at regular intervals. Water cooling system is
deployed to dissipate the heat generated during braking.
The draw-works must be provided with safety limit device like crown-o-
matic and floor-o-matic for safety against accidental over running of the
travelling block during tripping and hitting crown block or derrick floor.
This device must be reset at the start of operations in each shift.
D.2 Catheads and catline – The catheads are spool-shaped, rotating drums
powered by the jackshaft assembly. They consist of friction and
mechanical rotating heads. The friction catheads are used to transport
heavy objects around the rig floor by means of a manila rope. The
mechanical catheads comprise the makeup cathead on the driller’s side
and the breakout cathead on the opposite side
D.3 Hoisting Tackle – The massive weight of the workstring is handled by a
block and tackle system in which a continuous line is wound around a
number of fixed and travelling pulleys. The main components of hoisting
tackle are crown block, travelling block, hook, dead line anchor, weight
indicator and casing line.
D.3.1 Crown block provides a means of taking wire line from the hoisting drum
to the travelling block. The crown block is stationary and is firmly
fastened to the top of the derrick. It has a number of sheaves/pulley
mounted on a stationary shaft.
D.3.2 Travelling block sheaves should have suitable guards while in use to
prevent fingers of rig crew being drawn in to it during operations. When

any load is attached to the travelling block, it should not be left
unattended. When not in use, the travelling block should be kept as near
as possible to the rotary table and the brake lever of the draw-works
should be securely locked to prevent any inadvertent movement of the
block.
D.3.3 Hooks are attached to the travelling block with large shackles and are
used for various pulling functions of the rig. Hook should be equipped
with locking device to prevent the load from being accidently
disconnected from the hook. Elevators links should be securely latched
with the hook by lock nuts or suitable pins.
D.3.4 Dead Line Anchor and weight indicator – The deadline anchor consists of
a base and a drum attached to the rig floor or rig substructure. It provides
a means of securing the deadline and of measuring the hook load.
The weight indicator has two pointers; one shows total hook load and the
other shows weight on bit.
D.3.5 Casing line – It is basically a wire rope of round strands type. The strands
are made up of number of small wires wound around a central core.
To ensure optimum life of the casing line and to avoid any fatigue failure,
the casing line is slipped regularly after undergoing a prescribed Ton-
Mile of work. The wearing points of every casing line shall be moved by
cutting off at least thirty metres of the casing line after every 3000 tonne-
kilometres or at shorter intervals, where necessary so as to prevent
excessive wear of the casing line.
E. Rotary Table
Rotary table is powered directly from the draw works through a rotary
counter shaft / chain. The rotary table transfers rotary motion through a
master bushing to the Kelly to workstring. It serves as support table for
the string and to screw and unscrew the joints of a drill string, tubing and
casing. The master bushing also acts as a seat for slips.
F. Mud Pump
The rig pump is basically a piston reciprocating type. The pump capacity
should be sufficient to circulate the workover fluid and produce pressure
to overcome the frictional or drag forces. The flow rate should be
sufficient enough to cool the bits and produce annular velocities required
for lifting of cement/ fine metal cuttings. In general, positive
displacement triplex type pumps are commonly used on workover rigs as
they offer smooth displacement at low volumes.

All mud pumps must be provided with safety valve (relief valve) to avoid
any over pressurizing of pump beyond 90% of the capacity. These valves
must be reset after change of liner size in the pump.
G. Blow out Prevention Equipment Systems
When primary well control has been lost, it becomes necessary to seal the
well to prevent an uncontrolled flow of formation fluids. Blowout
prevention equipment systems are composed of all systems required to
operate the blowout preventers (BOPs) under varying rig and well
conditions. These systems are: blowout preventers (BOPs), choke and kill
lines, choke and kill manifold, hydraulic control system and auxiliary
equipment. The primary functions of these systems are to confine well
fluids to the wellbore, provide means to add fluid to the wellbore and
allow controlled volumes to be withdrawn from the wellbore.
G.1 Blowout Preventer
The equipment that seals the well is called a blowout preventer. The BOP
is a set of valves installed on the wellhead to prevent the escape of
pressure from the well during completion/ workover operations.
Different types of BOPs are available in nominal sizes from 3 1/16” to 30”,
with working pressure ratings from 2000 psi to 20000 PSI for both
standard and sour environments.
G.1.1 Annular Preventer
The first preventer normally closed when shut-in procedures are initiated
is the annular preventer. The four basic segments of the annular preventer
are the head, body, piston, and steel ribbed packing element. When the
preventer’s closing mechanism is actuated, hydraulic pressure is applied
to the piston, causing it to slide upward. This forces the packing element
to extend into the wellbore around the drill string (Fig 1.1). The preventer
element is opened by applying hydraulic pressure to slide the piston
downward that allows the packing to return to its original position.
The most important feature of the annular preventer is its capacity to
allow stripping operations to be carried out while maintaining a seal
during pipe/ tool joint passage. A standard annular BOP will strip pipe
and tool joints or close off the annulus on open hole to full working
pressure. The universal seal-off feature permits closure and seal-off on
any uniform tubular like drill pipe, tool joints, tubing, Kelly, drill collars
etc but will not seal around uneven objects like reamer, stabilizer, bit etc.

Fig 1.1: Hydril GX Annular Preventer
G.1.2 Ram Blow-out Preventer

Ram preventer seal the annulus by forcing two elements to make contact
with each other in the annular area. These elements have rubber packing
seals that affect the complete closure. Ram type preventers are available
as pipe, blind, variable bore, and shear rams.
Ram bodies will accept either blind, shear/blind, or pipe ram elements.
Also, units are available that are comprised of single, double, or triple ram
bodies. In the multiple-unit ram bodies, any combination of pipe and
blind ram elements may be used.
The rams of most BOP systems are closed by means of hydraulic piston.
The ram shaft is sealed against the well by a primary lip seal, installed in
the bonnet through which the operating rod passes. It is very important
that well bore pressure is sealed from the operating cylinder. If the well
pressure by passes the primary seal and enters the operating cylinder, it
may force the ram open. To prevent this, a vent hole between primary
mud seal and oil seal is provided to indicate about leaking mud seal. In
case of any mud seal leakage at the time of killing operation and fluid is
noticed venting out of the BOP, the secondary or auxiliary plastic seal
should be energized to seal against the piston shaft to create effective
sealing till the killing job is completed. However, this is just a temporary
solution and proper repair of BOP be under taken after the killing job. In

case of leakage at the time of testing the same, the same should be
repaired before commencing next operation.
Fig 1.2: Shaffer LWS Double Ram BOP
G.1.2.1 Type of Ram Preventers

i) Pipe Rams
Pipe ram provides a seal to well-bore around a particular pipe size for
which the pipe ram is designed. The basic strength and main limitation of
the pipe ram is the ram block cut-out. The ram preventer is the steel block
cut to fit the pipe size around which it is to be closed. The cut-out is meant
to close and provide a good seal around one particular diameter or size of
pipe. Most rams have guides to centre the pipe.
A special design feature of some pipe ram elements is that when closed
and locked, the ram can support the weight of the drill string, if
necessary, by hanging a tool joint on the ram. This feature is useful when
storm conditions exist or blowouts are impending. However, this usage is
not recommended under normal conditions.
Fig 1.3: Pipe Rams

iii) Variable Bore Rams
A variable bore ram (VBR) is a special pipe ram that can seal on a range of
pipe sizes or a hexagonal Kelly. VBRs can back up two sizes of standard
pipe rams in operations where a string is made up of two sizes of pipe.
They may also serve as the primary ram for one size pipe and a back-up
for another size. On wells with tapered string where space is a concern,
VBR can be used.
Fig 1.4 Variable Bore Ram
iii) Blind/ Shear Blind Ram

Blind rams are designed to seal the well if pipe is not in the hole. The
element is flat-faced and contains a rubber section.
Fig -1.5 Shear Blind Ram

Shear blind rams has capability to simultaneously shear specific size of
pipe and to provide a seal on the open well bore. When shear blind ram is
closed, both upper and lower steel blade assemblies move closer and cut
the pipe and after cutting the pipe the upper blade moves over the lower
blade. This offers the advantages of cutting the pipe and sealing on the
open hole after the pipe is cut.
G.1.2.2 Dual String Rams
When a well has two production strings for producing two pay zones, a
dual ram preventer is used that seal around both strings. These types of
rams have front packer with two/multiple grooves which will seal
around multiple string when ram is closed.
G.1.2.3 Slip Rams
When a pipe is sheared it will fall in the well. To avoid falling of the
sheared pipe, a slip ram is used below the shear ram that holds the string
weight only and do not seal the well bore. This type of ram has a front
packer made up of steel with dies that hold the sheared pipe and do not
allow the pipe to fall in the well and thus avoids subsequent fishing of the
sheared pipe.
G.1.3 Testing Of BOP Stack
Pressure Testing:
All the elements of BOP stack be tested at low pressure of 200-300 psi and
then at high pressure equal to the maximum anticipated pressure or RWP
of BOP element, whichever is less. Ensure that the casing burst pressure
should not be crossed if casing is exposed to testing pressure. Test
pressure be held for at least 5 minutes before completing the test. In case
of failure of either of low or high pressure test, the equipment should be
repaired/ replaced before next operation.
In any case BOP stack should not be exposed to well bore pressure before
undergoing successful pressure test.
For pressure testing, pressure should be applied from the anticipated
direction of well bore pressure.
Function Test
To ensure the proper functioning of BOP control unit and elements of
BOP stack, the stack should be regularly function tested every week. Pipe

ram should not be function tested without closing on matching pipe
inside.
All ram BOPs are designed NOT TO BE OPENED under well bore or
trapped pressure. Operator has to ensure equal pressure or zero pressure
on both sides of ram before opening the ram BOPs to avoid damage to the
top seal of ram block inside.
For details on testing of BOP stacks, please refer Chapter- 7 titled “Well
control Equipment”
G.2 BOP Control Unit
BOP control unit provides continuous energy in the form of hydraulic
pressure to the BOP stack. Hydraulic pressure is developed with a
hydraulic system designed and built to make available actuating pressure
to BOP in very short duration (5 seconds or less) and to maintain the
required pressures as desired.
Control unit consists of following equipment. (Refer Fig 1.6)
• Accumulator bottles
• Reservoir tank
• Charging system to pump hydraulic fluid into accumulator bottle
• Pressure regulating valve
• Operating manifold
• Pressure relief valve
• Pneumatic pressure transmitter
• Air junction boxes.
Fig 1.6: BOP Control / Accumulator Unit

(For details including design and operating requirements, please refer
Chapter-7)
G.3. Choke and Kill Manifold
The choke and kill manifold consists of high pressure pipe, fittings,
flanges, valves and manual and/or hydraulic operated adjustable chokes.
Typical choke and kill manifold used in workover operations in ONGC is
shown in Figure No. 1.7.The choke line and manifold provides a means of
applying back pressure on the formation while bleeding off well bore
pressure at a controlled rate or may stop fluid flow from the well bore
completely, as required. The Choke and Kill Manifold system provides a
means of pumping into the well bore when the normal method of
circulating down through the Kelly or drill pipe can not be employed.
The kill line connects the mud pump to a side outlet of well head or on
the BOP stack, below the ram type BOP.
Bill of Material for Choke and Kill Manifold
ITEM QTY DESCRIPTION
1 13 VALVE MANUAL GATE ALONG WITH HANDLE, 2-1/16”

–10K FLANGE CONNECTION
2 1 CHOKE ADJUSTABLE ALONG WITH HANDLE, 3 -1/16” –

10000 PSI, (2” ORIFICE)
3 1 CHOKE POSITIVE, 2-1/16”-10K (1” ORIFICE) C/W ½”

NEEDLE VALVE
4 2 STUD’D CROSS, 5 WAY, 2-1/16”-10K
5 3 STUD’D BLOCK, 3 WAY, 2-1/16”-10K
6 1 SPOOL CROSSOVER, 3-1/16”-10K X 2-1/16” -10K X 12.00”

OVERALL LENGTH
7 1 3-1/16”, 10K FLANGE CROSSOVER X 2” LP NIPPLE WITH

NPT THREAD C/W 2”, 1502 H/U MALE
8 1 2-1/16”, 10K FLANGE CROSSOVER X 2” LP NIPPLE WITH

NPT THREAD C/W 2”, 1502 H/U MALE
9 2 FLUID PRESSURE GAUGE (WITH FLANGE), 0-10000 PSI
10 3 FLANGE X OVER 2-1/16”X 10K WITH 2”, 1502

WELDNECK H/U FEMALE
11 2 FLANGE X OVER 2-1/16”X 10K WITH 2”, 1502

WELDNECK H/U MALE
12 3 2-1/16”, 10K FLANGE X 2” NIPPLE C/W 2”, 1502

WELDNECK H/U FEMALE
13 2 2-1/16”, 10K FLANGE X 2” NIPPLE C/W 2”, 1502

WELDNECK H/U MALE
14 - RING GASKETS, STUDS, NUTS- AS PER REQUIREMENT
15 1 2.1/16” 10 K CHECK VALVE with 2-1/16”, 10K FLANGE X

2” NIPPLE C/W 2”, 1502 WELDNECK H/U FEMALE at
inlet & 2-1/16”, 10K FLANGE X 2” NIPPLE C/W 2”, 1502
WELDNECK H/U MALE at outlet – To be supplied loose.
Fig. 1.7: Choke and Kill Manifold

1.1.2 Workover Equipment/Tools
A. Slip
Slip is wedge-shaped device, lined with tooth-like gripping elements
(called dies). Tubing/ drill pipe slips are mechanical or hydraulic or air
actuated. Dies of slips holds the workstring suspended in the hole when
adding or breaking joints. Slips should be greased on its tapered side to
facilitate its removal. Slip handle hinges should be properly lubricated to
keep them working easily.
B. Elevators
An elevator is a hinged mechanism that may be closed around drill pipe
or tubing to facilitate lowering them into the wellbore or lifting them out
of the wellbore. The elevator is hinged in the block. A latch in the front
opens to allow the tubing to be placed in the elevator and in the closed
position, the elevator arms are latched together to form a load-bearing
ring around the component. A shoulder or taper on the component to be
lifted is larger in size than the inside diameter of the closed elevator. In
the open position, the device splits roughly into two halves and may be
swung away from the drill string component.
Fig.1.8: Tubing/ Drill Pipe Elevator
C. Sucker Rod Manual Wrench and Elevator

Lightweight elevators designed for running and retrieving the sucker-rod
string in wells equipped with a rod pump. Rod elevators can be used on a
workover rig or a rod unit specifically designed for running and
retrieving rod strings. Sucker rod elevators hang from a rod hook while
the working hand is used to latch on to the sucker rods. Latches on the
front of the sucker rod elevator must be open by the operator before the
rod can be released. This prevents the rod from falling out. To prevent the
elevator from accidentally latching onto rods hanging in the derrick, the

swivel centre portion of the elevator should be turned down so that it lies
parallel to the elevator arms when not in use.
Fig 1.9: Sucker Rod Wrench

and Elevator
D. Swivel and Rotary Hose

The main function of the swivel is to prevent the rotary motion of the
Kelly from being transferred to the casing line. The swivel consists of a set
of heavy-duty roller bearing on the lower halves of the swivel. As the
swivel has to carry the entire weight of the tubing/drill string, it must be
ruggedly constructed and of the same rating as the traveling block. The
swivel also allows mud to be pumped through the Kelly through an
inside attachment, described as gooseneck.
The swivel is connected to a standpipe through a flexible rotary hose and
surface line to the mud pump.
Ends of the rotary hose should be fitted with safety chains or steel wire
ropes to provide support in the event of failure of normal connections.
The pump end of the hose should be secured with the derrick by chain.
Swivel end of the hose pipe should be secured with a similar chain
fastened to the body of the swivel. In no case chain should be fastened
with the goose neck of the swivel.
While circulating workover fluid at high pressure, the operation crew
should remain at a safe distance from the rotary hose.

Fig 1.10: SWIVEL
E. Kelly & Kelly bushing

Kelly is a heavy square or hexagonal steel pipe machined from high grade
steel round bar. The main function of Kelly is to transfer motion to the
workstring when the Kelly bushing is engaged to the master bushing. The
Kelly also serves as a medium for transporting mud down to the
workstring pipes and to the BHA. All connections from the swivel
through upper section of Kelly are left hand threads. Torque imparted at
the Kelly tends to tighten rather than back off each section. The length of
the Kelly ranges from 11 to 16.5 metres. Normally size of Kelly used in
workover rigs is 31/2” square or hexagonal. Hexagonal Kelly holds up
better under greater hook loads and tensile stresses than do square Kellys.
Life of the drive section is directly related to the Kelly fit with the Kelly
drive. A square drive section normally will tolerate a greater clearance
with acceptable life as compared with hexagonal section.
Kelly should be kept and transported in such manner so that it does not
bend.

Fig 1.11 Kelly Bushings
F. Drill Pipe and Tool Joints

The drill pipe connects the rig surface equipment with the bottom hole
assembly and the bit, to pump drilling fluid to the bit and to raise, lower
and rotate the bottom hole assembly and bit. The drill pipe furnishes the
necessary length for the drill string and serves as a conduit for the drilling
fluid. Drill pipe sections (or joint) are hollow, seamless tubes
manufactured from high-grade steel. The tool joints are connectors for the
drill string are a separate component and are attached to the pipe after its
manufacture.
The API has listed specification for a number of tool joints type in its
standard, however individual manufacturers have many design
variations.
G. Drill Collar
Drill collars, a component of a drill string, are thick/ heavy walled, large
O.D. steel tubes that provide weight on bit for drilling while allowing the
lighter drill pipe to remain in tension. Using these, drillers are able to
increase penetration rates and drill straighter holes with fewer drill string
failures.
Drill collars are machined from solid bars of steel, usually plain carbon
steel but sometimes of nonmagnetic nickel-copper alloy or other
nonmagnetic premium alloys. The bars of steel are drilled from end to
end to provide a passage to pumping drilling fluids through the collars.
The outside diameter of the steel bars may be machined slightly to ensure

roundness and in some cases may be machined with helical grooves
(“spiral collars”). Threaded connections, male on one end and female on
the other, are cut so multiple collars can be screwed together along with
other down hole tools to make a bottom hole assembly (BHA). Gravity
acts on the large mass of the collars to provide the downward force
needed for the bits to efficiently break rock.
H. Tongs
A tong is simply a mechanical wrench. Tubing tongs, casing tongs, drill
pipe tongs perform the same function. The power tongs are powered by
air or hydraulics. A throttle handle that actuates engagement and dis-
engagement controls them. Recommended torque settings are marked on
the torque gauge. Because of differences between the rotating torque
values and stalled torque values, the relief valve setting should be
positioned at 15% or 20% less than the recommended setting before
operating the power tong at full speed.
In workover operations, some of the most serious accidents are caused
during making up or breaking up of the pipes. On many rigs, pipes are
coupled or uncoupled by means rope around the free element and drawn
by winch/ cathead, a process that entails risk for fingers and hands.
I. Pipe Spinner
The pipe spinner is used for screwing/unscrewing of tubular with a
specified torque, while the tongs are used for final tightening/ breaking
of joints.
F1.11: Pipe Spinner

1.2 DO’S & DON’TS
Do’s and don’ts of rig and rig equipment are covered in Chapter-3 ‘WORKOVER
OPERATIONS’ , Chapter-7 ‘WELL CONTROL EQUIPMENT’ , Chapter-14
‘SAFETY’ and elsewhere in this manual.

CHAPTER – 2
RIG BUILDING OPEARTIONS
2.0 GENERAL
During rig building, rig remains idle and therefore best efforts should be
made to complete all the activities in a shortest possible. Rig building
operations are very critical and require time bound fool proof planning
while ensuring safety in each operations/ activities. Rig building
operations involves following activities.
A. Site Preparations
B. Route Survey
C. Rig Release / Rigging Down
D. Load Handling, Transportation of Rig and Rig Equipment
E. Rigging Up
2.1 SITE PREPARATION (BEFORE RIG RELEASE)

1) Once decision is taken to deploy a rig on a well, all statutory and
regulatory clearances should be obtained, wherever it is necessary
2) It should be seen that no overhead electrical line passes through
well site area (at least 30 mts away from well mouth).
3) An area of 110 m x 110 m size should normally be available /
acquired for safe operation of a workover rig.
4) Based on the type of rig, the well site must be prepared for proper
placement of rig and associated equipment. The land around the
well site should be cleared, graded & levelled.
5) Surrounding area of all equipment foundation should be
hardened to bear the load of heavy transport vehicles. Hard
surfacing of the well site should be done for movement and
proper handling of equipment during rigging up.
6) Rig foundation should be prepared as per the rig manufacturer
design and design should be based on load bearing capacity of
soil. Check the level of the base foundation. Unevenness of the

foundation may cause problems in rig centring. Foundation level
should be maintained for sub base structure and for the auxiliary
equipments.
7) Rig foundation can be made new or by modifying the existing
foundation of drilling rig. However, levelling and load bearing
capacity of the rig foundation must be assured.
8) For auxiliary equipment placement, levelled foundation strips
should be made. If concrete slabs or wooden logs are used as
foundation for auxiliary equipment or workover fluid tanks, then
all the slabs should be at the same level and ground should be
strong enough to support the load.
9) If necessary, approach roads/ bridges/ culverts etc should be
repaired and appropriate areas around the rig should be surfaced
to facilitate the transportation of rig equipments.
10) Check the level of the base foundation. Unevenness of the
foundation may cause problems in rig centring.
Foundation level should be maintained for sub base
structure and for the auxiliary equipments
11) Anchors for top man escape device, wind guy ropes etc. Should be
grouted properly as per the recommendations of the rig
manufacturer/API. If old anchors are to be used, they should be
inspected for rust, damage, general condition, load bearing
capacity etc. To ensure they don’t fail during rig operation.
In the absence of mast manufacturer’s recommendations or where
mast manufacturer’s recommendations cannot be utilized because
of obstructions at the well site location (such as roads, pits,
energized power lines, etc.), then the values shown in API RP-4G:
Figure E3 are recommended.
12) Entire drill site area should be fenced with barbed wire and there
should be only one entry point.
13) X-mass tree of old wells in cluster location should be caged and
nearby wells should be checked for any leakage.
14) Security personnel should be posted at new location before
commencing transportation.

2.2 ROUTE SURVEY (BEFORE RIG RELEASE)
Route survey shall be conducted prior to rig shifting. In case, if any
problem related to following aspects is noticed, then it should be
rectified before start of rig shifting.
1) Check width and strength of the roads, bridges and culverts for
safe passage of rig and equipment during transportation.
2) Look for radius of curvature on turnings. Approach road
should not have sharp turnings as this may cause over
turning of trailers during transportation. Approach road
should preferably be such that enough space for vehicle
movement is available.
3) Look for any low lying electrical cables/transmission lines
crossing the approach roads. Disconnect/de-energise
them with the approval of Competent Authority, if
required.
4) Look for railway crossing and traction lines, obstruction due to
trees / branches, crossing points availability / requirement, traffic
in the cities en-route at peak hours.
5) Route survey team should consist of: -
Rig In-charge
Electrical Engineer
Civil Engineer
Logistics personnel
Land acquisition man
2.3 RIG RELEASE/ RIGGING DOWN

1) Derrick floor should be free of all unwanted materials prior to
lowering of mast. It should be ensured that there is no loose item
on mast members.
2) Flow line of the existing well or cluster wells, if any should be
protected from any inadvertent damage by using half cut casing
or sand bags.
3) It should be ensured that safety clips of every pin are in place.
4) Rotary hoses should be secured.

5) Mast raising and lowering lines, sheaves and their guards should
be inspected for any damage.
6) Tackle system should be checked for free rotation of pulleys.
7) Proper functioning of the clutches, brakes and quick release valve
should be checked.
8) It should be ensured that the monkey board railings and fingers
are folded.
9) All long hanging lines, cat lines, and sand lines should be tied up
to the mast.
10) Ensure that all un-wanted persons are away from rig floor during
mast lowering.
11) Before telescoping top section down :
a. Release all guy lines to allow easy retraction of load
b. Bleed air from rams and circulate hydraulic oil (one
complete cycle) before releasing load latches.
c. Uncouple all electric and air lines in mast and free all other
lines
d. Remove tools/ loose material from derrick
e. Unlock the mast locking system
12) Mast should be lowered at slowest possible speed. Application of
brakes at any stage should not create any jerk. During lowering,
check the rotation of the pulleys, and if any abnormality is
observed, operations should be stopped for taking corrective
action.
13) A designated experienced person who knows the procedures
should lower the mast.
2.4 LOAD HANDLING AND TRANSPORTATION OF RIG

1) Rig equipment dimensional details, weight with regard to
transportation should be well documented. Proper transport fleet
should be deployed chosen based on equipment dimensions and
weight and route selected, especially in hilly area.
2) Capacity and fitness certificates of transport fleet including cranes
should be checked/ ensured before commencing load handling/
shifting.

3) Ensure that crane operator and other logistic crew are working
with proper PPE.
4) Planks / concrete slabs should be provided below the crane jacks
based on the weight of the equipment to be lifted and soil
condition.
5) Hooks for lifting should be engaged only on lifting lugs/eyes
provided on the equipment being lifted.
6) Unwanted person should not be allowed in the vicinity of the
lifted load. Tug lines should be used for handling loads while
lifting / placing. Never walk under suspended load.
7) Damaged or kinked or twisted slings should not be used for lifting
of loads. Only undamaged and load certified slings should be
used.
8) On trailers, load should be properly secured with chains/ropes
during transportation.
9) The equipment with liquid inside the tanks e.g. workover fluid,
diesel etc. Should not be lifted/ transported.
10) Minimum clearance from overhead lines to the transporting
equipment shall be maintained. In case minimum clearance
required is not met, then power lines shall be de-energized/
disconnected.
11) In case there are sharp bends and/ or sloppy hill terrains en route
to well site, there may be need to dismantle the mast from the rig
trailer. This type of situations should be considered well in
advance to avoid problems in transportation of the rig
12) Transportation of Mobile Rig
Prior to taking the carrier mounted rig on the road for
transportation to well site, the carrier should be checked to ensure
that it is in proper operating condition. Following, but not limited
to, should be checked:
a. Tyres pressure
b. Pneumatic/ air system pressure (100 psi minimum)
c. Engine instruments are functional
d. Power steering oil level

e. Radiator water level
f. Fuel level
g. Lubrication oil level: check with dipstick the lubrication oil
level of engine crankcase, hydraulic reservoir, and torque
converter/transmission.
h. Drive control in-position
i. Transmission in neutral
j. Derrick lowered
k. Rigs brakes on
l. Rig tied down
m. Inter-axle differential in unlock position
n. Wheel brake system
o. Parking brake released.
p. Mast is secured to the carrier.
q. Proper pads are available at mast rest.
r. Secure all matting boards, cables, etc.
s. Secure travelling block in its cradle
t. Ensure that jacks are retracted to maximum.
2.5 RIGGING UP
1) Ensure all equipment reaches at new location in good working
condition.
2) Align sub-base structure to the centre of the well. Assemble the
sub-structure. Place the rig on foundation and level the rig.
3) All hoisting lines, casing and sand lines should be inspected
thoroughly for broken wires, corrosion, incidental damage etc.
4) Fix the casing line guide roller on the mast wherever it is
applicable.
5) Reeve the travelling block, fix fast end, spool the casing line on
drum and tighten the dead end properly.
6) Check functioning of clutch and brake.

7) Check mast members for corrosion, cracks and bends etc before
lifting.
8) Grease all the pins before fitting and fit all the safety clips in all
pins.
9) Observe casing line of tackle system for any obstruction with
monkey board while lifting of mast.
10) Before raising mast to vertical position :
a. Level the rig from side to side.
b. Get the mast free and ready to raise (hoses, cables, lines,
etc.).
c. Unwanted lines like tong hanging lines, cat lines etc. Should
be tied to the side of the mast to avoid entangling during
lifting of mast.
d. Check the hydraulic fluid level.
e. Bleed the air out of all erect cylinders by circulating the
hydraulic oil. ( one complete cycle).
f. Make sure derrick and guy lines will not come within close
proximity to power lines.
g. Park automobiles out of fall lines.
11) While mast is raising :
a. Unwanted crew members, not involved in operation of
raising mast, should be at safe distance from the rig carrier,
rig floor and mast.
b. No employees should be allowed in derrick before mast is
engaged.
c. Keep block positioned in its cradle during this operation.
d. Keep all lines free while mast is being raised.
e. Raise the mast with slowest possible speed while observing
the lifting mechanism sheaves for any hindrance in rotation.
f. Keep a watch on hydraulic oil pressure. If it exceed the
normal operating pressure, stop the operation and check the
system before proceeding further.

g. Keep a watch on sequence of ram opening during mast
raising operation. If any abnormality observed, stop the
operation and check the system before proceeding further.
12) While Telescoping the mast:
a. Check again to insure that all wire lines stay clear.
b. Secure mast properly to the base section with bolts.
c. Operator should keep the travelling block close to the floor
at all times during the operation
d. Move ram stabilizers into place and properly secure the
telescoping ram cylinder.
e. Bleed out air from the cylinders by circulating the hydraulic
oil. ( one complete cycle).
13) After mast is up :
a. Climb the derrick (with a ladder climbing safety device) to
visually inspect load latches are engaged and properly
locked.
b. Operator should crack control valve to “lower position to
relieve pressure on telescoping cylinder.
c. Tighten load guys with equal tension.
d. Space out crown wind guys according to manufacturer’s
specifications.
e. The guy wires should never be turned back over small
radius eyes when making an end termination. Wire rope
thimbles or appropriately sized sheaves should be used to
turn back the guy wire ends.
f. Guy wire hardware such as shackles, turnbuckles, walking
boomers, chain come-a-longs, load binders, etc., that remain
in the live guy wire system should have safe working load
capacities.
g. The use of grab hooks or open hooks on guy wire
terminations is not recommended.
h. Lock mast erection control valve in neutral.
i. Align block and hook with well centre.
j. Inspect guy lines for the required number of clamps.

2.6 PROCEDURE FOR RAISING AND LOWERING OF MAST
As procedure for lowering and raising the mast may differ from rig to rig,
procedure as recommended by the manufacturer in operation manual
should strictly be followed. The recommended practices described above
are general in nature based on experience and should be followed to
inbuilt safety in operations. Further, following checks should be
performed and recorded before initiating the rigging up or down
operations;
a. The well has been killed/ closed and is in inactive
condition.
b. Hydraulic and pneumatic pressure lines functioning and
sealing.
c. Test pneumatic system of rig at a pressure 1.5 times the
working pressure but not less than 3 atmosphere above the
working pressure.
d. Check brakes, pins and shoes (if necessary burn brakes in
case there is oil on the same).
e. Lubrication of all necessary parts.
f. Locking device functioning properly.
g. Briefing of all operating crews and defining signalling
procedures.
h. Do away with the jerks while lowering and raising the mast.
i. Emergency plan drawn up and briefed to the operating
crews.
j. Raising and lowering of mast should be done in daylight
k. Guy lines, sub lines and such other lines shall not be
installed within six metres of any electric overhead
transmission lines.
l. All normal checks, as per the instructions of manufacturer,
during positioning, rigging and de-rigging should be made
and recorded.

2.7.1 DO’S
1) Obtain all statutory and regulatory clearances.
2) For safe operation of a workover rig, ensure the availability of an
area of 110 m x 110 m size.
3) Ensure no overhead electric line is passing through well site area
(at least 30 mts away from well mouth).
4) Cellar pit size should be reduced to 1.1 m X 1.1 m in size, if
necessary, and rig specific foundation should be made for
placement of rig.
5) Based on the type of rig, the well site must be prepared for proper
placement of rig and associated equipment. The land around the
well site should be cleared, graded & levelled. Surrounding area
of all equipment foundation should be hardened to bear the load
of heavy transport vehicles. Hard surfacing of the drill site should
be done for movement and proper handling of equipment during
rigging up.
6) Rig foundation should be prepared as per the rig specifications
and designed based on load bearing capacity of soil. Check the
level of the base foundation. Unevenness of the foundation may
cause problems in rig centring. Foundation level should be
maintained for sub base structure and for the auxiliary
equipments.
7) For auxiliary equipment placement, levelled foundation strips
should be made. If concrete slabs or wooden logs are used as
foundation for auxiliary equipment or workover fluid tanks, then
all the slabs should be at the same level and ground should be
strong enough to support the load.
8) If necessary, approach roads/ bridges/ culverts etc should be
repaired and appropriate areas around the rig should be surfaced
to facilitate the transportation of rig equipments. Approach road
should preferably be such that enough space for vehicle
movement is available.
9) Anchors for top man escape device, wind guy ropes etc. Should be
grouted properly as per the recommendations of the rig
manufacturer. If old anchors are be used, they should be

inspected for rust, damage, general condition, load taking capacity
etc. To ensure they don’t fail during rig operation.
10) Entire drill site area should be fenced with barbed wire and there
should be only one entry point.
11) X-mass tree of other wells in cluster location should be caged.
12) Check width and strength of the roads, bridges and culverts for
safe passage of equipment during transportation.
13) Look for radius of curvature on turnings as sharp turnings may
cause over turning of trailers during transportation.
14) Look for any low lying electrical cables/transmission lines
crossing the approach roads. Disconnect/ de-energise them with
the approval of Competent Authority.
15) Look for railway crossing and traction lines, obstruction due to
trees / branches, crossing points availability / requirement, traffic
in the cities en-route at peak hours.
16) Derrick floor should be free of all unwanted materials prior to
lowering of mast. It should be ensured that there is no loose item
on mast members.
17) Flow line of the existing well or cluster well, if any should be
protected from any inadvertent damage.
18) Mast raising and lowering lines, sheaves and their guards should
be inspected for any damage.
19) Tackle system should be checked for free rotation of pulleys.
20) Proper functioning of the clutches, brakes and quick release valve
should be checked.
21) Test pneumatic system of rig at a pressure 1.5 times the working
pressure but not less than 3 atmospheres above the working
pressure.
22) It should be ensured that the racking board, stabbing board,
railings, fingers of monkey board etc. Is folded wherever
applicable.
23) Rotary hoses should be secured.
24) All long hanging lines, cat lines, and sand lines should be tied up
to the mast.

25) Ensure that all un-wanted persons are away from the rig floor
during mast lowering/ raising.
26) Before telescoping top section down , release all guy lines, bleed
air from rams and circulate hydraulic oil before releasing load
latches, uncouple all electric and air lines in mast and free all other
lines, unlock the mast locking system.
27) A designated experienced person who knows the procedures
should lower the mast.
28) Select proper transport fleet based on equipment dimensions and
weight and route selected, especially in hilly area.
29) Wooden planks / concrete slabs should be provided below the
crane jacks based on the weight of the equipment to be lifted and
soil condition.
30) Hooks should be engaged only on lifting lugs/eyes provided on
the equipment.
31) On trailers, load should be properly secured with chains/ropes
during transportation.
32) Dismantle the mast from the rig trailer in case there are sharp
bends and/ or sloppy hill terrains en route to well site.
33) Prior to taking the carrier mounted rig on the road for
transportation to well site, the carrier should be checked in all
respect to ensure that it is in road worthy and in proper operating
condition.
34) Inspect all hoisting lines, casing and sand lines thoroughly for
broken wires, corrosion, incidental damage etc.
35) Reeve the travelling block, fix fast end, spool the casing line on
drum and tighten the dead end properly.
36) Check functioning of clutch and brake.
37) Check mast members for corrosion, cracks and bends etc before
raising.
38) Grease all the pins before fitting and fit safety clips in all pin.
39) Observe casing line of tackle system for any obstruction with
monkey board while raising the mast.

40) Before raising mast to vertical position, level the rig, make the
mast free from hoses, cables, lines etc. By tying them to the side of
the mast to avoid entangling during lifting of mast, check the
hydraulic fluid level, bleed the air out of all erect cylinders and
circulate the oil.
41) Unwanted crew members, not involved in operation of raising
mast, should be at safe distance from the rig floor and mast.
42) After mast is up climb the derrick to visually inspect that load
latches are engaged and properly locked.
43) Tighten load guys with equal tension, space out crown wind guys
according to manufacturer’s specifications, lock mast erection
control valve in neutral.
44) Align block and hook with well centre and inspect guy lines for
the required number of clamps and proper tension.
45) Strictly follow the procedure for lowering and raising the mast as
recommended by the rig manufacturer.
46) Raising and lowering of mast should be done in daylight
47) Guy wire hardware such as shackles, turnbuckles etc. That remain
in the live guy wire system should have safe working load
capacities.
48) Rig should be of sound construction, maintained in safe working
order, adequate strength, sufficient height and should be
adequately secured to prevent it from overturning because of
wind velocity and dynamic loading’
49) Guy ropes should be anchored properly as per the
recommendations of the manufacturer/API.
50) All normal checks, as per the instructions of manufacturer, during
positioning, rigging and de-rigging should be made and recorded.
51) All loose parts and tools shall be securely fastened.
52) The exhausts of internal combustion engines shall be provided
with water quenched or other effective spark arrestors.
53) While dismantling the rig the wellhead shall be protected against
damage from sliding or falling object.
54) Tongs, ends of rotary hose and suspension sheaves shall be fitted
with Safety Chains or wireline.

2.7.2 DON’TS
1) Don’t transport equipment/ tanks with liquid inside e.g.
workover fluid, diesel etc.
2) Don’t use damaged or kinked or twisted slings for lifting of loads.
Only load tested and certified slings should be used.
3) Never walk under suspended load
4) Do not use grab hooks or open hooks on guy wire terminations.
5) Don’t allow any person in derrick before mast is engaged.
6) Never turn back the guy wires over small radius eyes when
making an end termination. Wire rope thimbles should be used to
turn back the guy wire end.
7) Don’t allow any one to work at site without proper PPE.

CHAPTER – 3
WORKOVER OPERATIONS
3.0 GENERAL
Inspection and preparing the well for workover is of prime importance.
Well head, X-mas tree valves, flanges and fittings should be inspected in
advance for any damage/ corrosion, leakage or passing etc. Missing or
damaged valves and fittings should be replaced before rig is moved in.
Ensure that well head/ X-mas tree valves and fittings comply with API
criterion. Each annulus/ outer annulus should be checked for any
pressure. Corrective action/ precaution, if there is any, should be
addressed in workover plan of the well.
After placing all equipment as per standard layout plan and completing
the rig building at well site, next operation is to kill or subdue the well.
Before initiating the well killing operation, well should be shut to allow
the bottomhole pressure to stabilize. The well shall then be isolated from
all external control systems and the lines should be isolated by providing
double barriers.
Before calling pre-workover conference, readiness/ availability of the
following items must be ensured.
1) Workover plan incorporating the well completion details, history
of the well; complications encountered during drilling
/workover; completion of the well including details about the
casing and cementing, perforations, downhole equipment, tubing
and X-mas tree; problem in the well; present and expected
bottom hole pressure and temperature after workover job; type of
workover fluid and weight to be used; details of operation to be
carried out/ stepwise activity plan and other relevant details as
deemed necessary should be prepared and made available at site/
with Rig In-charge. All the shift in-charges shall be aware of the
content of such work-over plan.
2) Kelly, Kelly drive bushings, Kelly top sub, Kelly saver sub, upper
and lower Kelly cocks etc.

3) All type of handling tools like tubing and drill pipe elevators,
slips, pipe spinner, power tongs, tubing tongs, drill collar safety
clamps, FOSV etc.
4) Required quantity of proper size and type of drill string including
drill collars for drilling/milling and fishing operation.
5) Adequate quantity of HSD, oil and lubricants.
6) Fire fighting equipment duly inspected.
7) Chemicals required for preparation of workover fluid.
8) Supply of water for workover operations and drinking purpose.
9) Pressure testing of high pressure lines and air tank
10) Functional check of the available instruments like weight
indicator, tong torque gauge, rotary RPM meter, rotary torque
gauge, etc.
11) Functional check of power generating system, rig & hoisting
equipment, workover fluid circulating system
12) Ensure the quality of make up and break up tong lines is good.
Functional checks of hydraulic cylinder (make up & break out).
13) Safety kit and first aid kit as per the Mines Regulations.
14) Availability of Ambulance/Emergency vehicle.
15) Well head, BOP stack, choke and kill manifold as per well
requirement & functional and pressure tested to its rated capacity.
16) Functional checks of Twin stop device and Topman Evacuation
and Escape Device (TEED).
3.1 PRE-WORKOVER CONFERENCE AND SAFETY

MEETINGS:
Prior to commencing of any Workover operation, a pre-workover
conference shall be held with all personnel involved, covering procedure
for operation, hazards associated and emergencies. Pre-workover meeting
shall ensure the participation of the following personnel or their
representatives:
i. Area Manager
ii. Rig I/C
iii. Chemist

iv. Installation I/C
v. Representative from Health Safety & Environment - Well
Services
vi. Rig Safety Officer
vii. Mines Safety Officer
viii. Rig Maintenance I/C
ix. Representative from Maintenance Section- WS
x. Representative from Civil Engineering Section
xi. Representative from Logistics Department
xii. Representative from Fire Services Department
Above team should audit the compliance of safety norms as per Pre-
workover checklist (OISD Std-190) placed at Annexure-I at the end of this
chapter. The observations of the audit teams and earlier recommendation
(if any) must be rectified before commencement of operation.
3.2 SAFETY MEETINGS AND DRILLS

Controversial matter like employment difficulties, complaints, criticism or
similar nature should not be brought up in the safety meeting. On the job
safety meetings should be conducted weekly covering safety of crew,
safety aspects of operations, prevention of equipment damage and
associated hazards etc and the following:
• A short safety meeting whenever the workover job changes to the
extent that instructions are necessary or other circumstances that
might warrant a meeting.
• The meeting shall cover safe procedures for operation, hazards
associated & emergencies.
• The Driller-in-charge should instruct other crew members for
proper use of any equipment on the rig. The crewmembers
periodically should perform safety inspection of the rig and
associated equipment.
• Some topics of Safety Meeting are:
o Personal protective equipment (hard hats, safety shoes, face
protection etc)
o Operation of new equipment

o Fire extinguisher demonstration
o Emergency first aid procedures
o Equipment inspection procedures
o Well control methods/procedures
Date and time of safety meetings shall be recorded. Rig DIC to record all
safety points in Installation Managers Diary on daily basis
3.3 KILLING OR SUBDUING OF WELL:

1. Observe the well before subduing operation. Record shut in
pressure in tubing and annuluses of the well.
2. Before opening a well by removing x-mas tree / tubing hanger,
the formation pressure must be balanced by hydrostatic pressure
of workover fluid of desired density with minimum overbalance
pressure (5-10%). Workover fluid is pumped in the well by
forward (tubing to casing) or reverse circulation (casing to tubing)
3. Well subduing procedure and workover fluid should be designed
based on well type, well completion, formation pressure,
formation temperature, compatibility with formation / formation
fluid etc.
4. The line shall be tested 1-1/2 times the anticipated STHP or rated
working pressure which ever is less. No hammering shall be done
on pressurized line.
5. Monitor pump pressure during subduing. Monitor and check the
parameter of return fluid during circulation till well is properly
conditioned and stabilized.
6. If no pressure is observed, undertake flow test. If flow test is
negative, removal of X-mas tree / tubing hanger can be
undertaken.
7. If there is pressure in tubing and /or annulus, the well is allowed
to bleed of the gas. And as soon as liquid is observed, well should
be closed. Subsequently, the well is circulated with suitable work
over fluid to stabilise and condition the well. Again flow test is to
be performed. If flow test is negative removal of X-mas tree /
tubing hanger can be undertaken. However, if the flow test is
positive, well is showing pressure, it means that trapped pressure

is still in the well, which may require another one or two cycles of
circulation of kill fluid to stabilise the well.
8. Successful subduing of the well will be reflected by zero static
tubing and annulus pressure. To ensure that well is completely
dead, well should be open to pit / tank for 30 – 60 minutes to
check the activity of the well. If no activity, further operation for
removing the x-mas tree/ tubing hanger should be initiated.
9. Till flow test is negative, no attempt should be made to open the
well by removing X-mas tree/ Tubing hanger.
10. In SRP wells (tubing and insert pumps), circulation is established
only after lifting the polished rod by 4-5 ft, so that pump is out of
the catcher and providing path for circulation.
11. In other artificial lift completion wells / other type of
completions, subduing procedure should be designed
accordingly.
12. There are number of kill procedure available (namely forward
circulation, reverse circulation, Bullheading, deploying CTU,
lubricate and bleed etc.). Depending upon the circumstances that
prevails such as tubing and casing integrity, ability to circulate the
fluid from tubing to annulus or from annulus to tubing, formation
pressure, type of well fluid in the well etc, kill procedure should
be selected.
13. Bullheading is recommended where it causes no damage to the
formation.
14. Check for short circulation or quick pressure build-up during
subduing operation.
15. While subduing a well, the return line should be connected to the
Group Gathering Station (GGS)/ kill tank at well site.
During subduing, return line is connected to GGS to avoid oil
accumulation at well site. Usually the distance between the GGS
and the well is sometimes 2 to 3 kms. or even more. A significant
amount of pressure drop is experienced in flow lines of the well
leading to GGS that may cause additional back pressure to the
well and may create a fluid loss situation.

It is best practice to kill the well at well site in kill tank and then
pumping of produced oil/fluid in the well flow line that is
connected to the GGS.
16. In EOR effected fields, where under layers are charged due to
insitu combustion, sufficient quantity of water should be injected
in to the formation to form a barrier between well bore and air/
flue gases. Kill fluid should be circulated only when THP/CHP
become zero. to more.
3.4 X-MAS TREE AND TUBING HANGER REMOVAL

Christmas tree and tubing hanger removal requires careful planning. All
procedures should be well defined, reviewed and clearly understood by
rig crew and service personnel involved in the job. Once the job has been
planned and preliminary steps, like well killing, taken, work can begin for
X-mas tree and tubing hanger removal.
3.4.1 X-mas Tree Removal
1. Hold x-mas tree by tying it with a sling of proper load capacity.
2. Unscrew the nut-bolts of lower master valve of Christmas tree.
3. Lift the X-mas tree and place it at a proper safe distance from the
well head.
4. Inspect the nut-bolts, rings and ring groove. Lubricate and service
them, if required and keep them at a place (may be in store) from
where these can be available readily while installing the x-mas
tree.
3.4.2 Tubing Hanger Removal

1. Inspect and lubricate tubing hanger lift threads. These may be
corroded and may not be able to support the string weight.
2. Pick up to pull out of seals (or release packer) and remove tubing
hanger.
3. Stack tubing hanger at proper place.
4. Wells completed with packer and Tubing Hanger flange, ensure
that all T/H flange studs’ bottom nuts are removed so that T/H
flange can be lifted up and string can be put on spider slip for
unscrewing of T/H flange. BOP stack can be installed before
releasing the packer.

3.5 BOP INSTALLATION
1. Inspect the well head spool and groove of the ring and ring itself.
Clean the groove, lubricate and replace the ring, if required. Place
the lubricated new ring (proper rating and size) properly in the
ring groove.
2. Lift a serviced and pressure tested BOP stack and center it on
wellhead spool.
3. Install and tighten all BOP studs/bolts manually or preferably by
using a torque wrench.
4. Conduct function and pressure test of BOP.
(For details on selection, sizing, installation procedure, pressure and
functional testing of BOP stack please refer Chapter -7)
3.6 OPERATING PRACTICES OF EQUIPMENT

3.6.1 Procedures for Connecting Kelly, Swivel and Hook
1 The Kelly is connected to the swivel through a left hand
substitute. The swivel hangs in the hook with the help of a bail.
2 Engage the rotational lock in the desired direction of the hook
(hook tongue facing towards the swivel bail).
3 Keep the hook at a desired height so that the hook’s tongue can
enter the swivel bail on pushing the block and hook system
towards the swivel. When the hook’s tongue enters the bail of the
swivel, lift it up slowly and put the lock of the tongue in position.
4 After positioning the lock at correct place, lift the block and hook
in slow speed.
5 Care must be taken to prevent the hitting of the Kelly into the
pipe, resting on the rotary table. A rope may be used to control
the movement / rushing of Kelly from V-door/ slope.
3.6.2 Procedure for Disconnecting Swivel and Kelly from Hook
1 After disconnecting from drill string, lift the Kelly sufficiently and
put thread protector on Kelly saver sub.
2 Pull the Kelly (with a winch line, if available) towards the slope
and slowly lower it on the slope.

3 The hook is freed from the swivel by opening the tongue of the
hook and bringing out the hook from the bail. Then free the block
and hook.
4 The lock which restricts the rotation of the hook is then
disengaged and thus the block and hook become ready for
handling the drill string or for doing any auxiliary job. The tongue
lock of the hook is then closed.
3.6.3 Checking of Master Bushings and Rotary Slips
A slip test is an invaluable aid for determining the degree of rotary
equipment wears. This test should be performed every three months
and each time a new master bushings or set of slips with set of new
dies is put into service.
To determine effective gripping action of the rotary slips and master
bushings, follow simple field test procedure as described hereunder.
1 Pick up string and clean an area of pipe where there is no insert
marks and clean slip inserts with a wire brush.
2 Wrap two layers of test paper around the cleaned section of pipe.
Use adhesive tape at the top and bottom of the paper to hold it in
place.
3 Place the slip around the pipe against the paper. Hold the slips in
place while the pipe is being lowered at normal speed.
4 For accurate results, use a hook-load of at least 50000 to 100000
pounds.
5 After the slips are set, hold them firmly around the pipe as it is
raised. The slips should be carefully removed to prevent damage
to the paper.
6 Then carefully remove the paper. Observe the second layer of the
paper because the outside layer will have misleading slip
impressions.
7 Carefully examine gripping area to determine length,
circumferential amount and uniformity of holding by gripping
elements.
8 If the rotary master bushings and slips are in good condition, a
uniform gripping can readily be observed, matching the length of
the slip being employed. Under such conditions, the total

transverse load would be equally distributed over the maximum
slip area and crushing will not occur. If a full insert contact is
indicated, the master bushing and slips are in good condition and
no further analysis is necessary.
9 If the gripping pattern is such that it does not conform to the
entire slip, either the slips, or the master bushing or both are out
of specification. To determine which is at fault, the same tests
should be repeated with a new or like new set of rotary slips. If
this corrects the problem and the pattern is uniform, it is the
rotary slips which were at fault. On the other hand, if on using the
new rotary slips, the uniform pattern is not observed, the master
bushing is out of specification. It is necessary that the slips and /
or the master bushing be properly repaired or replaced
immediately.
3.6.4 Slip Handling Technique
1 Stop the downward motion of the drill pipe with the brake not by
the slips.
2 Do not let the slips ride the pipe. This not only damages the slips
but also reduces the configuration of the gripping elements.
3 Do not use slips designed for one specific size of pipe on any
other size of pipe.
4 If slip is not holding the pipe due to worn out dies, the same must
be replaced immediately. Slippage of pipe through the slips due
to worn out inserts can result in dropping of the pipe.
5 All damages to rotary slips should be immediately attended.
Avoid using old and new dies in combination. Never re-sharpen
inserts. Doing so will cause improper contact with the pipe,
resulting in both pipe and slip damage.
6 Never catch the tool joint box in the slips when the driller slacks
off. This often happens when coming out of the hole and the
driller does not pick up high enough for the slips to fall around
the pipe properly.
7 Rotary slips shall be set using handles with hand palms up. It is
forbidden to kick the slips into the rotary table bowl. When
finishing a trip or a connection, the rotary slips shall be set back
well clear of rotary table

3.6.5 Elevator Handling Technique
1 Elevators must be selected in different sizes to fit the size of the
tubing/ drill pipe being handled.
2 Elevators should be securely latched to the pipe.
3 Elevators links should be securely latched with the hook by lock
nuts or suitable pins.
4 While latching an elevator in motion, the rigman should place
their hands around the pipe only till the elevator has been
brought to complete stop, as otherwise it may results in injury to
the hands.
5 When tripping in or out of the hole, the rigman shall grasp the
elevator horns and the elevator links approximately 0.4 meters up
on the elevator links. Hands shall never be placed on or around
the link eyes where elevators can pinch.
3.6.6 Tongs Handling Technique
1 Uncontrolled rotation of pipes shall be effectively prevented
while making or breaking pipe connections. A back-up tong shall
be used for this purpose, whenever required.
2 Never use one tong as it greatly increases the possibility of
bending or “hooking” the pipe at the rotary. When making up or
breaking out drill pipe stands without back-up tongs, the pipe
may slip enough to make bad scars. Such scars are usually spiral
in nature because the pipe is dropping while it is slipping.
3 Both the tongs should be hanged ready for its use.
4 Tongs shall be placed opposite to each other (90 degree or 180
degrees apart) in such a manner that slipping and opening of the
jaws of the tongs is avoided when the pull is exerted.
5 Pull should not exceed recommended makeup torque with tongs
at 90 Degrees to the jerk line.
6 Keep the tool joint as close to the rotary table as possible during
makeup and breakout. There is a maximum height that a tool
joint may be positioned above the rotary slips and the pipe resist
bending.
7 Safety ropes controls the movement of the tongs, however, in case
rope break, serious accident can happen.

8 Tongs should be fitted with safety lines of sufficient length to gain
full benefit of pull from the break out cathead but should be short
enough to prevent complete rotation of the tongs.
9 The ends of tong safety lines shall be secured with not less than
three nos. of “U” clamps. Lines of tongs counter balance weights
shall be provided with guards to prevent accidental contact.
10 Welded tongs must not be used.

11 Torquing tool joints properly is the most important single factor
in prevention of tool joint troubles. Torque measuring equipment
should always be used to prevent under or over torquing.
3.6.7 Kelly Handling
1. Usually, two pressure safety valves are made up, one on each end
of the Kelly. The top one is called the upper Kelly cock and the
other valve, on the bottom of Kelly, is called the lower Kelly cock.
One or both of these valves can be closed to prevent the pressure
that may be coming up the drill stem from entering the Kelly or
rotary hose.
2. A lot of wear and tear is produced on the threads located on the
pin end of the Kelly, which always faces downward. To
counteract this, a Kelly saver sub should be used. A Kelly saver
sub is a piece of pipe with a male (pin) and a female (box)
threaded end. When the threads on the sub wear out or are
damaged, a new sub is made up to the Kelly.
3. Other than thread damage, three conditions may cause a Kelly's
removal from service:
i. Crooking or bending.
ii. Fatigue in the drive section.
iii. Rounding of the drive corners.
4. Several things can cause a Kelly to bend or crook. Most of them
result from poor handling. Dropping the Kelly, transporting it
along with heavy pipes without proper support, side pulling of it
with cable and loading or unloading it carelessly are some of the
practices that can cause damage.

5. In a Kelly, two areas are susceptible to fatigue under certain
conditions - the ends, where the flats join the upsets (thickened
areas) and the middle.
6. Rounding of the drive corners of the Kelly is a normal wear
process and should be expected. It is caused by the compressive
force of the drive rollers on the Kelly flats surfaces. It is
compounded and hastened by rotary torque and ever-growing
clearance between rollers and flats as wear continues. To lessen
rounding, following steps are suggested:
i. New Kelly should be used with new Kelly bushing roller
assemblies.
ii. If the assemblies are adjustable by adding or removing
shims, the roller must be adjusted for minimum clearance.
iii. Drive assemblies must be periodically replaced to ensure
that clearance from wear is held to a minimum.
iv. Kelly drive surfaces should be regularly lubricated.
No matter how well a Kelly is cared for; its corners eventually
become rounded.
7. Kelly should not be lifted from the derrick floor until the swivel is
securely latched to the hook.
8. Kelly should be kept and transported in such manner so that it
does not bend.
9. To increase the working life of a Kelly - use a saver sub; lubricate
the drive surfaces; do not use a crooked Kelly and do not weld on
the drive corners.
10. Inspection procedure for used Kelly:
i. Examine junctions between upset and drive section for
cracks.
ii. Check corners of drive section for narrow wear surface
particularly on hexagonal Kelly.
iii. Kelly straightness can be checked by watching for
excessive swing of the swivel and travelling block while
drilling,

3.7 TRIPPING PRACTICES
Pulling-out and running-in tubing/ drill pipes are part of well servicing
operations. Recommended safety guidelines and practices should be used
during tripping operations to prevent accidents and personal injury.
Before starting operations, brief the crew about the functioning of various
equipment and the important checks required to be performed.
1. Proper method of un-flanging well head and/or removal of
"donut".
2. Safe set-up for power tubing tongs and its operations.
3. Condition and functioning of various types of elevators, and
manual slips and tubing tongs and their use.
4. Proper torque on tubing/ drill pipes/ sucker rods make-up.
5. Topman escape device and safety belt.
6. Weight Indicator/ recorder (drill-o-meter) and its calibration.
7. Ensure that BOP pressure and functional testing has been done
and documented.
8. Both crown-o-matic and floor-o-matic safety devices are to be
checked for their proper functioning.
9. Availability of quick shut-off valve.
10. Check that both pneumatic and mechanical brakes are
functioning properly. Ensure that all brake band pins, their
locking cotter pins are in place.
11. Check the emergency kill provided at driller's panel.
12. Check the railings of monkey board and top man safety belt.
13. Place a rubber flapper on well head to prevent any foreign
material falling into the well.
14. The blocks shall not be moved until the driller ensures that the
topman has the safety harness on and properly secured. The
topman shall verbally confirm this to the driller.
15. Availability of various types of required number of fire
extinguishers and other equipment to fight the fire.
16. Ensure that brake cooling system and hydromatic braking is
functioning properly.

17. Use proper size pipe wiper during R/I and P/O operations. It
will not only help in keeping the string surface free of oil and dirt
but it also protect the well from falling of any foreign object in to
the well.
3.7.1 Procedure for Making up Joints (Running in - RIH)
1. Tubing/drill pipe or stand is picked off from storage (stabbing
board/Pipe racks) by elevator of the travelling block and swung
into the place over the tubing wedged in the rotary table.
2. Clean and inspect the threads of the pin and box joints of the
tubing / drill pipe, drill collar, if found all right, apply thread
dope.
3. Initially tighten tubing/ drill pipe using spinner. Drill collar joints
to be tightened initially with the help of chain tong.
4. Use the safety clamp for plain D/C. Measure & record their
length, ID and OD in BHA book.
5. As the upper joint is tightened to the lower joint, the drill-o-meter
needle will show that the pipe is in tension. When this happens
the block should be released slightly so that the weight indicator
shows weight equal to that of an empty block and the drill collar.
6. The tubing / drill pipe joint is then finally tightened with tongs.
7. The tubing/ drill string is then hoisted sufficiently to permit the
removal of the slip from the rotary table and the pipe is lowered
into the well.
8. After running in the required length of tubing in the well, the slip
is again set between pipe and bowl of the rotary table so that the
tubing rest on slips.
9. Unlatch elevator from the tubing for picking and lowering of next
tubing/ drill pipe.
Note:
a. Clean & dry the joint which is being added to the string.
b. The box threads and shoulders should be doped, distributing the
compound over the threads and the mating surfaces preferably
with a round, stiff bristle brush. Use of excessive dope over the
threads inside the box should be avoided as excessive dope will
go down and inside the tubular string while screwing.

c. Do not dilute the thread compound for the ease of application.
Dilution of thread doped will reduce the amount of available
metal filler and make the compound ineffective.
d. Pipe should never be made up by reversing the rotary table.
e. Manila rope should never be used over the drill pipe threads.
f. All tubing/ drill pipes, whether new, used, or reconditioned,
should always be handled with thread protectors in place.
g. Tubing should be handled at all times on racks or on wooden or
metal surfaces free of rocks, sand, dirt other than normal drilling
mud. When lengths of tubing are inadvertently dragged in the
dirt, the threads should be re-cleaned and serviced.
h. Carefully inspect the thread and make sure that threads are
undamaged, clean and well coated with compound before
running. Those found damaged, even slightly, should be laid
aside unless satisfactory means are available for correcting thread
damage.
i. Before running in the hole, tubing should be drifted with an API
drift mandrel to ensure passage of pumps, swabs and packers.
j. Elevators should be examined to note if latch fitting is complete
k. Spider slip that will not crush the tubing should be examined
before using to see that they are working together.
l. Tubing tong that will not crush the tubing should be examined
and use in the body of the tubing and should fit properly to avoid
unnecessary cutting of the pipe wall. Tong die should be fit
properly and confirm to the curvature of the tubing.
m. The use of pipe wrenches is not recommended.
n. The length of each pipe should be measured prior to running
3.7.2 Procedure for Breaking Up Joints (Pulling Out – POOH)
1. Before starting pulling out string from the well bore, Kelly, Kelly
cock, swivel, rotary bushing is stored safely on the derrick floor /
slope /catwalk.
2. Once the Kelly is out of the way, an elevator is hung from the
hook of the travelling block assembly and latched to the pipe just
below the tool joint/ box.

3. Then string is lifted so that tool joint/ box of the next drill pipe/
tubing is on the derrick floor (above the rotary table) at a
workable height.
4. The slip is set in the space available between the pipe and bowl of
rotary to provide support for the pipe until breaking up of the
joint is complete.
5. The pipe connection is loosen with break out tongs. Then
disconnection is completed by the spinner until the pipe
separates.
6. The tubing string is the pulled out with the help of travelling
block passed the Topman standing on the monkey board.
7. The Topman helps to store the pipe in the finger of the stabbing
board just after it disconnected below.
8. The pipe is then kept in stand in the racking area/ wooden
platform.
9. Like wise all the tubing along with tubing shoe/ BHA are pulled
out of the hole.

Note
a. Breakout tong should be positioned close to the coupling.
Hammering the coupling to break the joint is an injurious
practice. When tapping is required, use the flat face, never the
peen face of the hammer, Tap lightly at the middle and
completely around the coupling, never around the end or on
opposite side only.
b. Crack the D/C joint with the help of jerk line (or Ezy torque if
available).
c. Great care should be exercised to disengage all the threads before
lifting the tubing out of the coupling.
d. Tubing stack at derrick should be set on a firm wooden platform
and without the bottom thread protector since the design of the
protector is not such as to support the joint or stand without
damage to the field thread.
e. Protect threads form the dirt or injury when the tubing is out of
the hole.
f. Tubing set back in the derrick should be properly supported to
prevent undue bending.
g. Before leaving the location, always firmly tie a set back of the
tubing in place.
h. Distribute joint and tubing wear by moving a length from the top
of the string to the bottom each time the tubing is pulled.
i. When tubing is stuck, the best practice is to use calliper weight
indicator. Don’t be misleading by stretching of the tubing string,
into the assumption that the tubing is free.
j. After the hard pull to loosen a string, all joints pulled on should
be retightened.
k. Before tubing is stored or reused, pipe and threads should be
inspected and defective joints marked for shopping and re-
gauging.
l. When the tubing is being retrieved because of a tubing failure, it
is imperative to future prevention of such failures that a through
metallurgical study be made. Every attempt should be made to
retrieve the failed portion in the as failed condition.

m. Break the joint completely with the help of spinner and do not use
rotary for the same.

3.8.1 DO’S
1. Ensure that Well head and X-mas tree flanges, valves and fittings
comply with API criterion and should be inspected in advance for
any damage/ corrosion, leakage or passing etc. Missing or
damaged valves and fittings should be replaced before rig is
moved in.
2. Check each annulus/ outer annulus for any pressure.
3. Before calling pre workover conference, ensure readiness/
availability of the workover plan, all type of handling tools, drill
pipes and drill collars, all necessary POL, duly inspected Fire
Fighting equipment, drill water, chemicals, safety/ first aid kit,
emergency vehicle/ ambulance, blowout prevention equipment,
functional check of twin stop device, TEED etc.
4. Pre-workover conference should be attended by all identified
persons and team should audit the compliance of safety norms as
per OISD checklist placed as Annexure-I at the end of this
chapter.
5. On the job safety meetings and drills should be conducted weekly
covering various safety aspects of operations and associated
hazards and the emergencies.
KILLING OR SUBDUING OF WELL:
6. Well killing / subduing procedure and workover fluid should be
designed based on well type, well completion, formation pressure
and temperature, formation fluid etc.
7. Before removing x-mas tree / tubing hanger, the formation
pressure must be balanced by hydrostatic pressure of workover
fluid of desired density with minimum overbalance pressure.
8. The line shall be tested 1 1/2 times the expected STHP or rated
working pressure which ever is less. No hammering shall be done
on pressurized line.

9. During subduing, monitor pump pressure and check the
parameter of return fluid ill well is properly conditioned &
stabilized.
10. Observe the well before killing operation. Record shut in pressure
in tubing and annuluses of the well. If no pressure is observed,
undertake flow test. If flow test is positive, kill the well with kill
fluid. If flow test is negative, removal of X-mas tree / tubing
hanger can be undertaken.
11. Allow the well to bleed the gas if there is pressure in tubing and
/or annulus as soon as liquid is observed, well is closed. After
this well is circulated with kill fluid. To ensure that well is
completely dead, well should be open to pit / tank for 30 – 60
minutes to check the activity of the well.
Till flow test is negative, no attempt should be made to open the
well by removing X-mas tree/ Tubing hanger.
12. Number of kill procedure are available (namely direct circulation,
reverse circulation, Bullheading, deploying CTU, lubricate and
bleed as described in section 3.3 of this Chapter etc.). Depending
upon the prevailing circumstances kill procedure should be
selected.
13. Safe operating practices for rig and rig equipment should be
followed as briefed in this Chapter and elsewhere in this manual.
REMOVAL OF X-MAS TREE
14. All exposed tree flanges should be protected and all BOP flanges
should be inspected and cleaned.
15. New seal rings should be available, for once a metal seal ring has
been used, it is permanently distorted and must be replaced.
16. Tubing and casing pressures should be checked with gauges
known to be working properly.
17. BOP equipment should be ready for immediate installation
MASTER BUSHINGS AND SLIP
18. To determine the degree of rotary equipment wears, slip test
should be performed every three months and each time a new
master bushings or set of slips with set of new dies is put into
service.

19. Do not let the slips ride the pipe. Stop the downward motion of
the drill pipe with the brake not by the slips.
20. Do not use slips designed for one specific size of pipe on any
other size of pipe.
21. Check slip dies at the start of the shift / trip. If slip is not holding
the pipe due to worn out dies, the same must be replaced
immediately. Slippage of pipe through the slips due to worn out
inserts can result in dropping the pipe.
22. Don’t use old and new dies in combination and never re-sharpen
inserts.
23. Never catch the tool joint box in the slips when the driller slacks
off.
24. Rotary slips shall be set using handles with hand palms up. It is
forbidden to kick the slips into the rotary table bowl.
ELEVATOR
25. Elevators must be selected in different sizes to fit the size of the
tubing/ drill pipe being handled.
26. While latching an elevator in motion, the rigman should place
their hands around the pipe only till the elevator has been
brought to complete stop, as otherwise it may results in injury to
the hands.
27. When tripping in or out of the hole, the rigman shall never place
his hands on or around the link eyes where elevators can pinch.
TONGS
28. Never use one single tong as it greatly increases the possibility of
bending or “hooking” the pipe at the rotary.
29. During makeup and breakout, keep the tool joint as close to the
rotary table as possible.
30. Check tongs dies at the start of the shift / trip. If tong is not
holding the pipe due to worn out dies, the same must be replaced
immediately.
31. Both the tongs should be hanged ready for its use. The tongs
should be placed either at an angle of 90 degree or 180 degrees
apart. Also line pull should not exceed recommended makeup
torque with tongs at 90 degrees to the jerk line.

32. Tongs should be fitted with safety lines of sufficient length to gain
full benefit of pull from the break out cathead but should be short
enough to prevent complete rotation of the tongs. Strength of
safety lines should be more than the strength of pull line.
33. The ends of tong safety lines shall be secured with not less than
three nos. of “U” clamps. Check the U-Clamps of safety lines
daily.
34. Lines of tongs counter balance weights shall be provided with
guards to prevent accidental contact.
35. Torquing tool joints properly is the most important single factor
in prevention of tool joint troubles. Torque measuring equipment
should always be used to prevent under or over torquing.
KELLY
36. The life of the drive section is directly related to the Kelly fit with
the Kelly drive. A square drive section normally will tolerate a
greater clearance with acceptable life as compared with hexagonal
section.
37. Inspect a Kelly for cracks between upset and drive section and
straightness.
38. To increase the life of Kelly - Do use a saver sub; do lubricate the
drive surfaces; do not use a crooked Kelly; and do not weld on the
drive corners.
39. Kelly should not be lifted from the derrick floor until the swivel is
securely latched to the hook.
40. Kelly should be kept and transported in such manner so that it
does not bend.
TRIPPING PRACTICES
41. Recommended safety guidelines and work practices should be
used during tripping operation to prevent accidents and personal
injury.
42. Use proper size pipe wiper during R/I and P/O operations. It
will not only help in keeping the string surface free of oil and dirt
but it also protect the well from falling of any foreign object in to
the well.

43. Before starting operations, brief the crew about the functioning of
various equipment to be used and the important checks required
to be performed.
44. Floor shall be kept slip-free through regular cleaning.
Appropriate non-slip material shall be used around the rotary
table.
45. The driller's view of the rotary table and set back areas should not
be obstructed at any time.
46. Always start pulling out of tubing/ drillpipe while keeping an
eye on drill-o-meter.
47. Carry out the initial pulling out of tubing only in singles so that
the threads of each tubing (single) can be checked and if found
defective should be discarded.
48. While RIH, clean and inspect the threads of the pin and box joints
of the tubing / drill pipe.
49. Box and pin should be doped, distributing the compound over
the threads and the mating surfaces preferably with a round, stiff
bristle brush.
50. Don’t use excessive dope on the threads inside the box of tubing
as while screwing excessive dope will go down inside the string.
51. Initially tighten tubing/ drill pipe threads using spinner. Joint is
then finally tightened with power tongs.
52. Drill collar joints to be tightened initially with the help of chain
tong.
53. The pipe connection is loosen with break out tongs. Then
disconnection is completed by the spinner until the pipe
separates.
54. Never makeup or break the pipe by using rotary table.
55. Never use manila rope over the drill pipe threads.
56. All tubing/ drill pipes, whether new, used, or reconditioned,
57. Tubing should be handled at all times on racks or on wooden or
metal surfaces free of rocks, sand, dirt other than normal drilling
mud.

58. Before running in the hole, tubing should be drifted with an API
drift mandrel to ensure passage of pumps, swabs and packers.
59. Elevators should be examined to ensure that latch fitting is
complete.
60. Tubing tong that will not crush the tubing should be examined
and use in the body of the tubing and should fit properly to avoid
unnecessary cutting of the pipe wall. Tong die should be fit
properly and confirm to the curvature of the tubing.
61. Never use pipe wrenches for loosening or tightening of tubing/
drill pipes.
62. The length of each pipe should be measured prior to running
63. Carefully inspect the thread. Those found damaged, even slightly,
should be laid aside.
64. Breakout tong should be positioned close to the coupling.
Hammering the coupling to break the joint is an injurious
practice. When tapping is required, use the flat face, never the
peen face of the hammer, Tap lightly at the middle and
completely around the coupling, never around the end or on
opposite side only.
65. Great care should be exercised to disengage all the threads before
lifting the tubing out of the coupling.
66. Tubing stack at derrick should be set on a firm wooden platform
and without the bottom thread protector since the design of the
protector is not such as to support the joint or stand without
damage to the field thread.
67. Protect threads form the dirt or injury when the tubing is out of
the hole.
68. Tubing set back in the derrick should be properly supported to
69. Before leaving the location, always firmly tie a set back of the
tubing in place.
70. After the hard pull to loosen a string, all joints pulled on should
be retightened.

71. Before tubing is stored or reused, pipe and threads should be
inspected and defective joints marked for shopping and re-
gauging.
72. When the tubing is being retrieved because of a tubing failure, it
is imperative to future prevention of such failures that a through
retrieve the failed portion in the as failed condition.
73. When making up or breaking out drill pipes, personnel shall stay
clear of the lines when the tension is applied to the tongs. All
personnel shall clear the rotary table.
74. Ensure the hole remains filled with kill fluid and there is no
swabbing action during P/O.
75. The quality and quantity of the return fluid should be monitored
cautiously so that any early sign of well's abnormal behaviour can
be checked and remedial action may be taken immediately.
76. Pipe shall be racked by pushing against the outer face of the pipe
when setting it back. Feet shall be kept away from beneath the
pipe at any time.
77. While picking up, laying down tubular, the Vee door stairs shall
not be used.
78. Keep proper record of pipe tally showing lengths of the each
tubular being lowered and also the fishing neck diagram (ID and
OD) of the BHA tools.
3.8.2 DONT’S
1. Don’t start the rig operations unless draw works brakes are
checked.
2. Don’t work without proper PPE.
3. Never use pipe spinner to give torque while making up pie
connections.
4. While making tong lines,don’t use knots to make loops. Use
clamps and thimble and D-shackles instead.
5. Do not dilute the thread compound for the ease of application.
6. Pipe should never be made up by reversing the rotary table.
7. Manila rope should never be used over the drill pipe threads.

8. To increase the working life of a Kelly - use a saver sub; lubricate
the drive surfaces; do not use a crooked Kelly and do not weld on
the drive corners.
9. Never use welded tongs.
10. Never catch the tool joint box in the slips.
11. Avoid using old and new dies in combination. Never re-sharpen
inserts.
12. Do not let the slips ride the pipe.
13. Do not use slips designed for one specific size of pipe on any other
size of pipe.

ANNEXURE- I
PRE-WORKOVER CHECK LIST FOR WORKOVER

RIGS (OISD STD- 190)
Rig No.......... ...........
Well No......................
Date....................
Project…………….
We the undersigned as the member of pre-workover conference checked

the readiness of the workover rig...... ....................for commencement of
operations. Following observations recorded.
A) PRODUCTION PART
1. Whether contingency plan for fire and blow-out displayed
2. Whether HSE policy of ONGC displayed
3. Whether layout plan & prohibitory sign boards displayed
4. Whether members of Rig crew provided with PPE.
5. Whether railings around derrick floor/ engine/mud tank walk ways
provided
6. Availability of Well Plan
7. Availability of first-aid box & stretcher
8. Availability of fire fighting equipment
9. Availability of safety belt with life line
10. Availability & condition of Emergency vehicle
11. Availability of portable gas detector and its functional status
12. Condition of ladders
13. Condition of casing line
14. Condition of safety lines for tongs & status of fastening clamps
15. Condition of handling tools viz- elevators, slips & power tongs etc.
16. Status of control instruments
17. Functional status of Floor-o-matic and Crown-o-matic devices

18. Functional status of Top-man escape device
19. Functional status of Fall prevention device
20. Availability of Trip tank & its functional status
21. Status of BOP control system including remote control system
22. Status of Rig building
23. Any other point
B) MECHANICAL & ELECTRICAL PART
1. Condition of Power-pack Engines
2. Condition of Mud pumps
3. Condition of Compressors
4. Condition of Generators
5. Condition of mech./ pneumatic / hydro-matic brake
6. Condition of solid control equipment
7. Whether pressure relief line of mud pumps fitted and secured
8. Status of guards on moving parts
9. Status of auto shut off system
10. Status of pressure vessels testing & record thereof
11. Availability of spark arresters in the exhaust manifold of engines
12. Status of communication system
13. Status of earthing system
14. Whether sufficient illumination provided at the rig
15. Whether light point provided in the toilet
16. Availability of Emergency light
17. Availability of Aviation light at gin pole
18. Any other point
C) CIVIL PART
1. Status of hardening and rolling of Drill-site area
2. Condition of approach road
3. Parking area of logging unit
4. Capacity of waste pit

5. Capacity of oil-pit
6. Capacity of fire water tank
7. No. of rooms made for storing chemicals
8. Whether drinking water tank covered
9. Whether toilet provided with water connection
10. Whether septic tank provided
11. Whether proper drainage system with brick work provided
12. Whether fencing around Drill site provided
13. Whether fencing around oil pit provided
14. Whether fencing around fire pit provided
15. Whether locking system to chemical store room provided
16. Whether sand cushion provided at the landing points of Top-man
escape device
17. Any other point

CHAPTER - 4
WORKOVER AND COMPLETION FLUIDS
4.0 GENERAL
A completion or workover fluid is a special purpose fluid placed against
the producing formation during well completion and remedial workover
operations such as well killing, cleaning out, plugging back or perforating
etc.
Completion fluids are placed across the chosen pay zone after the well
has been drilled but prior to putting it on production. The fluid used
during the completion of a well has a significant impact on production
with respect to well potential.
Workover fluids are used during remedial work in producing wells,
usually as an attempt to enhance or prolong the economic life of the well.
As the potential for permanent damage is greater during completion and
workover operations than it is during drilling, the objective is to use a
fluid that not only control the formation pressure but also causes the least
possible damage to the producing zone.
4.1 FUNCTION AND CHARACTERISTICS OF WORKOVER

FLUIDS
4.1.1 FUNCTIONS
• Transportation of wanted & unwanted materials into and out of
the well
• Suspension of wanted and unwanted material when circulation is
stopped
• Control of surface formation pressure to prevent blow out.
• Absorption of heat and lubrication of pipe, bit and mills,
transmission of hydraulic forces.
• Provision of suitable medium for wire-line, logging and
perforation tools.

4.1.2 CHARACTERISTICS
• Dense enough to balance formation pressure but not fracture the
formation.
• Free of solid particles as far as possible. Solids can plug
perforation and reduce production.
• Non-corrosive to prevent failure of tubular goods and subsequent
fishing job.
• Stable if the fluid is to be left in the hole for an extended period.
• Cost effective
• Avoiding damage to the formation, down hole and surface
equipment, personnel and the environment.
4.2 TYPES OF COMPLETION / WORKOVER FLUID

The commonly used workover/ completion can be grouped under
following broad categories.
• Water based fluids
o Clean, solids-free brines
o Viscosified Brines
o Conventional water base muds
o Clear-water fluids
• Oil
• Oil base fluids
4.2.1 WATER BASE FLUIDS
4.2.1.1 Clean, Solid-Free Brines
They are the most commonly used fluids in completion and workover
operations. These brines are true solutions, meaning that they contain
only water and dissolved salts (ions), with no un-dissolved solids. Salt
when dissolved in water, yields clear brine — as long as it is below
saturation. They may be used as single-salt brines or mixture of two or
three different salt compounds. Advantages of clear brines solution are;
• Solids-free
• Inhibitive
• Available in a wide density range.

• Capable of being reclaimed for reuse.
A) Single Salt Brine
These brines are made with fresh water and one salt.
9 Ammonium Chloride (NH4Cl)
• It can formulate clear fluids to a density of 9.0 lb/gal.
• It is most often used (at 2 to 7%) in other clear-water
completion fluids, such as seawater, as a clay and shale
stabilizer in gravel pack and acidizing operations where its
compatibility with hydrofluoric acid is a benefit.
9 Potassium Chloride (KCl)
• Excellent completion fluid for water sensitive formations.
• Clear fluids up to a density of 9.7 lb/gal can be prepared.
• Corrosion rates are reasonably low and can be reduced even
more by maintaining the pH between 7- 10 and using a
corrosion inhibitor.
9 Sodium Chloride (NaCl)
• The most commonly used brine.
• Maximum density possible is 10 ppg.
9 Sodium Formate (NaCOOH)
• Alternative to chloride brines.
• Density up to 11.0 lb/gal can be achieved
• Better HSE characteristics than chloride and bromide brines.
9 Calcium Chloride (CaCl2)
• Used to prepare clear fluids up to a density of 11.8 lb/gal.
However at higher densities there may be operating
problem in winter because of freezing of the solution. At a
density of 11.6 ppg the freezing point of CaCl2 brine is 44
deg F.
• Dissolution in water gives high heat and the amount of
calcium chloride required to obtain the desired density
should be determined prior to preparing the solution or
density measurement must be made after cooling.

• Dry salt must be added very slowly to prevent boiling.
• Care should be taken to ensure compatibility with reservoir
fluids due to the divalent calcium.
• The corrosivity is comparable to KCl brine and require a
corrosion inhibitor.
9 Sodium Bromide (NaBr)
• Used for density up to 12.8 lb/gal
• More expensive and used as an alternative to calcium base
brines when formation waters contain high concentrations of
bicarbonate and sulphate ions.
9 Potassium Formate (KCOOH)
• It can give density up to 13.2 lb/gal.
• Alternative to chloride or bromide brines.
• Have better Health, Safety and Environmental (HSE)
characteristics compared to chloride and bromide brines.
• Show excellent thermal stabilization effects on natural
polymers and the potassium ion provides excellent clay
stabilization and swelling inhibition of shales.
9 Calcium Bromide (CaBr2)
• Calcium bromide solutions can be prepared to a density of
15.5 lb/gal
• The 14.2 lb/gal CaBr2 has a TCT around 0°F (-18°C).
• Like calcium chloride, calcium bromide generates heat when
dissolved in water, similar precautions should be observed.
9 Cesium Formate (CsCOOH)
• Cesium formate is being produced as a 19.7-lb/ga liquid
• Cesium formate also produces excellent thermal
stabilization effects in natural polymers, and provides clay
stabilization and inhibits swelling of shales.
• Formate-base brines have better Health, Safety and
Environmental (HSE) characteristics in comparison to
chloride and bromide brines

B) Mixed Salt Brine
When the brine densities greater that 11.6 ppg are required, the use of two
or more salts is usually preferred instead of single salt due to economics.
9 Calcium Chloride/ Calcium Bromide:
Most common two salt brine .The base ingredients of CaCl2/CaBr2
brine are a calcium bromide solution of about 14.1 to 14.3 ppg. The
pH range is 7.0 – 7.5.
9 Zinc Bromide/Calcium Bromide
Available as stock liquid weighing 19.2 lb/gal. It is very expensive
and is frequently blended with additional calcium bromide or
calcium chloride for greater flexibility and economics. The maximum
density for zinc bromide blends is 20.5 lb/gal. The discharge of zinc
to the environment is often restricted. Due to the high concentration
of dissolved salts and the low pH, zinc bromide brines must be
handled with maximum safety precaution.
4.2.1.2 Viscosified Brines
• Viscosified brines are used where additional parameters like
bridging, suspension, fluid loss control etc are required.
• Specially designed brine/polymer systems can be classified into
three major types:
o Acid-soluble brine/polymer systems, usually sized calcium
carbonates.
o Water-soluble brine/polymer systems, usually sized salt.
o Oil-soluble resin brine/polymer systems.
A) Bridging / Weighting Agents
• High purity, acid-soluble calcium carbonate used both as a
bridging and weighting agent. It is available in three standard
particulate sizes: Fine (F), Medium (M) and Coarse (C). They are
used for fluid-loss control in brine-polymer systems. A proper blend
of all three grades helps in excellent fluid loss control. Coarser
particles tend to bridge on the pore throat and the colloidal and sub-
colloidal particles seals inter particulate space. Particles with a
median diameter one-third to one-seventh of the size of the
formation pore throat are best. Wider the range of particle sizes, the
more likely that an impermeable filter cake would formed.

• Calcium Carbonate (sp. gr. 2.7) is widely available and has good
temperature stability, non-toxic, non-corrosive. CaCO3 is least
damaging, if size of particles is suitably chosen and the pill is placed
properly. Calcium carbonate is insoluble in formations fluids and
can be completely dissolved by 15 % HCI.
Continual loss of even carbonate particles deep into the formation is
not recommended. It is uncertain that an acid cleanup would
actually be able to contact the particles if penetrate deep into
formation.
• Oil soluble resins and sized Sodium chloride salt are also used as
bridging agents. Wells with formation temperatures bellow 162 deg
C (resin softening point) and producing either aromatic crude or
condensate, sized resin bridging particles should be considered
because of the assured self removal by dissolution.
• Sodium chloride (NaCl) has more versatility than either calcium
carbonate or resins but its use in low pressured formation is limited
by its high saturation density (1200 kg/m3). Sodium chloride (sp. gr.
2.18) as bridging particle is truly non- damaging. Sized salt particles
have same thermal stability as calcium carbonate.
• Micronized cellulose fibers have good sealing characteristic and
effectively stop fluid loss. Length of these fibers is normally 2-200
micron and diameter 20 micron and is used for seepage and whole
fluid loss control. They orient themselves in pack bundles in low
pressure zone and form a seal very quickly and do not allow-fluid to
pass in formation. However, lack of acid solubility restricts their use,
as complete removal of fibers is not ensured. The use of these fibers
is restricted in producing formations because of their general lack of
acid solubility.
B) Viscosifying Agents
• Brines have a natural viscosity that depends on the concentration
and types of salts in the blend. Typical base brine viscosities can be
found in Table below:

Brine Density Funnel viscosity PV
(ppg) (sec/qt) (cp)
NaCl 10 28 -
NaBr 12.5 27 -
CaCl2 11.6 34 9
CaBr2 14.2 31 -
CaCl2 /CaBr2 15.1 52 40
CaBr2/ZnBr2 19.2 41 40
• The Yield Points (YP) of clear brines is very low. This reduces their
ability to carry or suspend solids.
• Viscosifying agents or polymers and high annular velocity are used
to overcome the low carrying capacity of brines and to control fluid
losses to the formation.
• Once the brine is circulated back to the surface, it can be processed
and filtered before being pumped back down the hole.
• The most common polymers used as viscosifying agents are:
9 HEC
o This is a non-ionic, modified, high-molecular-weight,
natural polymer and has excellent brine viscosification
property.
o Least damaging (if hydrated properly) and hence most
favoured where suspension properties are not of prime
importance.
o It has excellent brine tolerance. Readily hydrate in most
of the commercial brines.
o It has excellent acid solubility.
o The suspension and filter loss properties are poor.
o Non-toxic and has good thermal stability. It has
temperature stability of 135 deg C.

o Keeping in view the superior quality of HEC over other
polymers, HEC is considered to be suitable polymer for
application in sub hydrostatic wells for loss control.
9 Guar
o This is again a non ionic natural polymer and has fair
tolerance for brines. It has very good viscosification
ability.
o It has fair acid solubility.
o The suspension and filter loss properties are poor.
o It has temperature stability of 121 deg C.
9 XC Polymer
o This is an ionic, modified natural polymer. The brine
viscosification property are comparatively lower than
HEC.
o It has fair brine tolerance.
o It has good acid solubility. It is also degraded by
hypochlorite. It degrades with time and temperature
o It gives excellent shear thinning properties.
o It has excellent low shear viscosity and gelation
properties which most other polymer lacks and this
makes it an ideal choice where suspension properties are
required.
o It has temperature stability of 135 deg C and hence
preferred over HEC where formation temperatures are
high.
9 CMC, Starch and PAC are the other polymers used for
brine viscosification
C) Mixing Of Polymer
When a water-soluble polymer is added to water, part of the polymer gets
partially hydrated and becomes semisolid called “fish eyes”. The size may
vary from few microns to several centimetres. Depending upon the
process of addition of polymer powder to brine, fish eyes of sizes from
several microns to several centimetres are formed. Microgels can be
described as smaller fish eyes and are generally of 10-100 micron size

Careful addition will avoid the formation of fish eyes. The fish eye
formation can be avoided by following two methods.
1) Prepare thick paste of HEC powder in a medium in which hydration
of HEC does not take place like alcohols, glycol, hydrocarbons etc.
and then add to brine.
2) Adjust PH of the brine to 5.5 - 6.0 by adding HCL or Citric acid. Add
HEC and mix for 15 minutes. After HEC powder is properly
dispersed in brine, raise pH of the of brine to 8.0 - 8.5 by adding
sodium hydroxide at shear rate of 100/sec
4.2.1.3 Conventional Water- Base Muds
Using conventional water-base drilling mud for completions or workover
operations is not advisable unless we are sure that they will not damage
the formation. Clays, weighting material and other additives present in
these muds can cause severe and permanent damage to producing
formation.
However in recent years the non damaging fluids grouped under “Drill
in Fluids” have been designed and used for drilling and completion of
reservoir sections. The use of these fluids as workover fluids may prevent
formation damage.
4.2.1.4 Clear-water fluids
• Low salinity water such as seawater or produced brines are
occasionally used as workover and completion fluid. Water is
inexpensive, relatively accessible in most areas, and requires few
special additives.
• Many a times formation water contains fine solids, paraffin,
asphaltene or scale which, if not controlled, may cause serious
formation damage. The water should be filtered before use.
• Seawater, which is frequently used in coastal areas due to its easy
availability, usually contain potentially damaging solids or
multivalent ions, such as Ca2+ , Mg2+ and Fe3+ , microorganisms
(bacteria) , high conc. of sulphates and hence need processing
prior to use as workover fluids. It may be necessary to add 3-4 %
KCl or NH4Cl to avoid clay swelling.
• The primary disadvantage that often negates its use is the clay
hydration type of formation damage that readily occurs with
fresh water filtrates.

4.2.2 OIL
In most producing areas, oil is plentiful and makes it economical to use as
workover /completion fluid. It is usually non-corrosive and does not
cause clay swelling in producing zones. It weighs about 7 ppg, which is
excellent for low pressure oil field.
It has lots of disadvantages
• Usually contains wax, fine particles of sand, solid or asphalts that
can damage the formation.
• It is corrosive if H2S or CO2 is present.
• It is a fire hazard and difficult to handle
• Oil may not be compatible with the reservoir oil if it is obtained
elsewhere in the field.
4.2.3 OIL BASE FLUIDS
• Oil-base invert emulsions fluids are sometimes used as
completion and workover fluids. In these generally the Calcium
Chloride brine is emulsified in oil, so that the oil is the external or
continuous phase.
• These fluids are minimally damaging to certain formations .The
thin, low-permeability filter cake also limits solids from invading
the producing zone. The filtrate is also oil, so that sensitive clays
are not affected.
• Oil-base fluids are often formulated with acid-soluble bridging/
weighting agents so that any residual filter cake or solids can be
acidized for removal.
Advantages Disadvantages
• Relatively low cost and • Handling and disposal

wide availability. issues
• High-temperature • Be restricted for
stability. environmental reasons
• Wide density range. • Change the wettability of
the formation.
• Low corrosion.

• Maximum inhibition. • Cause emulsion blocks.
• Minimum filtrate • Damage dry gas sands.
invasion
• Increase safety concerns.
• Resistant to
contamination
4.3 BRINE BASED WORKOVER FLUID Selection criteria

The brine based fluids are most favoured as completion and workover
fluids. Addition of various salts to fresh water has several beneficial
effects. Salt will increase the density of the fluid for greater hydrostatic
pressure control without increasing the solid concentration. In addition,
salt in fresh water creates an inhibited fluid that minimizes clay hydration
and results in less formation damage.
To select brine based workover/ completion fluid, following parameters
should essentially be considered;
9 Fluid density
9 Wellbore temperature.
9 Crystallization temperature.
9 Formation compatibility
9 Corrosion control.
9 Health, Safety and Environmental (HSE) characteristics.
9 Economics.
9 Suspended Solid
4.3.1 Fluid density
• The primary criterion for fluid selection.
• Should be equal or higher than the formation pressure except for
underbalanced pressure situations, where it should be enough
only to control the underbalanced portion of reservoir pressure.
• Commonly used overbalance levels are 200 psi for oil wells and
300 psi for gas wells and are sufficient to control the entry of
formation fluid under swabbing situations.

• Balanced or underbalanced workover operations are ideal for
prevention of formation damage but should be performed with
proper equipment.
4.3.2 Wellbore Temperature
• The density of a brine decreases as the temperature increases.
Hence bottom-hole temperature, both static and circulating, is an
important factor in selection of brine.
• Correction in density for temperature and pressure must be made
for avoiding well control problems.
• Temperature and the exposure time affects the stability of various
additives, corrosion rate etc. and may dictate the choice of
additives and corrosion inhibitors.
4.3.3 Crystallization temperature.
• Crystallization point is the temperature at which salt crystals will
begin to fall out of solution given sufficient time and proper
nucleating conditions.
• The precipitation of insoluble salts can cause a number of
problems like drop in fluid density, choking of lines and seizing
of pump.
• Unlike water, brines do not expand during crystallization.
Therefore, fluid lines, valves or pump heads will not rupture as
they can when water freezes.
• Several salt blends can be formulated for a particular density,
each having a different crystallization temperature.
4.3.4 Formation compatibility
• The compatibility of brines with the formation is another
important issue for selection of brine as incompatibility will lead
to formation damage resulting in loss of productivity. The filtrate
characteristics should be tailored to minimize formation damage
considering
o Clay swelling
o Clay dispersion/fine migration
o Wetability change
o Emulsion formation

o Sludge formation
o Scaling tendencies
4.3.5 Compatibility with the rock
• Brine should have compatibility with formation rocks so as to
prevent swelling, deflocculating and/or migration of formation
clays, especially in “tight” high-clay sandstone.
• Some salts are better clay stabilizers than others, and can prevent
clay swelling and migration. NH4Cl (3%) or KCl (3%) are the two
inhibitive salts frequently used in seawater for workover
operation.
4.3.6 Compatibility with formation water
• Brine should have compatibility with formation water. A
incompatible brine may result in the formation of scale.
• Scales are deposits of inorganic minerals and can form due to
mixing incompatible waters, solubility changes with temperature,
solubility changes with pressure and water evaporation.
• Most common cations responsible for scaling are multivalent
cations such as calcium (Ca2+), magnesium (Mg2+) and iron
(Fe3+).
4.3.7 Compatibility with hydrocarbon
• Any incompatibility between brine and hydrocarbon may result
in formation of oil/water emulsions and/or sludge, both of which
cause severe formation damage by blocking pores.
• Brine/crude incompatibility is especially important when low-
pH, heavy brines are used. Natural gas if rich in CO2 may cause
calcium carbonate to precipitate if mixed with a high pH brine
that contains calcium.
• Brine should be checked for its compatibility with rock and
formation fluids prior to its use in field. The following laboratory
tests can be used to evaluate the compatibility of a clear fluid with
a formation:
o Return permeability
o Formation water analysis
o Formation mineralogy
o Brine/water compatibility

4.3.8 Corrosion control
• The brine should not cause much corrosion to tubular and down
hole equipment.
• Salt solutions are often highly corrosive. Dissolved oxygen is the
primary corrosive agent in sodium, potassium, calcium, chloride
or bromide-brine base completion fluids.
• The solubility of oxygen in these brines decreases as saturation
with the salt is approached.
• Even though initially it may contain dissolved oxygen, if the brine
is not circulated during the completion in a manner that will
replenish the dissolved oxygen, the corrosion rate will decrease as
the oxygen is depleted. Oxygen scavengers are not normally
needed for brine fluids that will not be circulated.
• High-density zinc bromide blends are used in very high-pressure
situations for well control. These brines have a low pH. Raising
the pH would be detrimental, causing precipitation. The acidity of
the zinc can cause severe corrosion, unless proper protection is
provided with an appropriate corrosion inhibitor.
• Most oilfield zinc bromide completion brines contain a
thiocyanate (or other sulfur-base) corrosion inhibitor that forms a
protective film on the surface of steel.
• In addition to the monetary cost associated with corrosion itself,
soluble iron resulting from the corrosion process can lead to
formation damage and will contaminate a solid-free brine. If
soluble iron comes in contact with formation connate water, a
precipitate may form, reducing effective permeability.
4.3.9 Health, Safety and Environmental (HSE) characteristics.
• If brine comes into contact with eyes or skin, or if ingestion or
inhalation is suspected, take the following first-aid measures:
o Eyes: Flush eyes promptly with plenty of water. Skin: Flush
skin with plenty of water with soap.
o Ingestion: Consult the material safety data sheet for
response information and get medical attention.

4.3.10 Economics
Only one rule; the brine which is most economical, easily available and
meets the above requirements should be considered for use. The Reuse,
Recover, Recycle of these brines further improves the economics.
4.3.11 Suspended Solids
It is also critical to minimize the level of total suspended solids in the
completion/ workover fluid to minimize formation damage from
suspended solids. This damage is caused by plugging of pore channels by
suspended solids in the completion or work over fluid. This can be
avoided by filtering the brine through very fine filters. Mostly NTU
values of brines are measured because a brine which looks fairly clean by
naked eyes may not be so clean and solids as low as 500 ppm in the brine
may choke the perforations. NTU as low as possible is preferred and in
the range of 20 to 40 NTU is acceptable. But NTU as low as less than 10
are most desirable. Brines should be filtered for ensuring NTU within
range. Filtration units should be installed for circulating situations.
4.4 WORKOVER FLUID FOR SUB-HYDROSTATIC WELLS

There are two types of fluids:
1. Circulating Fluids
2. Non Circulating Fluids (Pills)
4.4.1 CIRCULATING FLUID
4.4.1.1 Oil / oil based fluids
Circulating fluid either oil (petroleum or petroleum product) or oil based
(emulsion) can be formulated in the range of sp gr between 0.9 to 1.0 or
more. But lower sp gravity fluids are difficult to formulate. Use of oil and
oil-based fluid is limited due to difficult handling and disposal. They
have risk of fire and explosion. The criteria that govern their use, as
workover fluid is high flash point and/ or low vapour pressure at
operating conditions.
Diesel oil is the most commonly used oil phase. The advantage to use
diesel to workover well is that it is less damaging to the productive
formation than any other oil.

4.4.1.2 Gas fluid
Gas can be used as completion and workover fluid in some low-pressure
reservoir. During operation, flow from the well is controlled only by
surface backpressure.
Nitrogen gas is commonly used in operations such as hole cleaning by
foam, well activating, proppant transportation, DST, dry perforation and
nitrified acidization etc.
4.4.1.3 Foam Fluids
• Foam acts like a pseudo plastic fluid and its stability is hardly
affected as long as it is in the dynamic state.
• Foam can be used for sand washing, re-completions and CTU
jobs.
• Foam has low density, high effective viscosity and high carrying
capacity making it a very good workover medium
• Foam can be used as completion and workover fluid to deal with
low-pressure gas wells as it does not invade the formation in
underbalanced condition and hence avoid formation damage.
• Air foam has a risk of fire/explosion also.
• Prior to execution of foam fluid, extensive training (safety and
technical) of working crews is required.
• Application of foam as workover fluid will need acquisition of
foam generation and application technology with lot of
infrastructure for surface handling of the same.
• Serious limitations of foam as work-over fluid are the stability of
foam in static condition and initial cost of equipments.
• Foam has handling problems.
4.4.1.4 Viscosified brines
Use of viscosified brines does not completely control loss of fluid in the
formation and continuous loss of fluid takes place at reduced rates.
Particulate (Calcium carbonate, resins, micronised cellulose fibers etc.)
loaded viscosified brines are used as circulating fluids for temporary
plugging of formation pore throats. The effectiveness of the system is a
function of quick formation of a thin cake around the well bore. However,

they suffer setback of severe solid settling in well bore in static state. Due
to this reason use of such type of workover fluids is very limited.
4.4.2 NON CIRCULATING FLUID
Pills (linear, cross linked gels and particulate) are used worldwide to
control fluid loss in depleted/sub-hydrostatic wells. Pills are very cost
effective and easy to prepare. The various non-circulating fluids are:
I. Polymer pills
II. Particulate pills
4.4.2.1 Polymer pills
Various polymers commonly used are guar gum, CMC, Xanthan, HEC
etc. Whether the linear or cross-linked gel will enter the formation or not
is generally dependent on polymer type and concentration, pore throat
sizes, over balance head and bottom hole temperature.
Salient feature of polymer pill are:
• Pills (gels) can be removed from the throats of pores of formation
by application of a breaker.
• Longer break time may be achieved but is a risk as minor
chemical variation may not allow a total breakdown of the gel
and hence permanent formation damage may be caused.
• Success of linear or cross linked gels in controlling fluid loss is
marginal because the polymer molecules have a very high affinity
for each other and their attraction for the formation grains is low.
• Polymer/ pill may fill the well bore, their ability to form a low
permeable plug is limited and fluid passes between gel plug and
the wall of the borehole in the formation.
4.4.2.2 Particulate pill
As the polymer gels do not completely stop the fluid loss in the formation,
temporary plugging of pore throats by addition of sized solid particles in
polymer gel becomes the choice of preference and such type of pill is
called particulate pill.
• Solids particles used for plugging/blocking formation are called
bridging or blocking agent.
• Blocking agents act as inert particle in the pill and are least
damaging, if properly sized.

• Blocking agents with polymer, forms a temporary thin plug like
mud cake and seals formation pores.
• Temporary plug or bridge can be removed by washing or
dissolved by chemical treatment.
• Besides restricting the flow of fluid near well bore, polymer in the
pill consolidates bridging particles on pore throats of formation.
• Guar gum, CMC, HEC, Xanthan etc are common polymer used.
• Bridging material are typically sized Calcium carbonates, Salts,
Resins and Micronised cellulose fibers.
• A typical pill contains sized bridging material and polymer
solution in brine (viscosified brines)
4.5 MECHANICAL FLUID LOSS CONTROL SYSTEMS:

Mechanical fluid loss control systems are essentially downhole
equipment, installed in a well for either temporary or permanent blocking
of fluid flow in the formation.
They are expandable plug or sliding sleeve type of communication device
installed for future application. Elastomeric and metallic components of
these devices must be compatible with formation fluid. Such devices are
glass disk assembly, frangible flappers, ball-dropper fluid loss device,
tubing latched plug, hydraulic reverse operated flapper, packer plug,
tubing plug, acid soluble plugs etc.
4.6 DISPLACEMENT OF MUD WITH BRINES DURING

COMPLETION
The displacement system is designed to maximize mud and solids
cleanout in one pass through the wellbore. Certain displacement
processes or procedures are common to any type of fluid displacement, be
they OBM/SBM or WBM.
The use of clean brine fluid alone does not guarantee success of job. All
the components involved in circulation, including storage tanks, solids-
removal equipment, manifolds, pumps, discharge lines, return lines and
the wellbore should also be free from solids.
4.6.1 PREPARING THE WELLBORE
Having a well-conditioned drilling/ workover fluid is the single most
significant factor in obtaining effective mud displacement. Thoroughly

fluidize the mud before displacement. To further improve its mobility, the
viscosity, YP and gels of the drilling fluid should be reduced, if possible,
during the pre-job circulation period.
• Displace the completion fluid at the highest displacement rates
and if possible under turbulent flow conditions.
• The pipe movement (rotation or reciprocation) helps break up
pockets of gelled mud and loosens cuttings. This is more
important in wells which are not truly verticals and where string
is not positioned concentrically in the hole. Rotation also
distributes the flow path of the displacement fluid across the
entire hole section. Mechanical scratchers or scrapers attached to
the drillstring can further enhance the beneficial effects of pipe
movement.
4.6.2 SPACERS
The Spacers are the first to be pumped in well ahead of brine. They are
used to
• To separate two incompatible fluids
• To remove Mud (WBM/OBM/SBM) and solids from tubular and
casing so that a clean wellbore is obtained for the completion fluid
displacement
• To restore tubular to a water-wet condition.
4.6.3 QUANTITY OF SPACER VOLUME
• The amount of time a spacer fluid is in contact with a section of
casing and formation has a direct influence on the amount of mud
displaced
• Contact time for most displacement fluids is about 10 min. This
means a 500 to 1,000 ft high column of spacer in annulus.
However, the minimum recommended fluid volume and contact
time vary somewhat, according to specific conditions.
4.6.4 VISCOSITY/DENSITY DIFFERENCES
• The spacer must be more viscous than either of the fluids it
separates.
• Higher viscosity also helps to stay in plug or laminar flow at
higher pump rates.

• However, some commingling with the other fluids will occur.
Therefore, the spacer also must provide enough distance between
the two fluids.
• Density differences do not affect displacement efficiency as other
factors. A density difference is advantageous when the
completion fluid has a higher density than the drilling fluid.
4.6.5 TYPICAL STAGED SPACER SYSTEMS
WBM displacement
• First spacer— viscosified water with surfactant.
• Second spacers — chemical wash.
• Third spacer — viscous brine.
• Circulate completion fluid after the spacers.
• Divert spacers to a separate pit.
• Continue to circulate and filter the completion fluid until the
specifications for turbidity are reached.
OBM/SBM displacement
The displacement of OBM/SBM is a challenging task. Designing of proper
spacer is necessary so that water wet condition of casing is restored and
brine can be successfully circulated and filtered.
• First spacer – base oil/synthetic preflush.
• Second spacer – viscosified water spacer with surfactant.
• Third spacer – chemical wash.
• Fourth spacer – viscous brine.
• Circulate completion fluid after the spacers.
• Divert the fluid containing chemical wash to a clean pit for
salvage.
• Continue to circulate and filter the completion fluid until the
specifications for turbidity are reached.
4.6.6 REVERSE CIRCULATION
The density of the brine and the density of the fluid that it displaces will
determine the flow path of the fluid during displacement. When the brine
is lighter than the fluid that is being displaced, reverse circulation is best

option to avid contamination through gravity sinking from heavy fluid.
This happens even with spacer use.
Commingling may occur in the tubing, but this poses little problem in
keeping the annulus clean. However, pressure-drop values should be
calculated and compared to tubing burst strengths.
4.7 FILTRATION
As solids can plug the pore throats of permeable formations, resulting in
formation damage, the workover brine should be filtered to remove the
suspended solids to reach some low level of turbidity. The brine can be
filtered to 2-5 micron size by using filters. There are two type of filters
generally used in brine filtration. The first stage uses a Diatomaceous
Earth (DE) filter medium and the second stage uses wound-fiber cartridge
filters to ensure the clean, non-damaging character of the fluids.
Depending on the brine requirement for workover operations, the brine
filtration system should be designed.
Diatomaceous Earth Filters
• Diatomaceous earth filters made from microscopic, fossilized
water plants called diatoms, are the best for removal of
suspended solids.
• Low cost, re usable nature and eases of internal inspection favour
their use.
• With removal of solids the filter cake thickens. Once a
predetermined limit is reached, the cycle is terminated and the
filter is cleaned and again pre-coated with DE. Cleaning and
precoating the unit usually takes 20 to 30 min, depending on the
number of plates. These filters are available in many different
grades and particle sizes but most field applications use a coarse
grade.
Cartridge Filters
• They are used downstream from the DE filter .They remove any
DE that bleeds through the DE press and fine left over solids.
• They are disposable type used in series

Fig 4.1: Typical Workover/Completion Fluid Operation and Catridge
Filters
Produced oils and other hydrocarbons affect brine density and can also
blind filtration units. Hydrocarbons will form a separate layer above
heavy brine and should be pumped off the surface.
4.8 PACKER FLUID

Fluid left in the tubing casing annulus above the production packer are
termed packer fluid. The packer fluid usually remains in the well until the
well is reworked or abandoned. A packer fluid is used to:
• Control fluid pressure and corrosion
• Prevent the casing from collapsing
• Prevent the production string or tubing from bursting
Criterion for selection should be:
• Cost effective
• Non corrosive
• Remain pumpable for a long period
• Stable with time and temperature
• Possesses sufficient density to control well pressure.

• Capable of keeping solid suspended in it so that they cannot settle
on top of the packer
4.9 HYDRAULICS OF WORKOVER FLUIDS

Proper hydraulics contributes in improvement of penetration rate of bit
while cleaning the well by lifting cuttings in an efficient manner. Proper
hydraulic programme consist of selection of most appropriate nozzle sizes
and circulation rate for an existing set of conditions found at the rig
It is important to minimise the pressure losses through drill string and
annulus so that the maximum of the available pump’s hydraulic horse
power (HHP) may be utilized at the bit.
The losses through drill string and annulus are directly proportional to
the square of the circulation rate (approximately), hence to avoid large
pressure losses through them, the circulation rate should be held as low
as possible, consistent with effective cutting removal and proper
utilization of the pump power.
Drilled cuttings are heavy and travel upward initially but tend to fall
thereafter. This downward velocity of cutting is called slip velocity.
Annular velocity/Circulation rate
Discharge Q = A*V where A is the annular cross-sectional area and V is
the annular velocity.
Circulation rate = 2-3 lit/Sec/Inch of hole size - (1)
431.5
Annular velocity (M/min) = ———————————— (2)
Hole sizes H (in) X Mud weight W (gm/cc)
Circulation rate that can transport cuttings to the surface is determined by

carrying capacity of drilling fluid, rate of penetration and the volume of
drilled solids. It depends on hole size, drill string size and annular
velocity. Maintain annular velocity about twice the slip velocity.

1) Select workover & completion fluid which is dense enough to
balance formation pressure, free of solid particles as far as
possible, non-corrosive, stable and cost effective
2) Select the packer fluid which is non corrosive, remain pumpable
for a long period, stable with time and temperature, sufficient
density to control well pressure, capable of keeping solid
suspended in it so that they cannot settle on top of the packer and
cost effective,
3) Use Viscosified brines where additional properties like bridging,
suspension, fluid loss control etc are required.
4) Use brine based workover/ completion fluid (single salt) of
appropriates density and characteristics as they are clean and has
minimal suspended solids.
5) When the brine densities greater that 11.6 ppg are required, two
or more salts brine such as calcium chloride/ calcium bromide
(CaCl2 / CaBr2) should be used.
6) As fish eyes/ microgels are potential source of formation damage,
formation of fish eyes and microgels should be avoided by
following the right procedure while preparing pill by dissolving
water-soluble polymers like HEC to water.
7) While displacing mud with brine, the displacement system should
be designed to maximize mud and solids cleanout in one pass
through the wellbore.
8) If feasible, mechanical fluid loss control systems should be
installed in a well for temporary or permanent blocking of fluid
loss in the formation.
9) To improve the penetration rate of bit while cleaning the well in
an efficient manner, most appropriate nozzle sizes and circulation
rate should be selected for an existing set of conditions found at
the rig.
10) To minimise the pressure losses through drill string and annulus,
the circulation rate should be held as low as possible, consistent

with effective cutting removal and proper utilization of the pump
power.
11) The workover brine should always be filtered to 2-5 micron size to
remove the suspended solids so that it will not damage the
formation.
12) Produced oils and other hydrocarbons affect brine density and can
also blind filtration units. Hydrocarbons will form a separate layer
above heavy brine and should be pumped off the surface.

Table- 1: Sodium chloride solution requirements.
Dry chloride or sodium chloride brine can be used to produce the required
crystallization point (CP).
Sodium chloride solution requirements to make 1 bbl (42 gal)

Using sacked NaCl Brine density at Specific CP (LCTD) Using 10.0 lb/gal
(100%) 700F (210C), lb/gal gravity, sg 0F (0C) NaCl brine
Fresh 100% Water 10 lb.gal
water, bbl NaCl, lb bbl NaCl, bbl
0.998 4 8.4 1.01 31 (-0.6) 0.96 0.04
0.993 9 8.5 1.02 29 (-1.7) 0.90 0.10
0.986 16 8.6 1.03 27 (-2.8) 0.84 0.16
0.981 22 8.7 1.04 26 (-3.3) 0.78 0.22
0.976 28 8.8 1.05 24 (-4.4) 0.72 0.28
0.969 35 8.9 1.07 22 (-5.6) 0.66 0.34
0.962 41 9.0 1.08 19 (-7.2) 0.60 0.40
0.955 47 9.1 1.09 17 (-8.3) 0.54 0.46
0.948 54 9.2 1.10 14 (-10.0) 0.48 0.52
0.940 61 9.3 1.11 11 (-11.7) 0.42 0.58
0.933 68 9.4 1.13 9 (-12.8) 0.36 0.64
0.926 74 9.5 1.14 6 (-14.4) 0.30 0.70
0.919 81 9.6 1.15 3 (-16.1) 0.24 0.76
0.910 88 9.7 1.16 - 1 (-18.3) 0.18 0.82
0.902 95 9.8 1.17 - 5 (-20.5) 0.12 0.86
0.895 102 9.9 1.19 5 (-15.0) 0.06 0.94
0.888 109 10.0 1.20 25 (-3.9) --- 1.00

Table 2: Potassium chloride solution requirements.
Dry potassium chloride can be added to produce the required crystallization

point (CP).
Potassium chloride solution requirements to make 1 bbl (42 gal)

Using sacked KCl Brine Specific CP Potassium Chloride % by
(100%) density at gravity, (LCTD) ppm pm weight
Fresh 100% 700F (210C), sg 0F (0C) KCl
water, bbl KCl, lb lb/gal
0.995 4.0 8.4 1.01 31 (-0.6) 005946 005392 1.1

0.986 11.6 8.5 1.02 29 (-1.7) 017041 015452 3.2
0.976 18.9 8.6 1.03 28 (-2-2) 027441 024882 5.2
0.969 26.1 8.7 1.04 26 (-3.3) 037460 033969 7.1
0.960 33.4 8.8 1.05 25 (-3.9) 047392 042976 9.1
0.950 40.7 8.9 1.07 23 (-5.0) 057102 051780 10.9
0.943 47.9 9.0 1.08 22 (-5.6) 066456 060263 12.7
0.933 55.2 9.1 1.09 20 (-6.7) 075743 068684 14.4
0.924 62.4 9.2 1.10 18 (-7.8) 084692 076799 16.1
0.917 69.7 9.3 1.11 16 (-8.9) 093582 084861 17.8
0.907 76.9 9.4 1.13 14 (- 102151 092631 19.5
0.898 84.2 9.5 1.14 18 (-7.8) 110671 100357 21.1
0.890 91.5 9.6 1.15 40 (4.4) 119013 107922 22.7
0.881 98.7 9.7 1.16 60 (15.6) 127054 115214 24.2

Table 3: Calcium chloride solution requirements.
Dry calcium chloride or calcium chloride brine can be used to produce the
required crystallization point (CP).
Calcium chloride solution requirements to make 1 bbl (42 gal)

Using sacked NaCl Brine Specific CP Using 11.6 lb/gal CaCl2
(94-97%) density at gravity, (LCTD) brine (38%)
Fresh CaCl2, 70 F (21 C),
0 0 sg 0F ( C)
0 Fresh 11.6 lb/gal
water, bbl lb lb/gal water, bbl CaCl2, bbl
0.998 3.8 8.4 1.01 31 (-0.6) 0.979 0.021
0.997 8.2 8.5 1.02 30 (-1.1) 0.948 0.052
0.994 13.4 8.6 1.03 29 (-1.7) 0.917 0.083
0.991 18.7 8.7 1.04 27 (-2.8) 0.887 0.113
0.987 24.2 8.8 1.05 25 (-3.9) 0.856 0.144
0.984 29.4 8.9 1.07 24 (-4.4) 0.826 0.174
0.980 35.1 9.0 1.08 22 (-5.6) 0.795 0.205
0.977 40.5 9.1 1.09 20 (-6.7) 0.765 0.235
0.972 46.2 9.2 1.10 18 (-7.8) 0.734 0.266
0.968 52.0 9.3 1.11 15 (-9.4) 0.703 0.297
0.963 57.8 9.4 1.13 13 (-10.6) 0.673 0.327
0.959 63.4 9.5 1.14 10 (-12.2) 0.642 0.358
0.954 69.3 9.6 1.15 7 (-13.9) 0.612 0.388
0.949 75.4 9.7 1.16 4 (-15.6) 0.581 0.419
0.944 81.5 9.8 1.17 0 (-17.8) 0.550 0.450
0.939 87.4 9.9 1.19 -4 (-20.0) 0.520 0.480
0.934 93.2 10.0 1.20 -9 (-22.8) 0.489 0.511
0.929 99.3 10.1 1.21 -13 (-25.0) 0.459 0.541
0.923 105.4 10.2 1.22 -18 (-27.8) 0.428 0.572
0.918 111.3 10.3 1.23 -23 (-30.6) 0.398 0.602
0.912 117.6 10.4 1.25 -29 (-33.9) 0.367 0.633
0.908 123.5 10.5 1.26 -36 (-37.8) 0.336 0.640
0.902 129.8 10.6 1.27 -43 (-41.7) 0.306 0.694
0.895 136.3 10.7 1.28 -51 (-46.1) 0.275 0.725
0.891 142.0 10.8 1.29 -57 (-49.4) 0.245 0.755
0.885 148.3 10.9 1.31 -35 (-37.2) 0.214 0.786
0.878 155.0 11.0 1.32 -19 (-28.3) 0.183 0.817
0.872 161.3 11.1 1.33 -6 (-21.1) 0.153 0.847
0.866 167.6 11.2 1.34 7 (-13.9) 0.122 0.878
0.859 174.1 11.3 1.35 19 (-7.8) 0.092 0.908
0.853 180.4 11.4 1.37 27 (-2.8) 0.061 0.939

0.846 186.9 11.5 1.38 36 (2.2) 0.031 0.969
0.840 193.2 11.6 1.39 44 (6.7) --- 1.000
Table 4: Sodium bromide solution requirements.
Dry sodium bromide can be sued to produce the required crystallization point (CP).
Sodium bromide solution requirements to make 1 bbl (42 gal)

Using sacked NaBr (95%) Brine density at Specific CP (LCTD)
Fresh water bbl 95% NaBr, lb 700F (210C), lb/gal gravity, sg 0F (0C)
0.999 2.1 8.4 1.01 31 (-0.6)

0.996 7.6 8.5 1.02 30 (-1.1)
0.992 13.7 8.6 1.03 29 (-1.7)
0.989 19.2 8.7 1.04 29 (-1.7)
0.984 25.0 8.8 1.05 28 (-2.2)
0.979 31.0 8.9 1.07 26 (-3.3)
0.975 36.7 9.0 1.08 25 (-3.9)
0.970 42.6 9.1 1.09 24 (-4.4)
0.966 48.3 9.2 1.10 23 (-5.0)
0.961 54.2 9.3 1.11 22 (-5.6)
0.956 60.2 9.4 1.13 21 (-6.1)
0.950 66.4 9.5 1.14 20 (-6.7)
0.946 72.0 9.6 1.15 19 (-7.2)
0.941 77.9 9.7 1.16 18 (-7.8)
0.937 83.6 9.8 1.17 16 (-8.9)
0.933 89.2 9.9 1.19 15 (-9.4)
0.927 95.4 10.0 1.20 14 (-10.0)
0.923 101.1 10.1 1.21 12 (-11.1)
0.918 107.1 10.2 1.22 11 (-11.7)
0.914 112.6 10.3 1.23 10 (-12.2)
0.910 118.2 10.4 1.25 8 (-13.3)
0.905 124.1 10.5 1.26 6 (-14.4)
0.900 130.2 10.6 1.27 5 (-15.0)
0.895 136.0 10.7 1.28 4 (-15.6)
0.891 141.7 10.8 1.29 2 (-16.7)
0.886 147.6 10.9 1.31 0 (-17.8)
0.882 153.3 11.0 1.32 -2 (-18.8)
0.877 159.2 11.1 1.33 -3 (-19.4)
0.872 165.1 11.2 1.34 -5 (-20.6)

0.867 171.1 11.3 1.35 -7 (-21.7)
0.862 177.0 11.4 1.37 -9 (-22.8)
0.857 183.0 11.5 1.38 -11 (-23.9)
0.853 188.6 11.6 1.39 -14 (-25.6)
0.847 194.8 11.7 1.40 -16 (-26.7)
0.844 200.2 11.8 1.41 -19 (-28.3)
0.839 206.2 11.9 1.43 -10 (-23.3)
0.834 212.0 12.0 1.44 6 (-14.4)
0.831 217.3 12.1 1.45 14 (-10.0)
0.825 223.6 12.2 1.46 27 (-2.8)
0.823 228.5 12.3 1.47 34 (1.1)
0.816 235.1 12.4 1.49 43 (6.1)
0.812 240.7 12.5 1.50 50 (10.0)
0.807 246.7 12.6 1.51 57 (13.9)
0.804 252.0 12.7 1.52 63 (17.2)
Table 5 Sodium bromide/sodium chloride solution requirements.
Solutions of sodium chloride or sodium bromide can be used to produce the required
crystallization point. To achieve the highest crystallization points, use dry sodium bromide
Sodium bromide/sodium chloride solution requirements to make 1 bbl (42 gal)

Using 10.0 lb/gal Nacl, 12.3 lb/gal NaBr, and sacked Brine Specific CP
(95%) NaBr density at gravity, (LCTD) 0F
Fresh water, 10 lb/gal 12.3 lb/gal 95% NaBr, 700F (210C), sg (0C)
bbl NaCl, bbl NaBr, bbl lb lb/gal
0.982 --- 0.018 --- 8.4 1.01 31 (-0.6)
0.957 --- 0.043 --- 8.5 1.02 30 (-1.1)
0.932 --- 0.068 --- 8.6 1.03 29 (-1.7)
0.907 --- 0.093 --- 8.7 1.04 29 (-1.7)
0.882 --- 0.118 --- 8.8 1.05 28 (-2.2)
0.856 --- 0.144 --- 8.9 1.07 26 (-3.3)
0.831 --- 0.169 --- 9.0 1.08 25 (-3.9)
0.806 --- 0.194 --- 9.1 1.09 24 (-4.4)
0.781 --- 0.219 --- 9.2 1.10 23 (-5.0)
0.756 --- 0.244 --- 9.3 1.11 22 (-5.6)
0.730 --- 0.270 --- 9.4 1.13 21 (-6.1)
0.705 --- 0.295 --- 9.5 1.14 20 (-6.7)
0.680 --- 0.320 --- 9.6 1.15 19 (-7.2)

0.655 --- 0.345 --- 9.7 1.16 18 (-7.8)
0.630 --- 0.370 --- 9.8 1.17 16 (-8.9)
0.605 --- 0.395 --- 9.9 1.19 15 (-9.4)
0.579 --- 0.421 --- 10.0 1.20 14 (-10.0)
--- 0.957 0.043 --- 10.1 1.21 25 (-3.9)
--- 0.913 0.087 --- 10.2 1.22 26 (-3.3)
--- 0.870 0.130 --- 10.3 1.23 26 (-3.3)
--- 0.826 0.174 --- 10.4 1.25 27 (-2.8)
--- 0.782 0.218 --- 10.5 1.26 27 (-2.8)
--- 0.739 0.261 --- 10.6 1.27 27 (-2.8)
--- 0.696 0.304 --- 10.7 1.28 28 (-2.2)
--- 0.652 0.348 --- 10.8 1.29 28 (-2.2)
--- 0.609 0.391 --- 10.9 1.31 29 (-1.7)
--- 0.565 0.435 --- 11.0 1.32 29 (-1.7)
--- 0.522 0.478 --- 11.1 1.33 29 (-1.7)
--- 0.478 0.522 --- 11.2 1.34 30 (-1.1)
--- 0.435 0.565 --- 11.3 1.35 30 (-1.1)
--- 0.391 0.609 --- 11.4 1.37 31 (-0.6)
--- 0.348 0.652 --- 11.5 1.38 31 (-0.6)
--- 0.304 0.696 --- 11.6 1.39 31 (-0.6)
--- 0.261 0.739 --- 11.7 1.40 32 (0.0)
--- 0.217 0.783 --- 11.8 1.41 32 (0.0)
--- 0.174 0.826 --- 11.9 1.43 32 (0.0)
--- 0.130 0.870 --- 12.0 1.44 33 (0.6)
--- 0.087 0.913 --- 12.1 1.45 33 (0.6)
--- 0.043 0.957 --- 12.2 1.46 33 (0.6)
--- --- 1.000 --- 12.3 1.47 34 (1.1)
--- --- 0.996 6.6 12.4 1.49 43 (6.1)
--- --- 0.993 12.2 12.5 1.50 50 (10.0)
--- --- 0.989 18.2 12.6 1.51 57 (13.9)
--- --- 0.986 23.5 12.7 1.52 63

Table 6 Calcium bromide solution requirements.
Dry calcium bromide can be used to produce the required crystallization point (CP).
Calcium bromide solution requirements to make 1 bbl (42 gal)

Using sacked CaBr2 (95%) Brine density at Specific CP (LCTD)
700F (210C), lb/gal gravity, sg 0F (0C)
Fresh water, bbl (95%) CaBr2 lb
0.822 197 11.7 1.40 -19 (-28.3)
0.817 203 11.8 1.41 -23 (-30.6)
0.811 210 11.9 1.43 -25 (-31.7)
0.806 216 12.0 1.44 -28 (-33.3)
0.801 222 12.1 1.45 -30 (-34.4)
0.795 228 12.2 1.46 -34 (-36.7)
0.790 233 12.3 1.47 -36 (-37.8)
0.784 240 12.4 1.49 -40 (-40.0)
0.778 247 12.5 1.50 -44 (-42.2)
0.773 252 12.6 1.51 -47 (-43.9)
0.767 259 12.7 1.52 -52 (-46.7)
0.762 265 12.8 1.53 -55 (-48.3)
0.756 272 12.9 1.55 -61 (-51.7)
0.750 277 13.0 1.56 -63 (-52.8)
0.746 282 13.1 1.57 -66 (-54.4)
0.739 290 13.2 1.58 -71 (-57.2)
0.732 298 13.3 1.59 -76 (-60.0)
0.728 302 13.4 1.61 -79 (-61.7)
0.723 308 13.5 1.62 -81 (-62.8)
0.717 315 13.6 1.63 -81 (-62.8)
0.711 322 13.7 1.64 -81 (-62.8)
0.704 328 13.8 1.65 -81 (-62.8)
0.699 334 13.9 1.67 -80 (-62.2)
0.692 342 14.0 1.68 -50 (-45.5)
0.687 348 14.1 1.69 -40 (-40.0)
0.681 354 14.2 1.70 5 (-15.0)
0.676 360 14.3 1.71 10 (-12.2)
0.669 368 14.4 1.73 23 (-5.0)
0.662 376 14.5 1.74 35 (1.7)
0.655 383 14.6 1.75 37 (2.8)
0.651 388 14.7 1.76 44 (6.7)
0.645 394 14.8 1.77 51 (10.6)
0.640 400 14.9 1.79 56 (13.3)

0.637 405 15.0 1.80 60 (15.6)
0.632 410 15.1 1.81 65 (18.3)
0.626 415 15.2 1.82 70 (21.1)
0.621 421 15.3 1.83 76 (24.4)
0.616 427 15.4 1.85 79 (26.1)
0.611 433 15.5 1.86 81 (27.2)
Table 7 Calcium bromide/calcium chloride solution requirements.
Solutions of calcium chloride brine, dry calcium chloride and calcium bromide can be used to
produce the required crystallization point (CP).
Calcium bromide/calcium chloride solution requirements to make 1 bbl (42 gal)

Using 11.6.0 lb/gal CaCl2, 14.2 lb/gal CaBr2, and Brine density Specific CP
sacked CaCl2 (95-97%) at 700F (210C), gravity, (LCTD)
11.6 lb/gal 14.2 lb/gal Sacked CaCl2 lb/gal sg 0F (0C)
CaCl2, bbl CaBr2, bbl (95-97%), lb

0.9714 0.0254 2.86 11.7 1.40 45 (7.2)
0.9429 0.0507 6.06 11.8 1.41 51 (10.6)
0.9143 0.0768 9.09 11.9 1.43 52 (11.1)
0.8857 0.1016 12.13 12.0 1.44 54 (12.2)
0.8572 0.1269 15.15 12.1 1.45 55 (12.8)
0.8286 0.1524 18.18 12.2 1.46 55 (12.8)
0.8000 0.1778 21.22 12.3 1.47 56 (13.3)
0.7715 0.2032 24.24 12.4 1.49 56 (13.3)
0.7429 0.2286 27.28 12.5 1.50 57 (13.9)
0.7143 0.2540 30.31 12.6 1.51 57 (13.9)
0.6847 0.2794 33.34 12.7 1.52 58 (14.4)
0.6472 0.3048 36.37 12.8 1.53 58 (14.4)
0.6286 0.3302 39.41 12.9 1.55 59 (15.0)
0.6000 0.3556 42.44 13.0 1.56 59 (15.0)
0.5714 0.3810 45.47 13.1 1.57 60 (15.6)
0.5429 0.4064 48.49 13.2 1.58 60 (15.6)
0.5143 0.4318 51.53 13.3 1.59 60 (15.6)
0.4857 0.4572 54.56 13.4 1.61 61 (16.1)
0.4572 0.4826 57.59 13.5 1.62 61 (16.1)
0.4286 0.5080 60.62 13.6 1.63 62 (16.7)
0.4000 0.5334 63.66 13.7 1.64 62 (16.7)
0.3714 0.5589 66.69 13.8 1.65 63 (17.2)

0.3429 0.5842 69.72 13.9 1.67 63 (17.2)
0.3143 0.6069 72.75 14.0 1.68 64 (17.8)
0.2857 0.6351 75.78 14.1 1.69 64 (17.8)
0.2572 0.6604 78.81 14.2 1.70 64 (17.8)
0.2286 0.6858 81.84 14.3 1.71 65 (18.3)
0.2000 0.7113 84.88 14.4 1.73 65 (18.3)
0.1715 0.7366 87.90 14.5 1.74 65 (18.3)
0.1429 0.7620 90.94 14.6 1.75 66 (18.9)
0.1143 0.7875 93.97 14.7 1.76 66 (18.9)
0.0858 0.8128 96.99 14.8 1.77 67 (19.4)
0.0572 0.8382 100.03 14.9 1.79 67 (19.4)
0.0286 0.8637 103.06 15.0 1.80 67 (19.4)
0.0000 0.8891 106.10 15.1 1.81 68 (20.0)

Table 8 Mixing Table for Sodium formate with 0.3 % moisture content

Table 9: Metric mixing table for potassium formate from standard brine stock
(1.57 s.g.), a diluted potassium formate brine stock (1.54 s.g.), and potassium
formate powder with water content of 0.3%.

Table 10 Metric mixing table for cesium formate from 2.20 s.g. cesium formate
brine stock and cesium formate powder with a moisture content of 0.15%.

CHAPTER - 5
HANDLING OF TUBULAR
5.0 GENERAL
Tubing and drill pipes are the most cost intensive items/ equipment in
workover. The operating personnel should be made aware about their
handling procedure, material and physical properties. New tubing is
delivered free of injurious defects as defined in API Specification 5CT and
within the practical limits of the inspection procedures prescribed therein.
5.1 RUNNING AND PULLING TUBING

5.1.1 PREPARATION AND INSPECTION BEFORE RUNNING
1) All tubing, whether new, used or reconditioned, should always be
handled with thread protectors in place.
2) Tubing should be handled at all times on racks or on wooden or
metal surfaces free of rocks, sand, or dirt.
3) Before running in the hole for the first time, tubing should be
drifted with an API drift mandrel to ensure passage of pumps,
swabs and packers.
4) Elevators should be in good condition and should have links of
equal length. Elevators should be examined to ensure that latch
fitting is complete.
5) Spider slips that will not crush the tubing should be used. Slip and
tong marks are injurious. Every possible effort should be made to
keep such damage at a minimum by using proper equipment.
6) Tubing tongs that will not crush the tubing should be used on the
body of the tubing and should fit properly to avoid unnecessary
cutting of the pipe wall. Tong dies should fit properly and
conform to the curvature of the tubing. The use of pipe wrenches
is not recommended.
7) The following precautions should be taken in the preparation of
tubing threads:

a. Immediately before running, remove protectors from both
field end and coupling end and clean threads thoroughly,
b. Carefully inspect the threads. Those found damaged should
be laid aside.
c. The length of each piece of tubing shall be measured prior to
running.
e. Check each coupling for makeup.
f. Before stabbing, liberally apply thread compound to the
entire internally and externally threaded areas.
8) When tubing is pulled into the derrick, care should be taken that
the tubing is not bent or couplings or protectors bumped.
5.1.2 STABBING, MAKING UP AND LOWERING
1) Do not remove thread protector from field end of tubing until
ready to stab.
2) If necessary, apply thread compound over entire surface of
threads just before stabbing.
3) In stabbing, lower tubing carefully to avoid injury to threads. Stab
vertically, preferably with the assistance of a man on the stabbing
board. Care should be exercised, especially when running doubles
or triples, to prevent bowing and resulting errors in alignment
when the tubing is allowed to rest too heavily on the coupling
threads. Intermediate supports may be placed in the derrick to
limit bowing of the tubing.
4) After stabbing, start screwing by hand or apply regular or power
tubing tongs slowly. Joints should be made up tight,
approximately two turns beyond the hand-tight position, with
care being taken not to gall the threads.
5.1.3 FIELD MAKEUP
1) Joint life of tubing under repeated field makeup is inversely
proportional to the field makeup torque applied. Therefore, in
wells where leak resistance is not a great factor, minimum field
makeup torque values should be used to prolong joint life. The
use of power tongs for making up tubing made desirable the
establishment of recommended torque values for each size,
weight, and grade of tubing.

2) Connections should be turned by hand to the hand-tight position
before slowly power tightening. The procedure should be
reversed for disassembly.
3) Finding bottom should be accomplished with extreme caution. Do
not set tubing down heavily.
5.1.4 PULLING TUBING
1) Breakout tongs should be positioned close to the coupling.
Hammering the coupling to break the joint is an injurious practice.
When tapping is required, use the flat face, never the peen face, of
the hammer, and tap lightly at the middle and completely around
the coupling, never near the end or on opposite sides only.
2) Great care should be exercised to disengage all of the thread
before lifting the tubing out of the coupling. Do not jump tubing
out of the coupling.
3) Tubing stacked in the derrick should be set on a firm wooden
platform and without the bottom thread protector since the design
of most protectors is not such as to support the joint or stand
without damage to the field thread.
4) Protect threads from dirt or injury when the tubing is out of the
hole.
5) Tubing set back in the derrick should be properly supported to
6) Make sure threads are undamaged, clean, and well coated with
compound before rerunning.
7) Distribute joint and tubing wear by moving a length from the top
of the string to the bottom each time the tubing is pulled.
8) When tubing is stuck, the best practice is to use a calibrated
weight indicator. Do not be misled, by stretching of the tubing
string, into the assumption that the tubing is free.
9) After a hard pull to loosen a string of tubing, all joints pulled on
should be retightened.
10) All threads should be cleaned and lubricated or should be coated
with a material that will minimize corrosion.
11) Clean protectors should be placed on the tubing before it is laid
down.

12) Before tubing is stored or reused, pipe and threads should be
inspected and defective joints marked for shopping and
regauging.
13) When tubing is being retrieved because of a tubing failure, it is
imperative to future prevention of such failures that a thorough
retrieve the failed portion in the “as-failed” condition for thorough
metallurgical analysis.
5.2 CAUSES OF TUBING TROUBLES

The most common causes of tubing troubles are listed below.
1) Improper selection for strength and life required, especially of
non-upset tubing where upset tubing should be used.
2) Insufficient inspection of finished product at the mill and in the
yard.
3) Careless loading, unloading, and cartage.
4) Damaged threads resulting from protectors loosening and falling
off.
5) Lack of care in storage to give proper protection.
6) Excessive hammering on couplings.
7) Use of worn-out and wrong types of handling equipment, spiders,
tongs, dies, and pipe wrenches.
8) Non-observance of proper rules in running and pulling tubing.
9) Coupling wear and rod cutting.
10) Excessive sucker rod breakage.
11) Fatigue, which often causes failure at the last engaged thread.
There is no positive remedy, but using external upset tubing in
place of non-upset tubing greatly delays the start of this trouble.
12) Replacement of worn couplings with non-API couplings.
13) Dropping a string, even a short distance. This may loosen the
couplings at the bottom of the string. The string should be pulled
and rerun, examining all joints very carefully.
14) Leaking joints, under external or internal pressure, are a common
trouble, and may be due to the following:

a. Improper thread compound and/or improper application.
b. Dirty threads or threads contaminated with coating material
used as protection from corrosion.
c. Undertonging or overtonging.
d. Galled threads due to dirt, careless stabbing, damaged
threads and poor or diluted thread compound.
e. Improperly cut field threads.
f. Couplings that have been dented by hammering.
g. Pulling too hard on string.
h. Excessive rerunning.
15) Corrosion. Both the inside and outside of tubing can be damaged
by corrosion. The damage is generally in the form of pitting, box
wear, stress-corrosion cracking and sulphide stress cracking; but
localized attack like corrosion-erosion, ringworm, and alliper
tracks can also occur. Pitting and wear by the sucker rod box can
be determined visually by calliper surveys. Corrosion products
may or may not adhere to the pipe walls.
Corrosion is generally due to the corrosive well fluid but may be
aggravated by the abrasive effects of pumping equipment, by gas
lifting, or by high velocities. Since corrosion may result from many
causes and influences and take different forms, no simple or
universal remedy can be given for control. Each problem shall be
treated individually, and the solution shall be attempted in light of
known factors and operating conditions.
5.3 TRANSPORTATION, HANDLING, AND STORAGE

API tubular goods in general and threads in particular, are made with
such precision that they require careful handling and whether new, used,
or reconditioned, they should always be handled with thread protectors
in place.
5.3.1 TRANSPORTATION
5.3.1.1 Water Transportation
Pipe suppliers or their agents should provide proper supervision at the
time of loading and unloading of water carriers to guard against
improper or insufficient onnage, inadequate bracing to prevent shifting
during lurching of the ship, stowing pipe in or adjacent to bilge water,

injurious chemicals or other corrosive material, dragging pipe along the
pile and permitting couplings or thread protectors to hook together or
strike the edge of a hatch opening or bump against the ship rail.
5.3.1.2 Railroad Transportation
When loading pipe on freight cars, wooden stringers should be provided
across the bottom of the car to provide suitable support for pipe, to allow
space for lifting, and to keep pipe away from dirt. If the bottom of the car
is uneven, the stringers should be rigidly shimmed so that their tops will
be in the same plane. Stringers should not be placed under couplings or
the upset part of pipe. The load should be tied down and properly bulk
headed to keep it from shifting.
5.3.1.3 Truck Transportation
The following precautions should be taken for truck transportation:
a. Load pipe on bolsters and tie down with suitable chain at the
bolsters. In hauling long pipe, an additional chain should be
provided in the middle.
b. Load pipe with all couplings on the same end of the truck.
c. Care should be taken to prevent chafing of tool-joint shoulders on
adjacent joints.
d. Do not overload truck to the point where there is any danger that
the load cannot be delivered to its destination without unloading.
e. After the load has been hauled a short distance, retighten load-
binding chains loosened as a result of the load settling.
5.3.2 HANDLING
The following precautions should be observed when handling tubing:
a. Before loading or unloading make sure that the thread protectors
are tightly in place. Do not unload pipe by dropping. Avoid rough
handling which might damage the threads or ding or dent the
body of the pipe. Damaged threads may leak or part. Dents and
out-of-roundness may reduce the collapse resistance of the pipe.
Special handling may be required for sour service and CRA
material. Impact against adjacent pipe or other objects may cause a
local increase in the hardness of the pipe to the extent that they
become susceptible to ulphide stress cracking. The owner of pipe
which requires special handling requirements should notify his

service providers of the applicable special handling requirements
and to which pipe the special requirements are applicable.
b. When unloading by hand, use rope slings to control the pipe.
When rolling down skids, roll pipe parallel to the stack and do not
allow pipe to gather momentum or to strike the ends, because
even with thread protectors in place there is danger of damaging
the threads.
c. When using a crane, the use of spreader-bar with a choker sling (s)
at each end is the recommended method of handling long pipe.
Each choker-sling shall be double wrapped.
d. When rolling pipe, on the rack, keep pipe parallel and do not
allow pipe to gather momentum or to strike the ends.
e. Pipe racks should be fitted with stoppers at both ends to prevent
tubing accidentally rolling off the racks or trucks.
5.3.3 STORAGE
The following precautions are recommended for pipe storage:
a. Do not pile pipe directly on ground, rails and steel or concrete
floors. The first tier of pipe should be no less than 18 inches (500
millimetres) from the ground to keep moisture and dirt away
from pipe.
b. Pipe should rest on supports properly spaced to prevent bending
of the pipe or damage to the threads. The stringers should lie in
the same plane and be reasonably level and should be supported
by piers adequate to carry the full stack load without settling.
c. Provide wooden strips as separators between successive layers of
pipe so that no weight rests on the couplings. Use at least three
spacing strips.
d. Place spacing strips at right angles to pipe and directly above the
lower strips and supports to prevent bending of pipe.
e. Stagger adjoining lengths of pipe in the tiers an amount
approximating the length of the coupling.
f. Block pipe by nailing 1 by 2 or 2 by 2 blocks at both ends of the
spacing strips.

g. For purposes of safety, ease of inspection, and handling, pipe
should not be stacked higher than 10 feet (3000 millimetres). Pipe
should not be stacked higher than five tiers at the rig.
h. Pipe in storage should be inspected periodically and protective
coatings applied when necessary to arrest corrosion.
i. All tubular should be identified for size, grade and stacked on
racks properly at its designated place without obstructing the
egress of heavy vehicles.
j. Discarded tubular should be identified with colour code and
should be kept separately.
5.4 INSPECTION AND CLASSIFICATION OF USED CASING

AND TUBING AS PER API RP 5C1
5.4.1 INSPECTION AND CLASSIFICATION PROCEDURES
5.4.1.1 Inspection Capability
Accepted methods of inspecting the body section of pipe are visual,
mechanical gauging, electromagnetic, eddy current, ultrasonic, and
gamma ray. These inspection techniques are limited to location of cracks,
pits and other surface imperfections. Service induced defects considered
to be representative of defects associated with used pipe inspection are as
follows: outside and inside corrosion damage; inside surface wireline
(longitudinal) damage; outside transverse and longitudinal slip and tong
cuts; inside surface drill pipe wear (casing only); transverse cracking
(work tubing only); and inside surface sucker rod wear (tubing only).
5.4.1.2 Measurement of Pipe Wall (Minimum Wall)
The only acceptable wall thickness measurements are those made with
pipe wall micrometers, sonic pulse-echo instruments, or gamma-ray
devices that the operator can demonstrate to be within 2 percent accuracy
by use of test blocks sized to approximate pipe wall thickness.
5.4.1.3 Procedure
Used casing and tubing should be classified according to the loss of
nominal wall thickness listed in Table 5.1. These percentages represent
reductions in the body wall from the API specified pipe wall thickness.
This loss of wall thickness affects the body areas along both the inside
and/or outside surfaces. Pipe with loss of wall thickness in the threaded
portion and/or upset section, whether threaded and coupled external
upset or integral joint, is not to be classified in accordance with Table 5.1.

Loss of wall thickness in the heavier upset sections could be permitted to
a higher percentage without penalty depending on the intended service.
Damages and/or wall reductions affecting the threaded ends of pipe
require individual consideration depending on the anticipated service by
the owner of the pipe.
In addition to the body wall loss classification shown in Table 5.1, the
colour code identification system used to denote the conditions is
provided in Table 5.2. The colour coding should consist of a paint band of
the appropriate colour approximately 2 inches wide around the body of
the pipe approximately 1 foot from the box end.
Table 5.1—Classification and Color Coding of Used Casing and Tubing
Class Color Loss of Remaining

Band Nominal Wall Thickness
Wall Thickness (percent
(percent) minimum)
2 Yellow 0 – 15 85
3 Blue 16 – 30 70
4 Green 31 – 50 50
5 Red Over 50 less than 50
Table 5.2—Color Code Identification
Conditions Color
Damaged field- or One red paint band approximately 2 inches wide

pin-end threads around the pipe adjacent to affected threads.
Damaged coupling One red paint band approximately 2 inches wide

or box connections around the affected coupling or box end.
Pipe body will not One green paint band approximately 2 inches wide
pass drift test at the point of drift restriction and adjacent to the
color band denoting body wall classification.

5.4.1.4 Performance Properties
Performance properties of new casing, tubing, and drill pipe are usually
based on equations in API Bulletin 5C3. However, there is no standard
method for calculating performance properties of used casing and tubing.
API Recommended Practice 7G provides a recommended practice for
calculating performance properties of used drill pipe. Drill pipe wear
usually occurs on the outside surface and, consequently, the performance
properties of used drill pipe are based on a constant ID, and the wall
thickness and OD vary with the degree of wear.
Casing and tubing wear (metal loss) and corrosion usually occur on the
inside surface. Performance properties should be based on a constant OD.
If external corrosion is evident, it must also be taken into account. Small
pits or other localized metal loss may not be damaging depending on the
application of the pipe, but this type of metal loss should be considered
and evaluated by the pipe owner.
If cracks are detected in a length of pipe during inspection and are
verified to be of sufficient length to be identified by visual, optical, or
magnetic particle inspection, this joint shall be rejected and considered
unfit for further service.
5.4.2 GENERAL COMMENTS
The following general comments concern loss of pipe wall thickness and
conditions of the threaded joint.
5.4.2.1 Pipe Wall
Metal losses in used casing and tubing usually occur on the inside surface
and range in character from isolated pits, gouges, or cuts to massive
reductions caused by mechanical wear or sand cutting. Wear occurs
inside casing and liners by rotation and movement of the drill string
while drilling. Wear occurs inside the casing even though rubber
protectors are applied to the drill pipe. The amount of wear increases
with the length of time the casing is drilled through. Frequently, wear
occurs on only one side, that being the casing on the low side of the hole.
The performance properties can be calculated by using the remaining
wall thickness. Some experience has shown that wire-line wear has a
greater effect than drill pipe wear on burst rating, and it has been
suggested that burst pressures be reduced if wall reduction is caused by
wire-line wear. The type of metal loss may influence the application of
used casing and tubing. Pipe with pits may not be used under some

corrosive conditions but may perform satisfactorily where corrosion is
not a factor. Pipe having more uniform metal loss from mechanical wear
should be less vulnerable to corrosive conditions and needs only to be
derated for the minimum remaining wall thickness.
5.4.2.2 Threads
When inspecting threads of used casing and tubing, one should check for
the following: pulled round threads, galling, and fatigue cracks in the last
engaged thread. A fast thread lead at the area of last thread engagement
of round threads would indicate that the threads became stretched when
pulled at loads exceeding the yield strength of the connection. They may
make into a coupling on the next makeup but would not have the
anticipated joint strength and could have inadequate leak resistance.
Galling is always a possibility that may be encountered while breaking
out connections, particularly when backups are placed on the coupling.
Also on repeated makeup, the threads make up more each time and
interference occurs. Work tubing and strings subjected to reciprocal
tension stress often develop fatigue cracks at the root of the last engaged
thread that could reduce tension values or propagate to joint failure
during further use. These situations would require shopping of the
threads to restore the length to usable status. It should not be expected
that threaded connections shall gauge properly after being made up
power tight, therefore minor deviations from the specified tolerances
should be accepted.
5.4.2.3 Pin Cone Reduction
Tubing that has made multiple round-trips in the hole, as in the case of
workstrings, may have pins reduced in diameter due to successive
yielding by repeated makeups. This condition may penalize joint
strength, leak resistance and in severe cases, lead to abutment of pin ends
near the center of the coupling in the made-up connection.
5.4.3 SERVICE RATING
Final rating of a length of pipe for further services requires consideration
of the ID wall condition and remaining wall thickness to evaluate
resistance of the body to collapse, burst, and tension; consideration of the
thread condition to evaluate resistance to leaks; and consideration of the
pin cone to evaluate makeup. Depending on circumstances and
emergency needs, gauging of the threads may be considered along with
the usual wall inspection to determine final performance properties.

Utilization of the used casing or tubing should be based on experience
and judgment with respect to well conditions and environmental factors.
5.4.4 RECONDITIONING
Tubular goods that have become damaged through use or abuse may
often be reconditioned to advantage. This should be done only in
accordance with API Specification 5CT. The acceptability of
reconditioned threads should always be confirmed by gauging and
inspection in accordance with API Specification 5B.
5.5 DO’S AND DON’TS

1) Type of tubing/ drill pipes and their material should be selected
in accordance with the strength and life requirement.
2) Inspection of finished product at the mill and in the yard should
be done in accordance with API Specification 5CT.
3) All recommended care should be taken during tripping, loading,
unloading, storage and cartage.
4) Always handle tubing with thread protector.
5) Don’t do excessive hammering on couplings.
6) Don’t drop the string, even a short distance, as this may loosen the
couplings down the bottom of the string.
7) The string should be pulled and rerun, examining all joints very
carefully.
8) Use proper thread dope/ compound using proper application
technique while making up pipe connection.
9) Don’t use diluted thread compound.
10) Don’t make up dirty/damaged threads.
11) Don’t use improperly cut field threads.
12) Don’t do undertonging or overtonging.
13) Don’t pull too hard on string.
14) API tubular threads are made with precision and therefore require
careful handling. Whether new, used, or reconditioned, they

TRANSPORTATION
15) Pipe suppliers should provide proper supervision at the time of
loading and unloading of water carriers.
16) When loading pipe on freight cars, wooden stringers should be
provided across the bottom of the car to provide suitable support
for pipe, to allow space for lifting and to keep pipe away from
dirt.
17) While transporting pipes in trucks, load pipe on bolsters and tie
down with suitable chain at the bolsters. Load pipe with all
couplings on the same end of the truck.
HANDLING
18) Before loading or unloading make sure that the thread protectors
are tightly in place.
19) Do not unload pipe by dropping. Avoid rough handling which
might damage the threads or ding or dent the body of the pipe.
20) When unloading by hand, use rope slings to control the pipe.
When rolling down skids roll pipe parallel to the stack and do not
allow pipe to gather momentum or to strike the ends.
21) When using a crane, the use of spreader-bar with a choker sling
(s) at each end is the recommended method of handling long pipe.
22) Pipe racks should be fitted with stoppers at both ends to prevent
tubing accidentally rolling off the racks or trucks.
STORAGE
23) Do not pile pipe directly on ground, rails and steel or concrete
floors. The first tier of pipe should be no less than 18 inches from
the ground to keep moisture and dirt away from pipe.
24) Pipe should rest on supports properly spaced to prevent bending
of the pipe or damage to the threads.
25) Provide wooden strips as separators between successive layers of
pipe so that no weight rests on the couplings. Use at least three
spacing strips.
26) Place spacing strips at right angles to pipe and directly above the
lower strips and supports to prevent bending of pipe.

27) Stagger adjoining lengths of pipe in the tiers an amount
approximating the length of the coupling.
28) For purposes of safety, ease of inspection, and handling, pipe
should not be stacked higher than 10 feet. Pipe should not be
stacked higher than five tiers at the rig.
29) Pipe in storage should be inspected periodically and protective
coatings applied when necessary to arrest corrosion.
30) All tubular should be identified for size, grade and stacked on
racks properly at its designated place without obstructing the
egress of heavy vehicles.
31) Discarded tubular should be identified with colour codeand
should be kept separately.
INSPECTION AND CLASSIFICATION
32) Used tubing should be classified according to the loss of nominal
wall thickness.
33) The performance properties of used pipes should be calculated by
using the remaining wall thickness.
34) Inspect threads of used tubing by checking pulled round threads,
galling, and fatigue cracks in the last engaged thread.
35) Final rating of a length of pipe for further services requires
consideration of the ID wall condition and remaining wall
thickness.
36) Gauging of the threads may be considered along with the usual
wall inspection to determine final performance properties.
37) Tubular goods that have become damaged through use or abuse
should be reconditioned only in accordance with API Specification
5CT.

CHAPTER - 6
WIRE ROPES
6.0 GENERAL
Wire ropes are made up of number of strands laid helically around a core.
It consists of three basic components namely the core, the multi -wire
strands and the individual wires that formed the strands. Core is in the
centre of wire rope and may consist of fibre–natural or synthetic,
stranded wire or a complete “Independent Wire Rope Core”.
For workover rig operation, the wire rope is spooled on the drum of the
draw works, reeved on the crown block and travelling block. Wire ropes
have following main applications in workover rigs:-
o Casing line system for lifting loads.
o Hoisting of mast
o Winch line
o Safety lines
o Guy rope of mast (Wind and load)
o Slings for lifting and dragging
Wire ropes are made from the cold drawn carbon steel of various grades,
depending upon the strength required. The API classifies various grades
as Extra Improved Plow Steel (EIPS); Improved Plow Steel (IPS); Plow
Steel (PS); Mild Plow Steel (MPS).
6.1 CLASSIFICATION OF WIRE ROPES

Wire rope is usually described by type of core and number of individual
wires per strand. The lay of the wire rope describes the direction of the
strands wrapped around the core and the direction of the wire rope
within the strands. The strands can be right or left lay.

Regular Lay
The wires are laid in one direction and the strands in other so that the
visible wires appear running parallel to the rope axis.
RIGHT LAY LEFT LAY RIGHT LAY LEFT LAY

REGULAR LAY REGULAR LAY LANG LAY LANG LAY
Lang’s Lay
In Lang’s lay the wires and strands are laid in the same direction so that
the visible wires run at an angle of about 30 degree to the rope axis.
Direction of Lay
The direction of lay or rotation of the strands is normally right hand but
the wire ropes also are of left hand lay.
Lay Length
It is the length of rope in which one strand makes one helical revolution
round the core. This may be expressed as X mm or as X x rope diameter.
A short lay rope has more elasticity than a long lay rope and the lay
length is dictated by the application for which the rope is intended.
Specification of Wire Ropes
Example - 1” X 5000’, 6 X19 S PRY RRL IMPS IWRC
Where
1“ - Diameter of line in inches
5000’ - Length of line in feet
6 - Number of strands per line
19 - Number of wires per strand
S - Seale pattern
PRY - Pre formed strands
RRL - Right Regular Lay
IMPS - Improved plow steel
IWRC - Independent Wire Rope Core

6.2 CARE & MAINTENANCE OF WIRE ROPES
6.2.1 STORAGE OF WIRE ROPES
1) Wire ropes should be stored in a well cleaned, ventilated dry
shed. The storage reel shall be protected from weather, dust,
chemical fumes, steam, brine, and any other corrosive agents. The
rope on the storage reel should not be in direct contact with the
deck or the ground.
2) The wire ropes should be stored thoroughly cleaned, greased/
lubricated and covered to minimize the effects of corrosion on
wire rope as it reduces the strength of wire rope.
3) 124Wire ropes should be inspected for corrosion at regular
intervals and recorded.
4) Wire ropes normally are supplied in coils or reels. When in coil,
they should be stored on wooden planks to keep them clear of
the floor. Before uncoiling, wire ropes should be put on a
turntable to prevent kinking.
Wire ropes when supplied on reels, before using, a spindle
should be put through the reel and the ends are to be jacked up
to allow the reel to rotate as the rope is pulled off.
6.2.2 HANDLING THE REELS
1) When handling wire rope on a reel with a binding or lifting chain,
wooden blocks should always be used between the rope and the
chain to prevent damage to the wire or distortion of the strands in
the rope.
2) Bars for moving the reel should be used against the reel flange,
and not against the rope.
3) The reel should not be rolled over or dropped on any hard, sharp
object in such a manner that the rope will be bruised or nicked.
4) The reel should not be dropped from a truck or platform. This
may cause damage to the rope as well as break the reel.
5) Rolling the reel in or allowing it to stand in any medium harmful
to steel such as mud, dirt, or cinders should be avoided.
6) The preferred method for lifting a reel with slings is to use a
spreader bar that is of sufficient length to keep the sling legs from
contacting the reel. This will prevent the flanges of the reel from

being bent, distorted, broken or damaged in any way by the
slings.
7) When lifting reels of wire rope, care must be taken that the shaft
through the reel is of adequate length for the task, plus its wall
thickness and diameter are of sufficient strength and size
respectively to safely support the weight without damaging the
centre holes of the two flanges of the reel.
6.2.3 CARE DURING OPERATIONAL USE OF WIRE ROPE
1) Wire ropes should not be struck with any object such as a steel
hammer, derrick hatchet, or crow bar which may cause
unnecessary nicks or bruises. Even when a soft metal hammer is
used, it should be noted that a rope can be damaged by such
blows. Therefore, when it is necessary to crowd wraps together,
any such operation should be performed with the greatest of care;
and a block of wood should be interposed between the hammer
and rope.
2) Rope should be kept tightly and evenly wound on the drums.
Tension should be maintained on the wire rope as it leaves the
reel by restricting the reel movement.
3) Sudden, severe stresses are injurious to wire rope and such
applications should be reduced to a minimum.
4) Experience has indicated that wear increases with speed;
economy results from moderately increasing the load and
diminishing the speed.
5) Excessive speeds when blocks are running up light may injure
wire rope. Rope speed of 40 ft/min rope travel for hoisting or
lowering is recommended.
6) Care should be taken to see that the clamps used to fasten the
rope for dead ending do not kink, flatten, or crush the rope.
7) The service life of wire rope is directly proportional to the
effectiveness of the lubrication of rope, as it also protects the wire
rope from abrasion, wear & corrosion.
8) Wire ropes are well lubricated when manufactured; however, the
lubrication will not last throughout the entire service life of the
rope. Periodically, therefore, the rope will need to be field

lubricated with a good grade of lubricant which will penetrate
and adhere to the rope and which is free from acid or alkali.
9) The use of solvent may be detrimental to a wire rope. If a rope
becomes covered with dirt or grit, it should be cleaned with a
brush.
10) Line whip and natural vibrations also cause fast line fatigue;
therefore, a wire line stabilizer must be installed on fast line.
11) All sheaves should be in proper alignment. The fast sheave
should line up with the center of the hoisting drum.
12) Worn sheave and drum grooves cause excessive wear on the rope.
Sheave grooves should be checked periodically with the gauge for
worn sheaves and dimensions. The sheave grooves should have a
diameter of not less than that of the gauge otherwise a reduction
in rope life can be expected.
13) Wire line must be periodically examined. A proper slip and cut-
off practice should be followed after evaluating the work done by
a rope. A record of work done in ton – mileage should be
maintained.
14) Use only dropforged clamps of U-bolt type.
15) Dead anchor should be equipped with a drum and strong
clamping device to withstand the wire rope loading. Diameter of
anchor drum or sheave should be minimum 12 times the normal
rope diameter.
16) All sheaves should be properly lubricated to ensure minimum
turning efforts.
17) Wire rope should be securely seized on each side of the cut before
cutting the rope. It will prevent the rope from untwisting.
18) Do not subject the wire rope to severe stresses due to impact and
shock loading.
19) Care should be taken to maintain proper winding of casing lines
on the draw works drum in order to avoid excessive friction
which may result in the formation of martensite. Martensite may
also be formed by excessive friction in worn grooves of sheaves,
slippage in sheaves, or excessive friction resulting from rubbing
against a derrick member. A line guide should be employed

between the drum and the fast line sheave to reduce vibration
and keep the drilling line from rubbing against the derrick.
20) Whenever possible, a new wire rope should be run under
controlled loads and a speed for a short period after it has been
installed. This will help to adjust the rope to working conditions.
21) DESIGN FACTOR: The design factor should be determined by
the following formula:
Design Factor = B/W
Where:
B = Nominal strength of the wire rope, pounds
W = Fast line Tension / load, pounds
Note:
a) Successful field operations indicate that the following design
factors should be regarded as minimum.
• Cable-tool line 3
• Sand line 3
• Rotary drilling line 3
• Hoisting service other than rotary drilling 3
• Rotary drilling line when setting casing 2
• Pulling on stuck pipe/ infrequent operations 2
• Mast raising and lowering 2.5
b) Wire rope life varies with the design factor. Therefore longer
rope life can generally be expected when relatively high design
factors are maintained.
6.2.4 HANDLING DURING INSTALLATION/ REEVING PROCEDURE
1) Blocks should be strung to give a minimum of wear against the
sides of sheave grooves. It is good practice to suspend the
travelling block from the crown block on a single line while
changing lines as it tends to limit the amount of rubbing on
guards or spacers, as well as chances for kinks. This practice is
also very effective in pull through and cut–off procedure.
2) The reel should be firmly supported on its horizontal axis with
the line unwinding from beneath the reel drum (not from the top

of the drum). The reel should be so placed that it is free to rotate
as the rope is pulled and in such a position ensure that it is not
rubbing against derrick members or other obstructions while
being pulled over the crown.
The reel should be jacked off the floor and hold by using suitable
fixture so that it can turn on its axis freely.
3) When leading the line from the reel to the first crown sheave, use
snatch blocks with large diameter sheaves to guide the line and
keep it from rubbing on derrick members and other obstructions.
4) While winding the wire rope on the drum, sufficient tension
should be kept on the rope to assure tight and even spooling. It is
most important to get the first drum layer full and tight without
over crowding so that it will support the succeeding layers. That
is to say the first layer acts as a sort of a “grooving” for following
layers.
Wear due to crossover points cannot be completely avoided. It
can be reduced by controlled spooling, which is provided by
grooved drums.
5) Brake the reel flanges so that the rope does not become loose on
the reel while being unwound, and so an even tension is applied
on the rope between the blocks. Do not apply the brake on the
rope itself.
6) When installing a new rope, it is important that twist or torque
not be in the installed rope. If twist or torque is apparent, the
twist should be removed before the rope is anchored.
7) When a worn rope is to be replaced with a new one, the use of a
swivel type-stringing grip for attaching the new rope to the old
rope is recommended. The new rope should not be welded to the
old rope to pull it through the system.
8) Wind all the old rope on the draw works drum and pull enough
of the new rope through to permit attaching to the drum. Keep as
much back tension in the rope as possible, because slackness can
cause loops and/or kinks to form.
9) Fasten the new line so that it will not run back through the blocks.
Remove the swivel grip. Take the old line off the drum and
transfer it to a storage reel.

10) After properly securing the wire rope in the drum socket, the
number of excess or dead wraps or turns specified by the
equipment manufacturer should be maintained.
When the travelling block is at the lower pick-up point, 6- 9 wraps
should be on the drum (if grooved). Plain-faced drums must have
a full layer of line plus 4-6 wraps on the second layer as needed.
11) Hold down sheaves is the best way to anchor the line when cut-
off practices are to be employed. The line should go around the
hold-down sheaves in the same direction as it comes over the
deadline sheave and from the storage reel.
12) Ensure that clamps used for fastening the rope to dead end do not
kink, flatten or crush the rope.
13) After anchoring the deadline end, raise the travelling block and
take off the supporting line. The block, hook and elevators may
then be lowered through the V-door far enough to unreel the line
on the drum, so that it can be re-reeled tightly.
6.3 CARE AND HANDLING OF SLINGS

The short wire rope lengths used to attach a load to the crane hoist line
hooks are known as slings. It is essential to select the right sling to do the
best and safest job possible. Examination of the load to be lifted must
include an accurate determination of its weight. Selection of sling should
always be of greater capacity than they actually needed to transport / lift
the load. In case field made slings are to be used then it should be made
by using proper size and number of wire rope clamps. Slings are very
much prone to wear and tear during use and storage and as such, care
should be taken while handling these slings. These should be periodically
examined for defects and deterioration.
It is recommended that the angle of spread between the legs of a sling
should not exceed 90 degrees and this requirement can be met by
increasing the length of the legs of the sling or by using a crossbar and
attaching the sling legs to each end. In multi leg sling operation, the most
favourable angle between the sling legs is within the range of 60 and 90
degrees. If this angle is more than 120 degrees, the effective load on each
sling becomes even more than the load of the object being lifted and as
such, the main purpose of using multi leg sling would be defeated.

6.4 SEIZING
Seizing Prior to Cutting.
Prior to cutting, a wire rope should be securely seized on each side of the
cut by serving with soft wire ties. For socketing, at least two additional
seizings should be placed at a distance from the end equal to the length of
the basket of the socket. The total length of the seizing should be at least
two rope diameters and securely wrapped with a seizing iron. This is very
important, as it prevents the rope from untwisting and insures equal
tension in the strands when the load is applied.
Procedure
The recommended procedure for seizing a wire rope is as follows and is
illustrated in Figure 6.1:
1) The seizing wire should be wound on the rope by hand as shown
in Detail 1. The coils should be kept together and considerable
tension maintained on the wire.
2) After the seizing wire has been wound on the rope, the ends of
the wire should be twisted together by hand in a counter
clockwise direction so that the twisted portion of the wires is near
the middle of the seizing (see Detail 2).
3) Using “Carew” cutters, the twist should be tightened just enough
to take up the slack (see Detail 3). Tightening the seizing by
twisting should not be attempted.
4) The seizing should be tightened by prying the twist away from
the axis of the rope with the cutters as shown in Detail 4.
5) The tightening of the seizing as explained in 1 and 4 above
should be repeated as often as necessary to make the seizing
tight.
6) To complete the seizing operation, the ends of the wire should be
cut off as shown in Detail 5, and the twisted portion of the wire
tapped flat against the rope. The appearance of the finished
seizing is illustrated in Detail 6.

Figure 6.1—Putting a Seizing on a Wire Rope
6.5 ATTACHMENT OF CLIPS

6.5.1 Type and Strength- The clip method of making wire rope attachment is
widely used. Drop forged clips of either the U-bolt or the double-saddle
type are recommended (in ONGC U-bolt type clamp are normally used).
When properly applied, the method develops about 80% of the rope
strength in the case of six strand ropes.
6.5.2 Turn Back- When attaching clips, the length of rope to be turned back
from the thimble when making a loop is dependent upon the size of the
rope and the load to be handled. The recommended lengths, as measured
from the base of the thimble, are given in Table 6.1.
6.5.3 Thimble- The thimble should first be wired to the rope at the desired
point and the rope then bent around the thimble and temporarily secured
by wiring the two rope members together.
6.5.4 Number and Attachment of Clips- Refer to Table 6.1 for minimum
number of clips and torque required. For U-Bolt Clips, apply U-Bolt over
dead end of wire rope with live end resting in saddle. All U-Bolt clips

should be attached in the same manner (See Figure 62 and 6.3) as per the
following steps.
i. Apply first clip one base width from dead end of rope. Tighten
nuts evenly, alternating from one nut to the other until reaching
the recommended torque.
ii. When two clips are required, apply the second clip as near the
loop or thimble as possible. Tighten nuts evenly, alternating from
one nut to the other until reaching the recommended torque.
iii. When more than two clips are required, apply the second clip as
near the loop or thimble as possible, turn nuts on second clip
firmly, but do not tighten. Space additional clips equally between
the first two. Take up rope slack. Tighten nuts on each U-Bolt
evenly, alternating from one nut to the other until reaching
recommended torque.
iv. Add one additional clip if a pulley is used in place of a thimble for
turning back the rope.
v. Apply first load to the assembly. This load should be equal or
greater than loads expected in use. Rope will stretch and be
reduced in diameter when loads are applied. Next, check and
retighten nuts to recommended torque. In accordance with good
rigging and maintenance practices, the wire rope and termination
should be inspected periodically for wear, abuse, and general
adequacy.
TABLE: 6.1 NUMBERS OF CLIPS FOR DIFFERENT WIRE ROPE
SIZES
Wire Rope No. of Clips Length of the Torque, Ft-lb
Dia, Inches rope turned back,
Inches
1/8 2 3-1/4 4.5
3/16 2 3-3/4 7.5
1/4 2 4-3/4 15
5/16 2 5-1/4 30
3/8 2 6-1/2 45

Wire Rope No. of Clips Length of the Torque, Ft-lb
Dia, Inches rope turned back,
Inches
7/16 2 7 65
1/2 3 11-1/2 65
9/16 3 12 95
5/8 3 12 95
3/4 4 18 190
7/8 4 19 225
1 5 26 225
1-1/8 6 34 225
1-1/4 7 44 360
Figure 6.2— Incorrect Methods of Attaching Clips to Wire Rope
Figure 6.3 — Correct Method of Figure Attaching Clips to Wire Rope
6.6 CORROSION IN WIRE ROPES

Large number of ropes fail due to corrosion either external, internal, or
both. This corrosion may be caused by a variety of reasons - the most
common being acid or alkaline water, sea environment, fumes, due to

industrial conditions etc. When any one or combination of these
conditions is present, corrosion may attack the whole rope from end to
end, but quite frequently the effects are intermittent throughout the
length of the rope.
Corrosion in most cases cannot be completely prevented, but it can be
resisted by cleaning and lubricating the ropes regularly, or by using
galvanised ropes.
Wire ropes supplied are greased but this initial greasing is not sufficient
to last the life-time of the rope. The rope must be kept clean. The deposit
that forms on top of the grease coating holds moisture and gradually
works into the strands until the grease becomes emulsified and if the
deposit has an acid contact, the grease finally becomes corrosive.
After cleaning the rope with waste or hessian cloth , (do not use kerosene
or gasoline as it may penetrate into the core and do away with the internal
lubrication) - the rope must be re-greased with a first quality lubricant
free from acid - such as petroleum jelly.
When corrosion is a serious obstacle to rope life it is usually better to use a
galvanised rope. The galvanising will eventually wear off the outer wires
where they come in contact with pulleys, drums, etc. but will remain on
inside the rope and give very good protection against internal corrosion.
6.6.1 LUBRICATION SYSTEM
1) Before applying lubrication, accumulations of dirt or other abrasive
material should be removed from the rope. Cleaning can be
accomplished by using a stiff wire brush and solvent, compressed
air, or live steam. Immediately after the wire rope is cleaned, it
should be lubricated.
2) Type of lubricant servo coat 110/120 or its equivalent can be used
for lubrication or as recommended by the manufacturer of wire
rope. The following are important characteristics of a good wire rope
lubricant:
9 It should be free from acids and alkalis.
9 It should have sufficient adhesive strength to remain on the
ropes.
9 It should be of a viscosity capable of penetrating the
interstices between wires and strands.

9 It should not be soluble in the medium surrounding it under
the actual operating conditions (i.e. water).
9 It should have high film strength.
9 It should resist oxidation.
9 It should be chemically stable.
3) While lubricating the slings/wire ropes, people should wear hand
gloves. Many techniques may be used for lubrication, these include
bath, dripping, pouring, swabbing, painting or pressure spray
methods.
4) Whenever possible, the lubricant should be applied at the top of a
bend in the rope, because at that point the strands are spread by
bending and are more easily penetrated. There should be no load on
the rope while it is being lubricated.
5) The service life of wire rope will be directly proportional to the
effectiveness of the method used and amount of lubricant reaching
the working parts of the rope.
6.7 WIRE ROPE REPLACEMENT

No precise rules can be framed for determination of the exact period of
use & replacement of wire rope, as there are many variable factors of load
/working conditions / environment etc. Its replacement is based largely
on remaining strength of wire rope in use after proper inspection and
evaluation. All wire rope will eventually deteriorate to a point where it is
no longer usable. Wire rope shall be taken out of service when any of the
following conditions exist.
1. In running ropes, six randomly distributed broken wires in one
lay or three broken wires in one strand in one lay.
2. Wear of 1/3rd of the original diameter of outside individual
wires. Kinking, crushing, bird-caging, or any other damage
resulting in distortion of the rope structure.
3. Evidence of any heat damage from any cause or marked
corrosion appears.
4. Reduction from nominal diameter for more than 1/64 inch for
diameters up to and including 5/16 inch.
1/32 inch for diameters 3/8 to 1/2 inch inclusive
3/64 inch for diameters 9/16 to 3/4 inch inclusive

1/16 inch for diameters 7/8 to 1 1/8 inches inclusive
3/32 inch for diameters 1 1/4 to 1 1/2 inches inclusive
Wire rope removed from service, due to any of the above mentioned
reasons, shall be identified and marked as unfit for use on crane or other
load carrying devices.
To gauge a rope be sure that the faces of the calipers are in contact with
the crowns of two opposite strands as in Fig.4a and not as in Fig.4b in
contact with four strands.
Fig.4a Fig.4 b
6.8 EVALUATION OF CASING LINE

6.8.1 TOTAL SERVICE PERFORMED
The total service performed by a casing line can be evaluated by taking
into account the amount of work done by the line in the various workover
operations and by evaluating such factors as the stresses imposed by
acceleration and deceleration loadings, vibration stresses, stresses
imposed by friction forces of the line in contact with drum and sheave
surfaces, and other even more indeterminate loads. However, for
comparative purposes, an approximate evaluation can be obtained by
computing only the work done by the line in raising and lowering the
applied loads in making round trips, and in the operations of drilling,
milling, and short trips.
6.8.2 ROUND-TRIP OPERATIONS
Most of the work done by a casing line is that performed in making round
trips (or half-trips) involving running the string of drill pipe/ tubing into
the hole and pulling the string out of the hole. The amount of work
performed per round trip should be determined by use of the following
formula:

D (Ls +D) Wm D (M+½C)
Tr = ------------------ + ----------------- -------------(a)
10,560,000 2,640,000
where:
Tr = ton-miles [weight in tons (2,000 lb) times distance moved in miles],
D = depth of hole, ft.
Ls = length of drill-pipe stand, ft.
N = number of stands of drill-pipe,
Wm = effective (buoyed) weight per foot of drill-pipe in workover fluid,
lb.
M = total weight of traveling block-elevator assembly, lb.
C = effective (buoyed) weight of drill collar assembly in workover fluid
minus the effective (buoyed) weight of the same length of drill-pipe in
workover fluid, lb.
6.8.3 WORK DONE BY CASING LINE
Work done by casing lines can be calculated by summing up of ton-miles
for all round-trip operations (Formula a above). Apart from drilling /
milling operation, there are other operations that work the casing line that
need to be accounted for in the ton-mile accumulation. They include
operations such as: jarring, pulling on stuck pipe, fishing operations,
running and setting or pulling out of downhole tools etc.
Daily work done by casing line should be recorded in the rotary drilling
line service record maintained at the rig by driller in charge.
In case ton– mile indicator is installed on the rig, calculations can be
avoided and more comprehensive and accurate reading of work done by
casing line can be obtained.
6.9 SLIPPING AND CUT OFF PRACTICE FOR CASING LINE

The service life of casing line can be greatly increased by the use of a
planned program of slipping and cut-off based upon increments of
service. The sole dependence on visual inspection to determine when to
slip and cut results in uneven wear, trouble with spooling (line “cutting
in” on the drum), and long cut-offs, thus decreasing the service life.
The general procedure in any program should be to supply an excess of
casing line over that required to string up, and to slip this excess through

the system at such a rate that it is evenly worn and that the line removed
by cut-off at the drum end has just reached the end of its useful life.
6.9.1 SERVICE GOAL
A goal for line service in terms of ton-miles between cut-offs should be
selected. This value can initially be determined from the procedure
outlined in API RP 9B and later adjusted in accordance with experience.
6.9.2 CUT-OFF LENGTH
The following factors should be considered in determining a cut-off
length:
9 The excess length of line which can conveniently be carried on the
drum.
9 Load-pickup points from reeving diagram.
9 Drum diameter and crossover points on the drum.
Care should be taken to see that crossover and pickup points do not
repeat. This is done by avoiding cut-off lengths which are multiples of
either drum circumference, or lengths between pickup points.
6.9.3 SLIPPING PROGRAM
The number of slips between cut-offs can vary considerably depending
upon drilling conditions and on the length and frequency of cut-offs. This
frequency can vary from one or two slips to as much as four slips between
cut-offs. Slips will be more if the digging is rough, if jarring jobs occur,
etc. In slipping the line, the rope should be slipped an amount such that
no part of the rope will be located for a second time in a position of severe
wear. The positions of severe wear are the point of crossover on the drum
and the sections in contact with the travelling and crown-block sheaves at
the pickup position. The cumulative number of feet slipped between cut-
offs should be equal to the recommended number of feet for ton-mile cut-
off. For example, if cutting off 80 ft every 800 ton-miles. 20 ft should be
slipped every 200 ton-miles and the line cut off on the fourth slip.
Cut off and slipping program should be planned as per the procedure laid
down in API RP 9G.
General practice followed in ONGC Workover operations for cut off is that the
wearing points of every casing line shall be moved by cutting off at least thirty
metres of the casing line after every 3000 tonne-kilometres or at shorter intervals,
where necessary so as to prevent excessive wear of the casing line.

6.10 FIELD TROUBLES AND THEIR CAUSES
All wire rope will eventually deteriorate in operation or have to be
removed simply by virtue of the loads and reversals of load applied in
normal service. There are, however, many conditions of service or
inadvertent abuse, which will materially shorten the normal life of a wire
rope of proper construction although it is properly applied. The following
field troubles and their causes give some of the field conditions and
practices which result in the premature replacement of wire rope. It
should be noted that in all cases the contributory cause of removal may be
one or more of these practices or conditions.
a. Rope broken (all strands).
Possible Cause: Overload resulting from severe impact, kinking, damage,
localized wear, weakening of one or more strands, or rust-bound
condition and loss of elasticity. Loss of metallic area due to broken wires
caused by severe bending.
b. One or more whole strands parted.
Possible Cause: Overloading, kinking, divider interference, localized wear,
or rust-bound condition. Fatigue, excessive speed, slipping, or running
too loosely. Concentration of vibration at dead sheave or dead-end
anchor.
c. Excessive corrosion.
Possible Cause: Lack of lubrication. Exposure to salt spray, corrosive gases,
alkaline water, acid water, mud, or dirt. Period of inactivity without
adequate protection.
d. Rope damage by careless handling in hauling to the well or location.
Possible Cause: Rolling reel over obstruction or dropping from car, truck,
or platform. The use of chains for lashing, or the use of lever against rope
instead of flange. Nailing through rope.
e. Damage by improper socketing.
Possible Cause: Improper seizing which allows slack from one or more
strands to work back into rope; improper method of socketing or poor
workmanship in socketing, frequently shown by rope being untwisted at
socket, loose or drawn.
f. Kinks, doglegs, and other distorted places.

Possible Cause: Kinking the rope and pulling out the loops such as in
improper coiling or unreeling. Improper winding on the drum. Improper
tie down. Open-drum reels having longitudinal spokes too widely
spaced. The addition of improperly spaced cleats to increase the drum
diameter. Stressing while rope is over small sheave or obstacle.
g. Damage or failure on a fishing job.
Possible Cause: Rope improperly used on a fishing job, resulting in damage
or failure as a result of the nature of the work.
h. Lengthening of lay and reduction of diameter.
Possible Cause: Frequently produced by some type of overloading, such as
an overload resulting in a collapse of the fiber core in swabbing lines.
i. Premature breakage of wires.
Possible Cause: Caused by frictional heat developed by pressure and
slippage, regardless of drilling depth.
j. Excessive wear in spots.
Possible Cause: Kinks or bends in rope due to improper handling during
installation or service. Divider interference; also, wear against casing or
hard shells or abrasive formations in a crooked hole. Too infrequent cut-
offs on working end.
k. Spliced rope.
Possible Cause: A splice is never as good as a continuous piece of rope, and
slack is liable to work back and cause irregular wear.
l. Abrasion and broken wires in a straight line. Drawn or loosened
strands. Rapid fatigue breaks.
Possible Cause: Injury due to slipping rope through clamps.
m. Reduction in tensile strength or damage to rope.
Possible Cause: Excessive heat due to careless exposure to fire or torch.
n. Distortion of wire rope.
Possible Cause: Damage due to improperly attached clamps or wire-rope
clips.
o. High strands.
Possible Cause: Slipping through clamps, improper seizing, improper
socketing or splicing kinks, doglegs, and core popping.

p. Wear by abrasion.
Possible Cause: Lack of lubrication. Slipping clamp unduly. Sandy or gritty
working conditions. Rubbing against stationary object or abrasive surface.
Faulty alignment. Undersized grooves in sheaves.
q. Fatigue breaks in wires.
Possible Cause: Excessive vibration due to poor drilling conditions, i.e.,
high speed, rope slipping, concentration of vibration at dead sheave or
dead-end anchor, undersized grooves and sheaves, and improper
selection of rope construction.
r. Spiraling or curling.
Probable Cause: Allowing rope to drag or rub over pipe, sill, or any object
during installation or operation. It is recommended that a block with
sheave diameter 16 times the nominal wire-rope diameter, or larger, be
used during installation of the line.
s. Excessive flattening or crushing.
Probable Cause: Heavy overload, loose winding on drum, or cross
winding.
t. Bird-caging or core popping.
Probable Cause: Sudden unloading of line such as hitting fluid with
excessive speed. Improper drilling motion or jar action. Use of sheaves of
too small diameter or passing line around sharp bend.
u. Whipping off of rope.
Probable Cause: Running too loose.
v. Cutting in on drum.
Probable Cause: Loose winding on drum. Improper cutoff and moving
program for rotary drilling lines. Improper or worn drum grooving or
line turnback plate.

6.11.1 DO’S
1) Wire ropes should be stored in a well cleaned, ventilated dry shed
and shall be protected from weather, dust, chemical fumes, steam,
brine, and any other corrosive agents.

2) The wire ropes should be stored thoroughly cleaned, greased/
lubricated and covered to minimize the effects of corrosion on
wire rope.
3) Wire ropes should be inspected for corrosion at regular intervals
and recorded.
4) Wire ropes when supplied on reels, before using, a spindle should
be put through the reel. Reel should be firmly supported and the
ends should be jacked up to allow the reel to rotate freely on
horizontal axis.
5) When handling wire rope on a reel with a binding or lifting chain,
wooden blocks should always be used between the rope and the
chain to prevent damage to the wire or distortion of the strands in
the rope.
6) Bars for moving the reel should be used against the reel flange,
and not against the rope.
7) The preferred method for lifting a reel with slings is to use a
spreader bar that is of sufficient length to keep the sling legs from
contacting the reel.
8) Suspend the travelling block from the crown block on a single line
(otherwise support in a vertical position) while changing the
casing lines to minimise the amount of rubbing on guards or
spacers, as well as chances for kinks.
9) While winding the wire rope on the drum, sufficient tension
should be kept on the rope to assure tight and even spooling. It is
most important to get the first drum layer full and tight without
over crowding so that it will support the succeeding layers.
10) The number of excess or dead wraps or turns specified by the
equipment manufacturer should be maintained.
11) Avoid kinking a wire rope when spooling or un-spooling since a
kink can be cause for removal of the wire rope or damaged
section.
12) Ensure that clamps used for fastening the rope to dead end do not
kink, flatten or crush the rope.
13) Periodically, the rope should be field lubricated with a good
grade of lubricant which will penetrate and adhere to the rope,
and which is free from acid or alkali.

14) Line whip and natural vibrations cause fast line fatigue.
Therefore, a wire line stabilizer must be installed on fast line.
15) Use turnback rollers on each side of the drum to reduce scrubbing
at those points where new layers of line are started.
16) Sheave grooves should be checked periodically with the gauge for
worn sheaves and dimensions. All sheaves should be properly
lubricated to ensure minimum turning efforts.
17) Wire line must be periodically examined. A proper slip and cut-
off practice should be followed after evaluating the work done by
a rope. A record of work done in ton – mileage should be
maintained.
18) Wire rope should be securely seized on each side of the cut by
serving with soft wire ties before cutting the rope. It will prevent
the rope from untwisting.
19) Care should be taken to maintain proper winding of rotary
drilling lines on the draw works drum in order to avoid excessive
friction which may result in the formation of martensite.
20) To start stringing the rope, remove the old rope from the dead
line anchor and fasten it to the new rope with a wire line grip
with swivel to prevent transferring twist to the drilling line.
21) Whenever possible, a new wire rope should be run under
controlled loads and a speed for a short period after it has been
installed. This will help to adjust the rope to working conditions.
22) Driller should reduce shock loads by picking up and releasing
loads as gently as conditions permit.
23) Always use a sling of greater capacity than actually needed to
transport / lift the load.
24) Slings should be periodically examined for defects and
deterioration.
25) Nylon slings should not be used on rigs.
26) In multi leg sling operation, the most favourable angle between
the sling legs is within the range of 60 and 90 degrees.
27) Dropforged clips of either the U-bolt or the double-saddle type
are recommended. For U-Bolt Clips, apply U-Bolt over dead end
of wire rope with live end resting in saddle

28) When attaching clips, the length of rope to be turned back from
the thimble when making a loop and minimum number of clips,
and torque required should be as recommended in API RP 9B.
29) The wire rope and termination should be inspected periodically
for wear, abuse, and general adequacy.
30) Periodically, a visual inspection should be made of casing line as
it is spooled on or off the drum. Weak places indicated by broken
or worn wires or distortion of the line may be removed from the
system by slipping and cutting the drilling line.
31) After cleaning the rope with waste or hessian cloth, (do not use
kerosene or gasoline as it may penetrate into the core and do
away with the internal lubrication) - the rope must be re-greased
with a first quality lubricant free from acid - such as petroleum
jelly.
32) Wire rope shall be taken out of service when in running ropes, six
randomly distributed broken wires in one lay or three broken
wires in one strand in one lay or wear of 1/3rd of the original
diameter of outside individual wires. Wire rope should be put out
of service if kinking, crushing, bird-caging, heat damage or any
other damage resulting in distortion of the rope structure.
33) Wire rope removed from service due to any reason, shall be
identified and marked as unfit for use on crane or other load
carrying devices.
34) To increase the service life of casing line, follow a planned
program of slipping and cut-off based upon increments of service.
35) Ton–mile indicator should be installed on the rig, to avoid
calculation and to obtain more comprehensive and accurate
reading of work done by casing line.
6.11.2 DON’TS
1) Wire ropes should not be struck with any object such as a steel
hammer, derrick hatchet, or crow bar which may cause
unnecessary nicks or bruises.
2) Don’t run the blocks with excessive speeds as it may injure the
wire rope.

3) Don’t use solvent to clean the wire rope as it may be detrimental l.
If a rope becomes covered with dirt or grit, it should be cleaned
with a brush.
4) Don’t allow any twist or torque when installing a new rope.
5) The reel should not be rolled over or dropped from a truck or
platform on any hard, sharp object. This may cause damage to the
rope (bruised or nicked) as well as break the reel.
6) Don’t roll the reel in or allowing it to stand in any medium
harmful to steel such as mud, dirt, or cinders.
7) Don’t use burnt oil for lubrication of wire rope.

CHAPTER- 7
WELL CONTROL
EQUIPMENT
7.0 GENERAL
The well control equipment is designed to shut in the well safely to
control any uncontrolled flow of fluids in/ from the well bore and to
provide means to regain the primary well control. Some components of
well control equipment are BOP (annular preventer, ram preventers -
pipe, blind, shear and variable), choke and kill manifold, hydraulic
control unit, diverter, riser, auxiliary equipment and drilling spool.
7.1 BOP STACK

7.1.1 BLOWOUT PREVENTER SIZE
a) The size of BOP stack means the vertical nominal inside diameter.
The selection of size of BOP should be such that it should allow to
pass through all the tools required for workover operations.
b) Blowout preventer stack configuration should be selected
considering the space available between top of cellar pit and
bottom of rotary table.
c) If the rated working pressure and size of wellhead flange does not
match with the BOP stack, it leads to the use of adopter flanges.
However, while designing BOP stack, efforts should be made to
use minimum number of flange connections on the stack.
d) BOP stack must withstand the maximum anticipated surface
pressure. The minimum pressure rating of all pressure control
equipment (BOP, valves etc.) must be equal or greater than the
maximum anticipated surface pressure.

e) The stack must have provision for inlet and outlet of fluid under
controlled pressure. Preventer’s side outlets may sometimes be
used for circulating fluid in the well at the time of killing.
f) Annular BOPs may have a one step lower rated working pressure
than the ram BOPs.
7.1.2 CONNECTIONS, SIZE & PRESSURE RATING OF BOP AND
W/HEAD FLANGES
a) The well head pressure rating should be more than the maximum
anticipated surface pressure.
b) The API standard rating flanges are to be used and BOP stack
should have minimum connections as far as possible.
c) Only studded/ flange/ hub type of connections are to be used in
BOP stack.
d) The BOP side outlets should be of same rating as of BOP stack.
7.1.3 BOP SERVICE CONDITIONS
a) In sour gas areas, BOP in use should be H2S trim to resist
sulphide stress cracking.
b) BOP & elastomer in use should be compatible to the fluid to be
used for workover operations.
c) BOP spare parts at rigs should be stored properly specially the
rubberized parts.
d) BOP should be pressure tested & function tested as per OISD RP-
174.
7.1.4 SELECTION CRITERIA FOR WELL CONTROL EQUIPMENTS
a) All the equipment should be selected to withstand the maximum
anticipated surface pressures.
b) The blow out preventer stack should consist of remote operated
equipment capable of closing in the well with or without the pipe
in the hole.
c) No threaded connections are to be used on flanges above 2000 psi.
d) In sour gas areas, H2S trim equipment should be used.
e) Kill lines & choke line should be of minimum 2 inch nominal size.

f) During workover operations, blind/ blind shear rams shall be
provided in the BOP stack. The shear blind rams shall always be
capable of shearing the drill pipe, tubing, wire cable in use under
no-load conditions and subsequently provide a proper seal.
g) Closing systems of surface BOPs should be capable of closing
each ram preventer and annular preventer smaller than 18 ¾” size
within 30 seconds and annular preventers of 18 ¾” or bigger size
within 45 seconds.
h) All 4 way valves at BOP control unit should be either in the fully
closed or open position as required, they should not be left in the
block/neutral position.
i) All spare BOP/valves operating lines and connections which are
not used in the system should be properly blocked off with blind
plugs at the BOP control unit (Accumulator Unit).
j) All the 4 way valves should have the provision to be operated
from remote panel.
k) The shear ram operating handles should be properly protected.
l) Wherever Cameron D type annular preventer is used, the annular
pressure reducing & regulating valve should be capable of
regulating from 0-3000psi.
7.1.5 BOP STACK PHILOSOPHY FOR WORK-OVER AND TESTING
OPERATIONS
ONGC approved BOP stack philosophy for Work-over and Testing
operations for different pressure ratings is as follows;
7.1.5.1 Pressure Rating Up To 5000 Psi
I. One double ram BOP of 5000 psi rating consisting of one blind ram
and the other correct size of pipe ram.
II. EOR (In-situ)
If requirement of shearing is anticipated during the operations, then
BOP stack should have;
a. One double ram BOP of 5000 psi rating consisting of one shear
blind ram on top and the other correct size of pipe ram.
b. One singe ram BOP of 5000 psi rating with correct size of pipe
ram.

In case requirement of shearing is not anticipated in the EOR wells,
then recommendation no 7.1.5.1(i) above should be followed.
III. For wells having Electrical submersible Pump (ESP) configuration
shall be
a. One annular preventer of 3000 psi / 5000 psi rating.
b. One double ram BOP of 5000 psi rating consisting of one blind
ram and the other correct size of pipe ram.
IV. API RP 53 recommends use of one step lower annular preventer in
BOP stack.
7.1.5.2 PRESSURE RATING MORE THAN 5000 PSI AND UP TO 10000 PSI
I. For wells having SBHP more than 5000 psi and up to 10000 psi the
configuration shall be;
i) For oil wells: One double ram BOP of 10000 psi rating consisting
of one blind ram and the other correct size of pipe ram.
ii) For Gas Wells: The BOP stack of 10000 psi rating have three rams
comprising of ;
a. One double ram BOP consisting of one shear blind ram on
top and the other correct size of pipe ram.
b. One singe ram BOP with correct size of pipe ram.
II. EOR (Insitu ) Wells
If requirement of shearing is anticipated during the operations, then
BOP stack should have
a. One double ram BOP of 10000 psi rating consisting of one
shear blind ram on top and the other correct size of pipe
ram.
b. One single ram BOP of 10000 psi rating with correct size of
pipe ram.
In case requirement of shearing is not anticipated in the EOR wells,
then recommendation no 7.1.5.2 I. above should be followed.
III. For wells having Electrical submersible Pump (ESP) configuration
shall be
a) One annular preventer of 5000 psi / 10000 psi rating.

b) One double ram BOP of 10000 psi rating consisting of one
blind ram and the other correct size of pipe ram
IV. API RP 53 recommends use of one step lower annular preventer in
BOP stack.
7.1.5.3 PRESSURE RATING MORE THAN 10000 PSI
I. For wells having SBHP more than10000 psi the configuration shall
be;
a) One annular preventer of 10000 psi rating.
b) One double ram BOP of 15000 psi rating consisting of one shear
blind ram on top and the other correct size of pipe ram
c) One single ram BOP of 15000 psi rating with correct size of pipe
ram.
II. API RP 53 recommends use of one step lower annular preventer in
BOP stack
III. For EOR (In-situ) wells, the recommendations as per Para 7.1.5.3 I.
shall apply.
IV. For wells having Electrical submersible Pump (ESP), the
recommendations as per Para 7.1.5.3 I. shall apply.
7.2 CHOKE & KILL MANIFOLD

The Choke and Kill manifold provides a means of applying back pressure
on the formation while circulating out influx from the well bore. The
Choke and Kill manifold proposed for workover operations in ONGC is
as described in Chapter-1 of this manual. Main design features of the
manifold are as follows:
a) Upstream valves, connections and lines including the choke should
have a working pressure equal to or greater than the rated working
pressure of the ram BOPs in use. All the connections in use should
be flanged or studded or hubbed and are to be in accordance with
API Specification 6A.
b) The choke & kill manifold should be placed in a readily accessible
location and at a safe distance from the well head.
c) Minimum two valves are recommended in choke line immediately
after the BOP stack with rated working pressure equal or greater
than the rated working pressure of Ram BOP in use.

d) A minimum of one variable choke & one fixed type choke should be
installed on all choke & kill manifolds.
e) Choke & kill manifold configurations should allow for re-routing of
flow without interrupting flow control.
f) Pressure gauges suitable for operating pressure and drilling fluid
service should be installed so that drill pipe and annulus pressures
may be accurately monitored.
g) Choke line and lines downstream of the choke should be as straight
as possible. Wherever the bends, blocks and tees are provided,
they should be targeted to minimize erosion.
h) If flexible lines are used, manufacturer’s guidelines should be
consulted on working minimum bend radius to ensure proper
length determination and safe working configuration.
i) The choke lines should be firmly anchored to prevent excessive whip
or vibration.
j) The choke line nominal diameter should not be less than 2 inches
and all other components should also not be less than 2 inches.
k) The vent/bleed line that bypasses the chokes should be at least
equal to the diameter of choke line.
l) All choke & kill manifold valves should be full bore and during
operations, all valves should be either fully opened or fully closed.
m) All lines, valves and flow fittings should have a working pressure at
least equal to the rated working pressure of the ram BOPs in use.
7.3 BOP Hydraulic Control System

a) One independent automatic accumulator unit with a control
manifold clearly showing open and closed positions for preventer(s)
to be provided. The unit should be located in a safe area out of zone-
II i.e more than 16 mtrs away from the well center.
b) The accumulator system should be capable of closing each ram BOP
within 30 sec. The closing time should not exceed 30sec for annular
preventers smaller than 18 ¾” nominal bore and 45sec for annular
preventers of 18 ¾ ” and larger.
c) Hydraulic operating equipment shall have at least a 3,000 psi
accumulator unit equipped with two regulator valves, one to

regulate the operating fluid pressure from 0-1,500 psi and the other
for regulating the pressure for annular preventer from 0-3000 psi.
d) BOP control systems should have sufficient usable hydraulic fluid
volume (with pumps inoperative) to close one annular-type
preventer, all ram-type preventers from a full-open position, and
open one HCR valve against zero well bore pressure. After closing
one annular preventer, all ram-type preventers, and opening one
HCR valve, if in use, the remaining pressure should be 200 psi or
more above the minimum recommended pre-charge pressure.
e) The usable fluid should be 1.5 times the closing volume of all the
BOP and opening volume of all the HCR, if in use,. The usable fluid
should be calculated based on final pressure as maximum of either
pre-charge pressure plus 200psi or the operating pressure required
to close any ram preventer (excluding shear ram) at rated working
pressure using closing ratio.
f) There should be minimum two sources for charging the
accumulators. The combination of air/ electric / engine driven
pumps shall be capable of charging the entire accumulator system
from the pre-charge to full charge pressure within 15 minutes or
less.
g) Each pump system should be protected from over pressurization by
a minimum of two devices to limit the pump discharge pressure.
One device, normally a pressure limit switch, should limit the pump
discharge pressure so that it will not exceed the working pressure of
the BOP control system. The second device, a relief valve, should be
sized to relieve at a flow rate at least equal to the design flow rate of
the pump systems and should be set to relieve at not more than 10%
over the control unit pressure. Devices used to prevent pump
system over pressurization should be installed directly in the control
system supply line to the accumulators and should not have
isolation valves or any other means that could defeat their intended
purpose. Rupture disc(s) or relief valve(s) that do not automatically
reset are not recommended to be used.
h) In addition to the main control panel at the unit, the BOP control
system should have one driller’s remote control panel located on the
rig floor near the Driller’s console. The remote control panel should
be connected to the BOP control unit in such a way that all the

functions can be operated independently from the panel and main
unit.
i) The control hoses connected to BOP functions must be flexible and
fire resistance.
j) The capacity of the reservoir tanks should be such that when the
system is not pressurized, the level of the fluid in the tank should be
about 1" below the inspection port and when the accumulator
bottles are fully charged at 3000 psi, the level in the tank should be
about 1" above the suction valves of the pump used in the unit.
k) As per API recommendation, the tank capacity should be at-Ieast
two times the usable fluid.
l) To avoid accidental operation of blind ram and blind-shear ram
selector valves are covered/ protected.
m) Fluid used in the accumulator should be noncorrosive, non-foaming
hydraulic oil.
n) All the manipulators valves should be kept in neutral position when
the unit is not charged, and should be kept in either open or close
position after charging the unit. All the 3 position 4 way
manipulator or selector valves should be attached with labels,
indicating their respective functions.
7.4 String Preventers ( FOSV/Kelly Cock/Inside BOP)

a) A spare full opening safety valve that is compatible with drill pipe
in use should be available on the rig floor at all times in the open
position and complete with removable handles for the ease of
stabbing.
b) Crossover for connecting the full opening safety valve to the drill
collars or tubing in use should be available on the rig floor.
c) An inside BOP, with the appropriate connections for the work/

drill string in use, should be available on the rig floor at all times.
7.5 PRESSURE AND FUNCTION TESTING OF WELL

CONTROL EQUIPMENT
For optimum control of any well kick situations successful functioning of
the blowout preventer stack, choke and kill lines and other related
equipment at their rated capabilities becomes pertinent. The BOP Stack
and allied equipment should be tested as per the OISD-STD-174. Record

should be maintained as per the formats prescribed in OISD STD174 wrt
7.5.1 N E E D OF PERIODIC TESTING
The periodic function and pressure test of BOPs (well control equipment)
should be carried out to ensure the following:
a) A l l t he functions of BOP stack and control unit are operational.
b) The integrity of the installed well control equipment at recommended
test pressure is in order.
c) T h e control system and BOP stack are compatible.
Before resuming the normal operations any deficiency observed during
testing should be rectified.
7.5.2 TEST FLUIDS
Clear water should be used for testing of BOP stack and other well control
equipment. It should be ensured that air is removed from the system
before test pressure is applied.
7.5.3 PRESSURE TEST
All BOP components that may be exposed to well pressure should be tested
first to a low pressure of 200 to 300 psi and then to a high pressure.
7.5.3.1 LOW PRESSURE TEST
Low pressure test should be conducted at 200 to 300 psi on all the rams,
annular preventers, manifolds, lower Kelly cock, etc. Any leak observed at
low pressure, the corrective remedial measure should be taken
accordingly.
7.5.3.2 HIGH PRESSURE TEST
A) After initial installation of BOP on well head
i. Rams, choke manifold and choke/ kill lines should be tested to the
rated working pressure of the ram BOPs or to the rated working
pressure of the well head on which the stack is installed, which ever
is lower.
ii. Annular BOPs may be tested to 70% of the rated working pressure or
to the test pressure applied to the ram BOPs, which ever is lower.
iii. Lower Kelly cock, Kelly, upper Kelly cock and drill pipe safety valve
should be tested to the rated working pressure.
iv. If the test stump is available at the rig, the BOP should be tested prior

to installation at high pressure as mentioned above and the
subsequent high pressure test should be conducted after installation
as mentioned below in point no. 7.5.3.2 B
B) Subsequent high pressure test
i. Subsequent high pressure test of ram BOPs and choke manifold should
be limited to maximum of 10 % greater than the maximum
anticipated surface pressure but not to exceed the working pressure of
the ram BOPs. The maximum anticipated surface pressure should be
determined by data given in work-over plan.
ii. Annular BOPs should be tested to a minimum of 50% of their
working pressure or to greater than the maximum anticipated
surface pressure whichever is lesser.
7.5.4 TEST DURATION
The low as well as high pressure test should be conducted for a period of
5 minutes.
7.5.5 TEST FREQUENCY
A) Function test:
All operational components of the BOP equipment systems should be
function tested at least once a week.
B) Pressure test:
Pressure test on the well control equipment should be conducted at least:
i. On installation
ii. After the repair/ disconnection of any pressure containment seal in
the BOP stack, choke line or choke manifold, but limited to the
affected component.
iii. Once in 21 days.
7.5.6 TESTING EQUIPMENT
Following testing equipment are recommended to be used for testing BOP
Stack:
A) Test Pumps
A small l o w d i s c h a r g e high pressure pump should be used for
pressure testing. Wherever test pump is not available for any specific
reason than cementing/ pumping unit should be used.
B) Cup Tester

i. Cup of the cup tester should be selected on the basis of upper most
part of casing and it should be compatible with the casing size &
grade.
ii. The tensile strength of the test pipe used with cup tester should be
sufficient to avoid failure during testing
C) Test Plug
i. The annulus valves of the well head should be opened before
lowering the test plug.
ii. Test plug should be compatible with the tubing spool size/make.
iii. Test plug is to be lowered and landed into the tubing spool with a
test pipe joint.
iv. To test the blind or shear blind ram, test pipe should be removed,
leaving the test plug resting on the tubing spool.
7.6 FUNCTION TEST

i. All operational components of the BOP equipment systems should
be function tested at least once a week to verify the components’
intended operations.
ii. The test should be conducted when the workstring is inside casing.
iii. Both power source of accumulator unit should be turned off after
recording initial accumulator pressure.
iv. All the blow out preventers should be function tested. Closing time
of rams should be recorded.
v. For surface BOP stack closing time should not exceed 30 seconds for
each ram preventers and annular preventers smaller than 18¾" and
45 seconds for annular preventer of 18¾" and larger size.
vi. Record final accumulator pressures after all the functions. It should
not be less than 200 psi above the recommended pre-charge pressure
of accumulator bottles.
vii. All the gate valves and blow out preventers should be returned to
their original position before resuming operations.
viii. All the results should be recorded in the prescribed format.
7.7 PRESSURE TESTING:

i. All blow-out prevention components that may be exposed to well
pressure should be tested first to a low pressure and then to a high
pressure. These include blow-out preventer stack, all choke manifold
components, upstream of chokes, kill manifold / valves, Kelly
valves, drill pipe and tubing safety valves and drilling spools (if in
use). Pressure test (both low and high) on each component should be
of minimum 5 minutes duration each. All the results should be
recorded in the format.
ii. Test BOP using cup tester or test plug.
iii. Before pressure testing of BOP stack, choke and kill manifold should
be flushed with clean water.
iv. Clean water should be used as test fluid.
v. High pressure testing unit or cementing unit should be used for
pressure testing.
vi. Well control equipment should be pressure tested.
a) When installed.
b) Following repairs that require breaking a pressure connection
c) But not less than once every 21 days.
vii. Low pressure test should be carried out at 200-300 psi.
viii. Once the equipment passes the low pressure test, it should be tested
to high pressure.
ix. Initial pressure test of blow-out preventer stack, manifold, valves
etc. should be carried out at the rated working pressure of the
preventer stack or wellhead whichever is lower. Initial pressure test
is defined as those tests that should be performed on location before
the before pre workover or before the equipment is put into
operational service.
x. Subsequent high pressure tests should be carried out at a pressure
greater than maximum anticipated surface pressure. Exception is the
annular preventer which should be tested to 50% of its rated
pressure or maximum anticipated surface pressure whichever is
lower.
xi. The pipe/ tubing used for testing should be of sufficient weight and
grade to safely withstand tensile, yield, collapse, or internal
pressures.

xii. Precaution should be taken not to expose the casing to pressures in
excess of its rated strength. A means should be provided to prevent
pressure build up on the casing in the event the test tool leaks
(wellhead/ tubing spool valve should be kept open when pressure
testing with test plug).
xiii. Pressure should be applied from the direction in which all the
BOP’s, choke and kill manifold, FOSV / Kelly cock/Inside BOP etc.
would experience pressure during kick.
7.8 CASING TEST

The following sequence of operation should be followed to test casing:
i. Run in drill string and bit, up to the top of the bridge plug/cement
plug.
ii. Break circulation and test casings to 200 psi greater than the
anticipated formation pressure.
iii. Do not exceed 80% of the burst rating of the casing.
iv. Use the cementing unit to test the casing.
v. Test should be conducted for 15 minutes.
7.9 INSTALLATION REQUIREMENT FOR WELLHEAD & BOP

EQUIPMENT
a. Wellhead equipment should withstand anticipated surface
pressures and allow for future remedial operations.
b. When ram type preventers are installed, the side outlets should be
below the rams.
c. All connections, valves, fittings, piping etc. exposed to well
pressure, should be flanged or clamped or welded and must have a
minimum working pressure equal to the rated working pressure of
the preventers.
d. Always install new and clean API ring gaskets. Check for any
damage in the ring as well as grooves before use.
e. All correct size bolts/ nuts and fittings should be used and
tightened to the recommended torque. All connections should be
pressure tested before operation is resumed.
f. All manually operated valves should be equipped with hand
wheels, and always be kept ready for use.

g. Ram type preventers on surface BOP stack should have extension
rods & hand wheels for manually locking the rams and to be kept
ready for use.
h. BOP equipment should be function tested and pressures tested,
when installed and at the appropriate time during operations to
determine that BOP functions properly.
i. Choke lines shall be as straight as practicable and firmly anchored to
prevent excessive whip or vibration.
j. Ensure that the instructions of the BOP operating manual of the
manufacturer's are followed and no alterations are made to the BOP
equipment without consulting the manufacturer.
k. Before running in of tubing/ drill pipe, blowout preventer must be
fitted with correct size of pipe rams and BOP stack to be pressure
tested.
l. To control the flow activity through tubing/drill pipe during
tripping a device like inside BOP/Kelly cock / NRV with matching
thread of tubular being handled should always be available at the
derrick floor.
7.10 INSTALLATION OF BOP STACK

Described below a procedure for installation of a typical BOP stack
consisting of one double ram BOP and one annular preventer.
i. After removing the X-mas tree, inspect and lubricate tubing hanger
threads. These may be corroded and may not support the string
weight.
ii. Inspect the well head spool, groove of the ring and steel ring. Clean
the casing head flange, ring groove and replace the ring, if required.
Put a steel ring gasket of correct type and rating in the well head
groove.
iii. Lift a serviced and pressures tested double ram BOP stack equipped
with pipe rams matching with pipe sizes to be used and a blind ram
and center it on well head spool.
iv. The vertical bore should be at least equal to the maximum inner
diameter of the inner most casing.

v. Slowly lower BOP (the direction of the BOP handles should be so
kept that BOP rams can be easily operated) and rest BOP on the well
head. Tighten the double ram BOP on the well head.
vi. Clean the top ring groove of the ram type BOP and place a ring
gasket of correct size and rating.
vii. Lift annular BOP and slowly install it above double ram BOP taking
proper care. Keep the fluid outlet valves on the sides so that the
fluid lines can be easily fitted.
viii. Clean the ring groove above the annular BOP and install the ring
and the flow nipple to facilitate the flow of work over fluid from the
well bore to the channel/ tank.
ix. Connect BOP handles on the double ram BOP ensuring that
manually operated shafts and wheels must extend beyond the
substructure boundary and be easily accessible. Erect a name plate
in front of the hand wheel displaying the direction and number of
turns which are required for preventer closure by an arrow in red
paint.
7.11 TESTING PROCEDURE

7.11.1 FUNCTION TEST
Function test is performed to verify the components’ intended operations.
i. The test (ram BOP and annular BOP) should be conducted when the
work string is inside casing.
ii. Test should be conducted after installing FOSV/ inside BOP on work
string.
iii. Both pumps (pneumatic and electric/diesel) of accumulator unit
should be turned off after recording initial accumulator pressure.
iv. All the ram preventers (except blind/shear) and HCR’s in
choke/kill line should be function tested and closing time should be
recorded.
v. Blind ram should be operated for function test when work string is
out of hole.
vi. Pipe/tubing ram should be closed against correct size pipe/tubing
in the hole..
vii. Operation of shear ram should be kept to bare minimum.

viii. Closing time should not exceed 30 seconds for all ram preventers
and annular preventers.
ix. Function test should be carried out alternatively from main control
unit/derrick floor panel.
x. Record final accumulator pressure after all the function tests and it
should not be less than 1200 psi or 200 psi above the pre-charged
pressure of accumulator which ever is maximum as per API or
value based on closing ratio of ram preventer (which ever is
maximum)
xi. All the gate valves and blow out preventers should be returned to
their original position and continue normal operations.
xii. All the results should be recorded in the DPR and in prescribed
formats (OISD STD 174; Annexure VII) given at the end of this
chapter.
7.11.2 PRESSURE TEST
A. Testing of Blind Ram
i. Make up appropriate tubing spool test plug and run in on a drill
pipe/tubing. Set the plug in tubing spool seat. Back off and remove
drill pipe/tubing joint
ii. Fill BOP stack with water. Open all the valves and chokes in
choke/kill line and choke and kill manifold and allow water to flow
through each out let. Flush all the lines and BOP with water.
iii. Open both the valves on tubing spool below test plug seals to
recognize leaking seals as well as well activity and prevent
formation or casing damage in case of any leakage through test plug.
iv. Close valve on BOP outlet going to choke/ kill line.
v. Fill and top up BOP stack with water.
vi. Close blind ram with 1500 psi closing pressure.
vii. Check closing line and preventer for leaks.
viii. Apply pressure by cementing unit or high pressure test unit through
main kill line and pressurise up to 200 to 300 psi and hold for 5
minutes. If pressure is holding, test up to final test pressure as
decided. Again hold for at least for 5 minutes.

ix. If there is a drop in pressure, check all the valves, flanges and seals
that are under pressure. Also check blind ram and test plug for
leaks. If leakage is observed corrective action may be taken after
releasing pressures and opening blind ram. Retest the blind ram as
described above.
x. Open blind rams with 1500 psi. Check opening lines for leaks.
xi. Record test results.
B. Testing of Annular BOP and Pipe Rams
i. Flush lines with water.
ii. Make up test plug with sufficient weight and rest test plug at tubing
spool.
iii. Run in appropriate size of drill pipe/tubing and make up with test
plug.
iv. Ensure that integral port in the test plug is open.
v. Fill up drill pipe/tubing with water. Make up FOSV on top of drill
pipe.
vi. Close valve on the outlets of BOP going to choke line and valve kill
line.
vii. Close annular preventer with appropriate closing pressure as per
manufacture recommendation.
viii. Check closing line and annular preventer for leaks.
ix. Apply test pressure through drill pipe and raise pressure to 200 to
300 psi and hold for 5 minutes. Check for any leakage. If pressure is
holding, increase the pressure upto final test pressure and hold for at
least 5 minutes.
x. Check for leaks and release pressures.
xi. Open annular preventer.
xii. Now close upper pipe ram with 1500 psi.
xiii. Check closing line and preventer for leaks.
xiv. Again, apply test pressure through drill pipe and raise pressure upto
200 to 300 psi and hold for five minutes. Check for any leakage. If
the pressure is holding, then increase the pressure upto final test
pressure and hold for at least 5 minutes.

xv. Test pressure should be limited to the pressure rating of the weakest
member exposed to the test pressure.
xvi. Check for leaks and release pressures.
xvii. Open pipe rams with 1500 psi.
xviii. Check opening lines and preventer for leaks.
xix. Test all other pipe rams in BOP stack in this manner by repeating
step no. ix to xiv. Make sure that the pipe rams size fits the drill
pipe/ tubing size in the well, if not change the drill pipe/ tubing
and then test the rams.
Variable bore rams should be initially pressure tested on the largest
and smallest OD pipe/ tubing sizes that may be used during the
well operations
xx. If there is any leakage, corrective action may be taken after releasing
pressure and retested as per procedure detailed above.
C. Testing of Kill/ Choke Line, Manifold Valves, Flanges and Fittings
i. With the test plug seated in tubing spool, kill/ choke lines and
manifold fittings are flushed with water. For this purpose, close
upper pipe ram and open all valves and chokes on choke and kill
manifold to allow the flow of water through each outlet.
ii. Keeping upper pipe ram closed, close the first available valve(s)
from the BOP stack in choke/kill line.
iii. Apply test pressure through drill pipe/tubing and raise pressure
upto 200 to 300 psi and hold for 5 minutes. Check for any leakage. If
pressure is holding, then increase the pressure up to the rating of the
weakest member exposed to test pressure (same as that of ram BOP)
and hold for 5 minutes.
iv. Open the valve(s) closed in step no.iii above and close next valve in
the choke/ kill line while moving towards choke and kill manifold.
Repeat step iii.
v. Repeating this process, test all the valves and fitting on choke / kill
line(s) and choke and kill manifold.
vi. Once testing of all the valves is over, remove test plug along with
drill pipe/tubing.
D. Testing Of Kelly Cocks and Rotary Hose

Pick up Kelly, install full open safety valve on bottom of lower Kelly cock.
Using an adapter, connect to a high pressure test pump or cementing
pump. Open appropriate stand pipe valve(s) and Kelly valve(s). Fill
system with water and close stand pipe valve. Pressurise to test rotary
hose and Kelly cocks in sequence.
An alternate method for testing Kelly cocks and rotary hose will be to
apply test pressure through kill line with test plug seated and pipe ram
closed. Here, it is to be ensured that the port provided on the test plug
body should be open.
All the results should be recorded in the DPR and in prescribed formats
(OISD STD 174; Annexure VIII) given at the end of this chapter.
7.12 BOP DRILLS

i. BOP drills must be conducted weekly (subject to BOP is installed on
wellhead) to familiarize all personnel engaged in well completion
/workover operations with appropriate safety measures.
ii. Drill should be initiated at unscheduled times when operations and
hole condition permits.
iii. All Crew members shall be instructed in the operation of BOP
system and their responsibility in the event of Blow out.
iv. To conduct drill, a kick should be simulated.
v. The reaction time from the moment kick is simulated to the
designated crew member's readiness to start the closing procedure
should be recorded and response time should not be more than 60
seconds.
vi. Total time taken to complete the drill should be recorded and it
should not be more than 2 minutes
vii. The drills should be documented in DPR.
viii. Following drills should be performed:
• On bottom drill
• Trip drill
• Drill collar/ BHA in blowout preventer drill
• String out of the hole drill.
ix. Action to be taken in the event of well activity situation and the
duties of each crew member on the rig at the time of BOP drills and

actual emergencies should be clearly known to everyone and a
standing orders specifying above should also be displayed at rig
floor & DIC’s office.
7.13 DO’S & DON'T

7.13.1 DO’S
1) BOP equipment must be selected in such a manner that internal
vertical bore is large enough to pass through all the tools
required for workover operations.
2) Select BOP stack configuration considering the space available
between top of cellar pit and bottom of rotary table.
3) While designing BOP stack, efforts should be made to use
minimum number of flange connections on the stack.
4) BOP stack must withstand the anticipated maximum well head
pressure.
5) The BOP system, system components and related well-control
equipment shall be designed, used, maintained and tested in a
manner necessary to assure well control in foreseeable conditions
and circumstances.
6) Manifold lines, valves, check valves and flow fittings etc. should
have a working pressure equal to or greater than the rated
working pressure of the ram BOPs in use.
7) The choke and kill manifold should be placed in a readily
accessible location, at a safe location from the well. (Minimum 30
mts).
8) All the manifold valves should be full bore. During operations, all
valves should be either fully opened or fully closed.
9) Configuration of Choke and Kill manifold should allow for re-
routing of flow without interrupting flow control.
10) The choke line and lines downstream of the choke should be as
straight as possible and be firmly anchored to prevent excessive
whip or vibration.
11) Have a bore of sufficient size to prevent excessive erosion or fluid
friction. Should be of sufficient diameter to permit reasonable
pumping rates without excessive friction. The minimum

recommended size is 2-inch nominal diameter. Kill line should be
of minimum 2 inch size.
12) The accumulator capacity should be adequate for closing all the
preventers with safety margin without recharging accumulators.
13) The accumulator unit should be located in a safe area minimum
10 metres away from the well centre.
14) The BOP stack should have remote control panel clearly showing
open and closed positions for each preventor. This Control Panel
should be located near to the drillers console at rig floor.
15) Well control fluids, equipment and operations shall be designed
utilized, maintained and/or tested as necessary to control the well
in foreseeable conditions and circumstances.
16) For ONGC operations, while designing BOP stack ONGC
approved BOP stack philosophy for Workover and Testing
operations as detailed in section 7.1.5 above should be adhered.
17) All connections, valves, fittings, piping etc. exposed to well
pressure, should be flanged or clamped or welded and in
accordance with API Specification should be employed. They
must have a minimum working pressure equal to the rated
working pressure of the preventers.
18) Always install new and clean API ring gaskets. Check for any
damage in the ring as well as grooves before use.
19) All correct size bolts/nuts and fittings should be used and
tightened to the recommended torque. All connections should be
pressure tested before commencing workover operations..
20) All manually operated valves should be equipped with hand
wheels and always be kept ready for use.
21) Ram type preventers on surface BOP stack should have provision
for extension rods and hand wheels. Extension rods must extend
beyond the substructure boundary and be easily accessible. Erect
a name plate in front of the hand wheel displaying the direction
and number of turns which are required for preventer closure by
an arrow in red paint.
22) BOP equipment should be function and pressure tested, when
installed and at the appropriate time during operations to
determine that BOP functions properly.

23) To control the flow activity through tubing/drill pipe during
tripping, a device like inside BOP/Kelly cock / NRV/ FSOV with
matching thread of tubular being handled should always be
available at the derrick floor.
24) Adhere to regular test procedure (pressure and functional test) for
optimum control of any well kick situations, successful
functioning of the blowout preventer stack, choke and kill lines
and other related equipment at a pressure recommended by API.
25) Use clear water as test fluid. It should be ensured that air is
removed from the system before test pressure is applied.
26) BOP components that may be exposed to well pressure should be
tested first to a low pressure of 200 to 300 psi and then to a high
pressure.
27) In performing a low pressure test, do not apply a high pressure
and bleed down to low pressure. Should a leak occur at low
pressure, corrective remedial measure may be taken accordingly
at this stage.
28) After initial installation of BOP on well head, rams, choke and kill
manifold and choke/ kill lines should be tested to the rated
working pressure of the ram BOPs or to the rated working
pressure of the well head on which the stack is installed, which
ever is lower.
29) Annular BOPs may be tested to 70% of the rated working
pressure or to the test pressure applied to the ram BOPs, which
ever is lower.
30) Lower Kelly cock, Kelly, upper Kelly cock and drill pipe safety
valve should be tested to the rated working pressure.
31) Subsequent high pressure test of ram BOPs and choke manifold
should be limited to a pressure greater than the maximum
anticipated surface pressure but not to exceed the rated working
pressure of the ram BOPs.
32) In case of downstream valves of choke and kill lines, test pressure
on initial as well as subsequent tests should be limited to 50% of
its rated working pressure.
33) A stable low test pressure as well as stable high test pressure
should be maintained for at least 5 minutes.

34) Function test on all operational components of the BOP
equipment systems should be performed once a week.
35) All pressure tests on well control equipment should be conducted
at least
- Immediately upon installation.
- After the repair of any pressure containment seal in BOP but
limited to the affected component.
- Not exceeding 21 days
36) While testing BOP stack and other equipment, test plug/ cup
should be used to isolate the entire casing and open
hole/perforated intervals from the applied test pressures
37) Operation of shear ram should be kept to bare minimum.
38) Closing time should not exceed 30 seconds for all ram preventers.
39) Function test should be carried out alternatively from main
control unit/derrick floor panel.
40) BOP drills must be conducted weekly (subject to BOP is installed
on wellhead) to familiarize all personnel engaged in well
completion /workover operations with appropriate safety
measures. Response time should be recorded in daily progress
report and in prescribed format
41) All closing unit control valves be clearly marked to indicate which
type of BOP or gate valve is to be operated from a particular
control valve.
42) Open, close and neutral positions of control valves should clearly
be marked.
43) All the closing unit control valves should be kept in open position
(not in the neutral position) during normal operation.
44) Control valve that operate the blind or blind shear ram should be
covered to prevent accidental closure.
45) Recommended oil level should be maintained in the control unit
reservoir.
46) Control unit should be located at a place which is easily
accessible.

47) Annular Preventer should be tested to 70% of its rated working
pressure or to the rated working pressure of stack or wellhead
whichever is less.
48) Before pressure testing of BOP stack, choke and kill manifold
should be flushed with clean water. Clean water should be used
to test BOP stack, choke and kill manifold and lines etc.
49) There should always be an NRV/ INSIDE BOP/ FOSV assembly
on the derrick floor at all times with proper connection to the drill
pipe/drill collar/tubing.
50) Hand control wheels for manually closing the preventers should
be braced.
51) BOP handling system should be inspected before lifting BOPs.
Use a chain or wire-rope of proper capacity for lifting BOP stack.
52) Accumulators should have rated closing pressure & adequate
volume to close all preventers without recharging.
53) API Ring gaskets should be stored properly with air tight
wrappings intact till they are put to use.
54) Periodical checks should be conducted at all flanged connections
for any loosening of studs and bolts due to vibration to which
stack is subjected during drilling operations.
55) While installing the well head, BOP and other well control
equipment, make sure that all the studs of proper size are fitted
and tightened properly.
56) Make sure all 1” control lines from BOP Control unit to BOP stack
are connected properly and tested.
57) Make a daily check for any leakages in the control lines from BOP
control unit to BOP stack and arrest leakages if observed
58) Make a daily check for correct accumulator, manifold and
annular pressure at BOP control unit.
59) For testing the blind/blind shear ram either use a test plug or
tubing hanger cone with a NRV/blind.
60) Action to be taken in the event of well activity situation and the
duties of each crew member on the rig at the time of BOP drills
and actual emergencies should be clearly known to everyone and

a standing orders specifying above should also be displayed at
drill floor & DIC’s office.
61) BOP drill and trip drill should be held on weekly basis and
should be recorded in DPR and in the prescribed format.
7.13.2 DON’TS
1) Do not place the choke and kill manifold under the sub-structure.
2) Do not use other than the recommended grade of oil in closing
unit reservoir.
3) Never lift the BOP by putting slings on the ram shafts which may
damage the ram BOP.
4) Never keep Hi-Low By-pass valve in Neutral; always keep it in
low bypass mode except in emergency requirement when blind
shear ram is to be operated, it is to be kept in high bypass mode.
5) During workover operation, never strip tubing using BOP rams in
closed position for bottom / sand clearing. This is not permitted
as it may cause excessive wear and damage to the BOP pipe rams,
packers and ram block.

Annexure-VII of OISD STD 174
BOP FUNCTION TEST REPORT AND ACCUMULATOR DRILL

RIG : DATE:
WELL : PROJECT:
BOP STACK DETAIL:
1. Annular BOP -
2. Single & Double ram type BOP -
3. Upper pipe ram size -
4. Lower pipe ram size -
S.No. Description Function Time Accumulator Accumulato Remarks
Closed/ r
Open Minutes Initial Pr. (Psi)
Final Pr.
(Psi)
01. Annular preventer
02. Lower pipe ram
03. Upper pipe ram
04. Blind/shear ram
05. Hyd. Valve on choke
06. Hyd. Valve on kill line
01. Conduct BOP function test/accumulator drill once in a week /every round trip
whichever is earlier.
02.
a) Record initial accumulator pressure
b) Turn off both electric and pneumatic pumps
c) Close annular and pipe rams one by one and record time to close each
preventer
d) Open the hydraulic Valve on choke line and kill line
e) Record the final accumulator pressure after each operations
f) Turn on electrical/ pneumatic pump and open all the preventer. Record the
opening time.
03. Carry out function test alternatively from rig floor and remote operated panels.
04. Final accumulator pressure should be not less than 1200 psi or 200 psi above
precharge pressure of accumulator bottles.

Special attention needed to
SIGNATURE: SIGNATURE:
NAME : NAME :
SHIFT DRILLER DIC/TOOL PUSHER

Annexure-VIII of OISD STD 174
BOP PRESSURE TEST REPORT

PROJECT : TEST FLUID - WELL NO. :
RIG : DATE :
TESTING EQUIPMENT-TEST PUMP/CEMENTING UNIT:
S.NO.
TYPE OF BOP TEST PRESSURE & DURATION REMARKS
Low Duration High Duration
Pressure Psi Pressure minutes
Minutes
Psi
01. Annular BOP

02. Upper pipe ram
03. (Lower
i ) ram (size….)
pipe
04. Blind ram/shear ram
05. Choke manifold
06. Kill manifold
07. Hyd. Valve on choke
li
08. Hyd. Valve on kill line
09. HP valves on choke &
10. kill if ldcock
Upper Kelly
11. Lower Kelly cock
12. FOSV
13. Inside BOP
N.B.
01. Keep annulus valve open on well head when test plug is used
during test & check for any leakage during BOP testing.
02. Testing line should be flushed with water before pressurisation.
Special attention needed to
SIGNATURE: SIGNATURE :
NAME : NAME :
SHIFT DRILLER DIC/TOOL PUSHER

CHAPTER – 8
WELL CONTROL
8.0 INTRODUCTION
Kick is defined as an influx or flow of formation fluid into the well-bore
and can occur at any time the formation pressure is greater than the
hydrostatic pressure being exerted by workover fluid at the well bore. A
blow-out is the result of uncontrolled flow of formation fluid at the
surface or sub surface from the well bore.
The maintenance of sufficient hydrostatic head exerted by workover fluid
to hold back the formation fluid pressure is termed as “Primary Well
Control”. If due to any reason, hydrostatic pressure in the well bore falls
below the formation pressure, formation fluid may enter in the well bore
and if so happens, the primary control may be temporarily lost and a
proper use of blow out preventers and kill procedures will provide
“Secondary Well Control”, or in other words secondary well control
involves detection & safe handling of kicks so as to re-establish primary
well control.
“Tertiary Well Control” involves the techniques used to control a blow-
out once the primary & secondary controls are lost. This primarily
involves a re-establishment of the secondary control system such as the
well bore conduit, well head & BOP equipment & subsequently
establishing the Primary Control.
8.1 CAUSES OF KICKS

Kicks occur as a result of formation pressure being greater than workover
fluid hydrostatic pressure which causes fluid to flow from the formation
into the well bore. The main factors which can lead to this condition are
classified hereunder.
8.1.1 IMPROPER HOLE FILL UP DURING TRIPPING
During workover and completion operations, improper filling of the hole
during tripping out is predominant cause of kick. To prevent kick while
tripping, basic requirement is that hole must be kept full of workover
fluid. When the drill pipe / tubing string is pulled out of the hole, the

fluid level in the hole decreases by a volume equivalent to the steel
volume or steel volume plus fluid removed depending upon dry or wet
pull out.
i) When tripping out dry pipe:
Barrels to Fill= Metal displacement (bbls/ft) x Length pulled out (ft)
ii) When tripping out wet pipe:
Barrels to Fill = {Metal displacement (bbls/ft) + Pipe Capacity
(bbl/ft)} x Length Pulled (ft)
The fluid level fall depends on the volume of pipe metal pulled out from
the well and the casing capacity. With the pipe no longer in the hole, the
overall working fluid level decreases and so is hydrostatic pressure. To
prevent hydrostatic pressure from dropping as the string is pulled out,
the volume of metal and fluid removed from the well must be refilled
with fluid of correct weight. If the hole remains full or does not take the
calculated volume of workover fluid, it is assumed that formation fluid
has entered the well bore. Increase in pit volume will also be observed
confirming the kick. Whenever such situation is noticed the pipe should
be run or stripped back to bottom (depending upon the well condition)
and workover fluid is circulated to clear the hole.
Similarly the sequence of events leading to a kick while tripping-in the
hole are that the hole does not stop flowing during making connection
between the stands and increase in pit volume can also be observed.
Therefore, while pulling out, the well should be filled continuously by
using trip tank and differences of calculated and actual workover fluid
volume be recorded at regular interval. Similarly while running in the
string, monitor displacement volume correctly at regular intervals.
In the field normally the practice is to fill up the hole either on a regular
fill up schedule or to fill up continuously with a re-circulating trip tank. A
trip tank has a calibration device to monitor the volume of fluid entering
the hole. The tank can be placed above the preventer to allow gravity feed
into the annulus, or a centrifugal pump may pump fluid into the annulus
with the overflow returning to the trip tank. The advantages of a trip tank
include the hole remains full at all times and an accurate measurement of
the working fluid entering the hole is possible.
As per OISD STD 174, trip tank should be installed on workover rig
deployed for servicing of high pressure/ gas wells for continuous fill up

and monitoring the hole during round trips. Indicator to monitor tank
level can be either mechanical or digital and clearly visible to driller.
8.1.2 SWABBING
Swab pressures are created by pulling out the workstring from the
borehole. It reduces the bottom hole pressure. If the reduced bottom hole
pressure becomes less than the formation pressure, a potential kick may
enter the well bore. Early detection of swabbing on trips is critical for
minimizing the size of influx.
While pulling out a pipe in well, swab force is dominant. Swabbing is
caused by the inability of the circulating fluid to fall past the workstring
as fast as the string is pulled. Swabbing create a suction effect near well
bore and thus induce flow of formation fluid into well bore even if well is
full of correct fluid weight. Swab pressure is negative and reduces the
effective hydrostatic pressure throughout the well below the tubing shoe.
If this pressure reduction lowers the effective hydrostatic pressure below
the formation pressure, a potential kick is developed. The likelihood of
swabbing is increased by
(i) Pulling the workstring too fast / high pulling speed
(ii) Workover fluid properties - using a fluid of high viscosity and
high gel strength.
(iii) Pulling out a plugged string
(iv) Having small clearance between the string and the well bore.
(v) Hole configuration
Swabbing is detected by closely monitoring hole fill up volume during
trips. If swabbing is detected, the pipe is run back to bottom and the hole
is circulated to remove the invading swabbed fluid. Reducing the speed at
which pipe is pulled out can usually reduce swabbing.
8.1.3 ABNORMAL FORMATION PRESSURE
Abnormal formation pressure may be encountered in any area where the
pressure gradient is higher than normal (pressure gradient 0.465 psi / ft).
During workover and completion operations, abnormal pressure may
develop for a number of reasons including formation charged by
underground blow out, zones charged by injection (water, steam, CO2,
air, gas etc), faulted structure, formation fracture from one zone to
another, casing failure or leak etc.

8.1.4 INSUFFICIENT WORKOVER FLUID DENSITY
Insufficient work over fluid density could be the result of dilution at
surface, down hole dilution or unexpected reservoir formation pressure. If
workover fluid exerts less hydrostatic head than the pore pressure, the
formation fluid may begin to flow into the well bore. The best solution is
to maintain the workover fluid density slightly greater than that required
to balance the formation pressure in order to avoid workover fluid loss.
8.1.5 LOST CIRCULATION
Lost circulation is another factor which reduces the hydrostatic pressure.
When a kick occurs due to lost circulation, the problem may become more
severe. A large volume of kick fluid may enter the hole before the
workover fluid level increase is observed at the surface. It is a
recommended practice to keep the annulus always topped to avoid
considerable reduction in BHP when lost circulation is encountered.
In workover and completion operations, lost circulation sometimes occurs
that causes level of working fluid in the well to fall as the fluid flows into
the zone of loss. If the pressure exerted by the column of workover fluid
in the well bore is greater than the fracture pressure of formation, then
formation is fractured itself, and workover fluid is lost from the well into
the formation at fast rates. Due to this fluid level in the well bore drops,
resulting in a kick or a blow out.
Other causes of lost circulation are excessive surge pressure and poor
formation integrity. In case multizone perforation a weak up-hole zone
can cause loss circulation due to low fracture gradient. To maintain the
hydrostatic pressure in multizone perforation sometimes bridging agent
is used to plug off the troublesome formation.
In case of reverse circulation & when the fluid weight is very near to
fracture gradient. ECD is also a critical factor for lost circulation. In such
case pump rate should be maintained as low as possible.
8.1.6 GAS CUT WORKOVER FLUID
Gas contaminated mud/ workover fluid will occasionally cause a kick. As
the gas is circulated to the surface, it expands and reduces the hydrostatic
pressure sufficient to allow a kick to enter. Although the workover fluid
density is reduced considerably at the surface, the hydrostatic pressure is
not reduced significantly since the most gas expansion occurs near surface
and not at the bottom.

8.1.7 OBSTRUCTION IN THE WELL BORE
High pressure may be entrapped below an obstruction in the well and can
lead to a kick formation. Thus during workover and completion
operations such as milling through an obstruction, like packer, cement
plug or bridge, collapsed casing etc. extreme caution is to be taken.
Operator must be aware of the possibility and be prepared to take
immediate action. In case of a kick, the well is required to be lined up
through the choke manifold and milling operation is suspended.
8.1.8 EQUIPMENT FAILURE
Though rig equipment are always designed for harsh working conditions
but due to constant wear and tear, salt water environment, H2S exposure,
corrosive formation fluid, extreme corrosive offshore environment etc, a
best designed equipment eventually wear out even if best preventive care
is taken. Even frequent movement of rig from one location to another take
a toll on sensitive members of the rig. Several blow outs have been
reported due to failure of just one piece of equipment. A simple example
of equipment failure is failure of pump while circulating the well and
conditioning the mud/ workover fluid in the well. As soon as pump is
failed, circulating pressure will be lost and well may begin flowing slowly
and get momentum and becomes uncontrollable.
8.1.9 SURGING
When controlled speed are not followed during trip-in (particularly with
tools with less annular clearance like packer, scrapper, fishing tool) , an
excessive surge pressure will be developed, leads to increase in bottom
hole pressure. When this increase in bottom hole pressure exceeds the
fracture pressure of an exposed formation, lost circulation will occur
causing a well kick. Surge pressure should be minimized by tripping-in at
controlled speed ensuring volume of fluid coming out of the well equals
to the metal volume of string being trip in.
Precaution should also be taken while starting the pump. Pump speed
should be slowly built up to achieve required pressure, otherwise surge
pressure can be created causing lost circulation.
8.1.10 HUMAN ERROR
Some times a kick or blow out occurs due to error or mistake done by the
operator while working over and completing a well. This may be due to
lack of correct judgment /decision, non- conformance with the standing
instructions/ procedures, poorly trained crew and poor planning. An

operator may confuse to take a proper action when he observes a kick. In
case of doubt one must have to shut in the well swiftly according to the
set procedure and no time is allowed to be lost in thinking what to do.
Operators must have gone hands-on training to deal with uncontrolled
flow exigencies. Each rig crew must be rotated and have proficiency in
each type of job at rig floor. Periodic drills to act in case of kick or blow
out can enhance confidence and proficiency of crews.
8.2 WARNING SIGNS/ KICK INDICATION

During workover and completion operations, a kick always gives a
warning before it takes the form of blowout. The various warning sign
and kick indication are described below:
8.2.1 WARNING SIGNS
Recognition and awareness of warning signals and appropriate reaction
by field personnel can help successful completion of work over
operations. Various waning signs are;
I. Well Is Not Taking The Calculated Amount Of Fluid during trip
During trip out operation, compensation of workover and completion
fluid is required to maintain hydrostatic pressure at correct value to
prevent a kick. If well is not taking the amount of fluid while
compensating/ filling the fluid in the well or well starts flowing before
filling, formation fluid has already invaded into the well and may convert
into a blow out.
Return fluid volume, while trip-in should also be maintained. If the
volume of return fluid is more than the volume of steel run into the well,
a possible warning signal occurs.
When improper hole fill up or return volume is detected, then workstring
should be run or stripped back to bottom as the well conditions demand
and circulated as per laid down procedure to remove the influx.
II. Decrease in Pump Pressure and Increase in Pump Speed
Circulating pressure is greatly affected by frictional forces in the
circulation system and imbalance in hydrostatic pressure in working
string and the annulus. In case of kick, there is under balanced condition
between the fluid in the drill pipe and the mixed column of workover
fluid and influx in the annulus. Formation gas entered into annulus rises
and expands causing fluid in annulus lighter than fluid in workstring.
This pressure imbalance causes gradual reduction in circulating pressure

and thus increases pump speed accordingly. If much gas has entered in
the annulus, the well starts flowing faster and may convert in a blow out.
In such case, BOP is required to be closed immediately.
III. Increase In Gas Content:
A Hydrocarbon detector can detect increase in gas content swabbed into a
well bore and finally migrated to the surface.
IV. Change In Chloride Content
Some times due to insufficient pressure, seepage of formation fluid occurs
into the well bore and mingles with workover and completion fluid and
changes the chloride content. Change in chloride content can indicate that
formations fluid incursion has taken place in the well bore.
V. Change In Flow Properties Of Circulating Fluid
Change in flow properties such as viscosity of workover and completion
fluid can be the result of change in downhole conditions and one of which
may be increasing pressure that may lead to a kick.
VI. Increase In Flow Line Temperature
Usually an abnormally high pressure formation has higher temperature
gradient than normal formation. If influx from such formation has
originated in the well bore, it will increase the temperature of the
workover and completion fluid. Therefore, constant monitoring of
temperature of fluid coming out of the well will help in detecting
occurrence of a kick.
VII. Change In String Weight
The fluid in hole provides a buoyant effect to the workstring and
effectively reduces the actual weight of pipe that must be supported by
the derrick. Heavier fluids have greater buoyant force than less dense
fluids. When a kick, which is a low-density fluid, enters to the well bore,
the total buoyant force of the fluid system reduced. As result of this the
string weight observed at the surface begins to increase.
8.2.2 POSITIVE INDICATIONS OF KICK
I. Pit Volume Increase
An increase in pit/ tank volume is a clear positive indication of flow into
the well bore and can be easily verified. If an increase in pit volume is
seen, shut off the pump and make a flow check. If the well does not flow,
no kick is entering.

II. Increase in Return Flow (Pumps On)
After the early warning signs, the first positive kick sign is increase in
flow rate at the flow line with pumps on. In case a kick has entered the
well bore the rate of return from the well will increase though this
increase initially is too small to be detected. In such case flow check is
done. If the well is found flowing even after suspending pumping the
workover fluid, a kick has entered in the well bore and well is required to
be shut in for circulation of the kick. Flow check is done for at least 30
minutes and if no flow is observed it is concluded that kick has not
entered in the well bore.
III. Flow from Well (Pumps Off)
Stopping the pump causes a reduction in bottom hole pressure equivalent
to the annular pressure drop, so flow check is a reliable method of
checking for a well kick. If the well does not flow when the pump is shut
off and remains static for two or three minutes, then no well kick is
entering.
After recognition of positive indication immediate action is to be taken to
control the well.
8.3 TRIP MARGIN

During pulling out, upward motion of the workstring in the borehole
(which is assumed to be full of workover fluid) creates a swab pressure.
This decreases BHP when pipe is in motion. One way of minimising this
is to use safe tripping speeds and having close monitoring of pipe volume
pulled out & workover fluid volume pumped in to keep the hole full.
Another practice to tackle the problem is to keep workover fluid weight
gradient slightly greater than the formation pressure gradient. The
resulting overbalance permits safe tripping and connection operations.
This extra workover fluid weight is called trip margin.
Normally annular pressure loss is used for calculation of trip margin but
using a trip margin requires a good judgment, because too large a margin
or too small a margin can cause lost circulation or well kick respectively.
8.4 SLOW CIRCULATION RATE

During well control operations, to avoid further entry of formation fluid,
it is essential to keep BHP minimum equal to formation pressure. This is
done by imposing certain calculated back pressure in addition to system

pressure losses on the well bore. Kicks have to be circulated out at slow
circulation rates.
Theoretically speaking the kill rate or slow circulation rate should be the
minimum possible pump speed at which pump can run smoothly without
any knocking etc.
8.5 LINE UP FOR SHUT IN

Whenever the warning signs of kick are observed, the well should be
controlled according to correct procedure. If there is any doubt as to
whether the well is flowing, shut-in the well and check the pressures.
The main purpose of the shut in procedure is to:
1. Stop the influx of the formation fluid entering into the well bore
2. Protect the crew and rig
3. Provide an opportunity to organize the kill procedure
4. Allow recording of shut in workstring and casing pressure
Several types of shut in procedures are available for well control
depending upon the type of a rig in use and the activity occurring when
the kick is detected. Depending on the situation, operator may opt to shut
in a well by adopting hard shut in or soft shut in procedure. Hard shut in
means closing the BOP without first opening an alternate flow path up
the choke line. Soft shut in means closing the BOP after opening the
alternate flow path up the choke line.
The primary advantage of a hard shut-in is that the kick influx is held to a
small volume because the well is closed-in more quickly. Disadvantage of
a soft shut in is that it requires more steps and time than hard shut-in. The
result can be a larger influx of kick fluids.
When one or more positive kick sign are observed, flow check is made. In
case of self flow, well should be shut in as described below depending
upon the string position. (Hard shut in procedure)
8.5.1 WHILE DRILLING
1. Stop rotary (if rotary is in operation)
2. Pickup Kelly so that tool joint is clear of BOP sealing element.
3. Stop mud pump, check for self flow.
4. Close uppermost applicable preventer / pipe rams of BOP. Close
all the valves on side outlet of BOP and tubing spool.

5. Line up the annulus of the well through choke (on choke and kill
manifold) to pit/ tank. Open manual valve(s) on choke line when
choke is in fully closed position.
6. Allow pressure to stabilise and record SITHP, SICP and pit gain
8.5.2 WHILE TRIPPING
1. Position the tool joint of workstring above the rotary table and set
the pipe in slips.
2. Install Full Opening Safety Valve (FOSV) in open position and
close it.
3. Close uppermost applicable preventer / pipe rams of BOP. Close
all the valves on side outlet of BOP and tubing spool.
manifold) to pit/ tank. Open manual valve (s) on choke line when
5. Make up Kelly and open FOSV.
6. Allow pressure to stabilise and record SITHP, SICP and pit gain.
8.5.3 WHILE STRING IS OUT OF THE HOLE

1. Close blind/ shear ram of BOP. Close all the valves on side outlet
of BOP and tubing spool.
manifold) to pit/ tank. Open manual valve(s) on choke line when
3. Allow pressure to stabilise and record SICP and pit gain.
8.5.4 If kick indications are observed while any of the following completion/
work over operation are in progress, special considerations may be
required to line up the well for shut-in depending upon the real time
situation:
• Coiled tubing
• Wire line operation
• Pulling/Running rods
• Pulling/Running of gas lift valves on tubing.
• Pulling/Running submersible pump.

8.6 WELL KILLING PROCEDURE
The basic aim of any well control method is to kill the kick and bring the
well under control. The objectives of these methods are to;
1. Remove kick fluid from the well.
2. Fill the well with fluids of sufficient weight to exert pressure
equal to or greater than formation pressure.
Many well control methods are available, however, three most often used
are
1. Driller’s Method,
2. Wait and weight Method
3. Volumetric Method
The basic principle of the above three methods is to maintain the constant
bottom hole pressure throughout the well control operations, regardless
of the nature of the influx, either by keeping the pump speed constant or
by adjusting the choke as required.
8.6.1 DRILLER’S METHOD
The Driller’s Method is the most basic of all methods and can be
employed in a number of well control situations. This technique is used
for circulating formation fluid out of well with or without killing the well.
It is a two-circulation kill method. The first circulation is to get the influx
out from well bore using original fluid density. The second circulation is
done to kill the well with the kill fluid.
First Circulation
i. Lined up the pump with the original fluid tank which was in use
before the kick.
ii. Bring the pump up to kill speed in steps of 5 SPM, gradually
opening the choke holding casing pressure constant at the shut in
casing pressure.
iii. When the pump is up to kill speed, read and record the tubing
pressure, displace the influx maintaining tubing pressure constant.
iv. Circulate out the influx from the well maintaining tubing pressure
constant.
v. When the influx is out, stop the pump reducing the pump speed
in steps of 5 SPM gradually closing the choke, maintaining casing

pressure constant. Record pressure, SITP OR SIDPP and SICP
should be equal to original SITP OR SIDPP.
Note: In case recorded SIDPP & SICP are equal but more than original
SITHP OR SIDPP value, it indicates trapped pressure in wellbore.
Whereas if SICP is more than original SITHP OR SIDPP, it indicates that
some influx is still in the wellbore.
Second Circulation
i. Line up suction with kill fluid.
opening the choke, holding casing pressure constant.
iii. When the pump is at kill speed, pump kill fluid from surface to bit
or tubing shoe holding casing pressure constant.
iv. Pump kill fluid from bit to surface, maintaining tubing pressure
constant equal to FCP.
v. When the kill fluid reaches surface, stop the pump reducing the
pump in steps of 5 SPM, gradually closing the choke while
maintaining casing pressure constant. Record pressures, SITP OR
SIDPP and SICP both should be equal to zero.
vi. Open & observe the well. Add trip margin before resuming
normal operation.
Applicability
• To remove kicks swabbed in during a trip out of the hole.
• To remove gas kick where high migration rate can cause shut in
problem.
• Well where lost circulation is expected.
• Where no weighting material (heavy fluid) is available at the time
of kick
8.6.2 WAIT AND WEIGHT METHOD
The wait and weight method is one circulation method and probably the
most common method in use today.
In this method, operations are delayed (wait) once the well is shut in,
while a sufficient volume of kill (weight) fluid has been prepared. As the
kill fluid is pumped to the bit the hydrostatic pressure in the Tubing/Drill
Pipe increases, this causes the tubing pressure to fall. At the same time,

influx which is on its way up the annulus expands continuously and gains
volume / height, thereby causing the hydrostatic pressure in annulus to
fall and casing pressure on the rise. Because of this, for maintaining BHP
constant a calculated step down plan for the tubing pressure must be used
while pumping the kill mud from surface to the tubing shoe/ bottom.
Killing Procedure
i. Line up suction with kill fluid.
opening the choke, holding casing pressure constant.
iii. When the pump is at kill speed, pump kill fluid from surface to
bit, maintaining tubing / pressure as per step down schedule
(during this step tubing pressure will fall from ICP to FCP).
iv. Pump kill fluid from tubing shoe to surface, maintaining tubing
pressure constant equal to FCP.
v. When the kill fluid reaches surface, stop the pump reducing the
pump speed in steps of SPM, gradually closing the choke
maintaining casing pressure constant. Record pressures, SITP OR
SIDPP and SICP both should be equal to zero.
vi. Open & observe the well. Add trip margin before resuming
normal operation.
Advantage and Disadvantage of Wait and Weight method:-
Advantage
• Lower annulus pressure.
• Well can be killed in one circulation.
• Less time on choke operation.
Disadvantage
• Large non-circulating time.
• In case of salt-water kick, sand settling around.
• More chances of migration.
8.6.3 VOLUMETRIC METHOD
The volumetric method is a non circulating killing method used for
removing gas influx when there is little or no tubing in the hole, or when
the hole can not be circulated. It works equally well for a situation where

the well is closed-in and waiting on orders or equipment. In this method
the influx is brought up to the surface by means of migration & controlled
expansion. This process involves bleeding of calculated volume of fluid at
the surface till the influx reaches the surface thereby allowing the casing
pressure to increase to maintain BHP constant. Thereafter, the calculated
volume of fluid is pumped in to the well & gas influx is bled thereby
allowing the casing pressure to decrease while maintaining BHP constant.
The basis of the volumetric method is that each barrel of fluid contributes
a certain pressure to the bottom of the hole. This may be measured as
psi/bbl. A record of casing pressure is kept, if the casing pressure rises,
fluid can be bled from the well according to the psi/bbl value calculated
to maintain a constant bottom hole pressure.
The volumetric method works by bleeding off (or adding) fluid because
the BHP is the sum of the casing pressure & the pressure exerted by the
fluid column.
The Volumetric method of well control should not be equated with classic
well killing methods. Volumetric method is used to control BHP within
limits by coordinating the increase (due to gas migration) or decrease
(because of bleeding of gas) in annulus surface pressure with the
corresponding decrease or increase in annular hydrostatic pressure.
Volumetric method is implemented mainly in two steps namely the
"bleeding" and "lubrication" process. In the bleeding process the gas influx
is allowed to migrate in the annulus and thereby causing an increase in
the annular surface pressure as well as the BHP. The goal of maintaining
the BHP constant is achieved through corresponding reduction in annular
hydrostatic pressure by bleeding calculated volume of fluid, which in
turns reduces the fluid column height in the annulus and allows the gas to
expand. The bleeding process has to be repeated several times till the gas
reaches the surface.
Once the gas is at the surface, the process of lubrication starts. In
lubrication process annular hydrostatic pressure is increased by injecting
a calculated volume of same or heavy fluid through kill line while the
BHP is maintained constant by bleeding gas through choke and reducing
surface pressure by the same amount. The process may be repeated
several times till all the gas influx is fully removed from the annulus and
the annular surface pressure is brought down to zero or at a level wherein
tripping / stripping of the bit to the bottom or removing/ replacing of

choked or damaged string becomes feasible. Once the bit is at the bottom,
the well can be killed / circulated with appropriate kill weight fluid.
Applicability
• String is out of the hole
• String is plugged
• String is at considerable distance from bottom and kick is below
string
• Casing pressure develops on production or injection well because
of tubing or packer leak
• During stripping or snubbing operations, high pressure wells that
approach the rated pressure of the wellhead or tubing may exceed
the safe working limits of the equipment if increased dynamic
pumping pressure are imposed such as bullheading.
8.7 KILLING A KICK DURING WORKOVER

Well killing procedures for workover operations depends upon the
number of variables. Major variables are well’s present flowing status,
the magnitude of the formation pressure, formation fracture pressure and
casing burst pressure. Additionally, certain unknown parameters such as
tubing holes, packer leaks and sand plugging must also be studied before
deciding killing procedure.
Killing a kick during workover requires an evaluation of (1) the depth of
the workstring in well (2) restriction in workstring (3) Well bore and
formation characteristic that may affect circulation or alternate kill
procedure such as bullheading or lubrication.
8.7.1 CIRCULATION PROCEDURES
Applicable when the workstring is near the bottom of the well. Two
circulation routes are possible:
1. Down the workstring and up the annulus forward circulation (Long
way)
2. Down the annulus and up the workstring – reverse circulation (short
way)
The primary advantage of the long circulation is that kill pressures are
lower than those seen while killing an identical kick with reverse

procedure. Gas migration is not a severe problem in view of the higher
liquid velocity observed in tubing.
Short circulation advantages include a significant reduction in the time
required to circulate the kick fluid from the well and better control of high
surface pressure due to the generally greater burst strength of workstring
as compared to casing.
The disadvantages of short circulation include possible plugging when
attempting to reverse flow if bit jet or circulating port is in the workstring.
The Slow circulating rates used in the short circulation may allow gas
migration up the annulus at a rate greater then the downward flow rate.
Gas migration may range 30’ / min in the case of gas migration through
fresh water to as low as 2’/ min (or less) in heavy viscous brines. Gas
migration can be controlled by increasing the pumping rate or by adding
viscosifier to the kill fluid.
The reverse circulation utilizes the pumping casing pressure to monitor
the kill operation.
8.7.2 BULLHEADING
Pumping kill fluid into the annulus (or tubing) of a closed well, so that
fluid/brine and formation fluids are displaced back downhole into the
weakest exposed interval is known as Bullheading. Well shut in will stop
influx when BHP equals formation pressure.
This method consists of pumping kill fluid to the well and forcing the
well fluids back into the formation without pumping at a rate which will
fracture the formation. This method is the only method possible when a
well has been completed without tubing. It can also be used when the
tubing has been landed in a packer and the circulation devices, such as a
sliding sleeve, have jammed. This would mean that it is not possible to
establish circulation around the tubing shoe or near the tubing shoe.
In this method the pump rate has to be high enough to ensure that the
rate the kill fluid is moving down the tubing is faster than it will free fall.
This will prevent the contamination of the kill fluid by oil in an oil well,
and gas cutting in a gas well. In effect, a piston effect is required so that
the kill fluid is going down the tubing as a piston sweeping all the well
fluids below it.
Bullheading is a valuable tool for fighting kicks under many
circumstances such as: -

• The influx contains more H2S than the operation can tolerate.
• Plugged or parted tubing cannot get kill fluid to bottom.
• A weak zone below the kick takes fluid too fast for a kill.
• To gain time when short of material, skilled personnel, or
equipment.
Bullheading also has several crucial disadvantages:
• Crews do not fully understand when the technique should be
used.
• Fluid will go to the weakest interval and may not follow the
preferred path.
• Potential is created for an underground blowout. Underground
blowouts are an important consideration because they can often
develop into surface blowouts.
• Even a successful bullhead may not kill the well.
8.8 KILLING A PRODUCING WELL

Workover operation on a hydrocarbon producing well requires killing of
the producing well. Numbers of killing procedures are available
depending on various parameters such as tubing and casing integrity,
ability to circulate the fluid in the annulus, formation pressure, and the
characteristics of the completion equipment and the formation parameters
that may control killing techniques. Many a times, the killing technique is
well specific. Type of fluid being produced from the well, formation
characteristics, tubing holes and the condition of the packer fluid in the
annulus are dominant considerations dictating kill procedure.
Abnormally high pressure wells will require killing method similar to
that is used for normal pressure well in addition to some special
considerations.
8.8.1 PREPARING THE WELL FOR KILLING
Prior to initiating well killing operations, several safety measures must be
exercised. The well must be shut-in in advance of operations to stabilize
bottom hole pressure and allow time to inspect and service the X-mas
tree. The well shall then be isolated from all external control systems, the
lines isolated by double barrier isolation and depressurized.
The killing procedures can be categorized into

A. Tubing kill Procedures (without hole in the tubing)
B. Tubing kill Procedures (with a hole in the tubing)
C. Annulus kill procedures
A. Tubing Kill Procedures (without hole in the tubing)
Bullheading, snub coil tubing, snub jointed tubing, lubricating,
perforating the tubing and pulling the tubing out of the packer are some
of the tubing kill methods.
1) Bullheading is the common method used to kill a packer
completed well. Here, the formation fluid is squeezed back into
the formation through the perforations with the kill fluid used as
chasing fluid. The parameters affecting this method are described
in detail in the section 8.7.2 above.
2) Coil tubing is often used to kill a producing well. The objective is
to circulate brine water or other kill fluid down the coiled tubing
and up the coil tubing–production tubing annulus. A primary
application for this method is in cases where the well cannot be
killed by bullheading because the wellbore is plugged with sand
or junk. The coiled tubing is helpful in removing the sand
plugging material during circulation.
3) Snubbing units are frequently used for high pressure well killing
providing the same type of well control as the coil tubing with
the exception that more time is required to snub in jointed pipe
than continuous coiled tubing. The primary advantages of
snubbing units over coil tubing are the ability to rotate the jointed
pipe and the greater pipe strength.
4) Lubrication and bleed is occasionally used for killing wells
during workover. This is time consuming process. The method is
employed for two prime reasons. First, high pressure wells that
approach the rated pressure of the wellhead or tubing and may
exceed the safe working limits of the equipment if increased
dynamic pressures are imposed such as with bullheading or
snubbing methods. In the wells where the wellbore is plugged,
this method can also be used where bullheading is not possible.
The lubrication method can be used either to kill the well
completely or to reduce the shut in pressures to a level that will
allow safe operations of other kill methods.

5) Perforating the tubing and circulating a kill fluid is the primary
method of killing producing wells. A perforating tool can make a
circulating port in the tubing that will allow direct
communication with brine water. In this situation, reverse
circulation is usually done by pumping down the annulus,
through the perforation(s) and up the tubing.
Attention must be given to the selection of a perforation tool. It is
imperative that the tool, mechanical or otherwise, have the
capability to perforate the tubing without damaging the adjacent
casing.
6) Pulling the tubing out of the packer to circulate a kill fluid out of
the bottom of the tubing is a technique employed by many
operators. This procedure involves lifting the tubing a sufficient
height to pull the seal assembly from the polished bore in the
packer. The disadvantage of this method is that it requires that
sections of the production tree be removed or unflanged to pick
up the tubing before subduing the well.
B. Tubing Kill Procedures (with a hole in the tubing)
Killing a producing well that has a hole in the tubing or a leak in the
packer requires additional considerations. The primary concern is
determining the location of the hole. Additional concerns include the
effect of the formation pressure exposed on the casing and 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 rigging-up surface equipment and pumping a volume of brine water
(may be coloured) until it is returned to the choke on the annulus. This
volume can be used to calculate the location of the hole.
Deep holes can generally 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 pressure.
C. Annulus Kill Procedure
A loss of integrity in the tubing string resulting from a hole or leak will
cause a pressure buildup on the casing or annulus. Killing the tubing by
lubricating or snubbing will not necessarily kill the annulus. In this case, it

is necessary to perform a kill on the annulus using one of the previously
described methods. These include Bullheading, lubricating, or reverse
circulating. With these procedures gas migration can be a serious problem
when pumping down the annulus.
8.9 DO'S AND DON'TS

8.9.1 DO'S
1) As per OISD STD 174, trip tank should be installed on workover
rig deployed for servicing of high pressure/ gas wells.
Trip tanks is used to monitor the hole fill up during tripping.
While pulling out, the well should be filled continuously by using
trip tank and differences of calculated and actual workover fluid
volume be recorded at regular interval. Similarly while running in
the string, trip tank should be used to monitor the displacement
volume correctly at regular intervals.
2) Pressure gauges installed on wellhead, choke and kill manifolds
should be in working condition and calibrated.
3) All lines should be properly anchored.
4) In case of wet pulling out, to prevent hydrostatic pressure from
dropping, the volume of metal and fluid removed from the well
must be refilled with fluid of correct weight.
5) Flow checks should be carried out more frequently during wet
pulling out.
6) At least one trained person should be present on derrick floor to
observe well for any activity even during shutdown period.
7) All the flameproof lights and control panels available on the rig
should be kept in order and flameproof features maintained.
Equipment which are not having flameproof features should not
be kept in drill floor or within hazardous area.
8) On observing any sign of activity in the well, close the BOP and
there after tubing safety valve should also be closed to control the
well.
9) Operators must have gone hands-on training to deal with
uncontrolled flow exigencies.

10) Each rig crew must be rotated and have proficiency in each type
of job at rig floor. Periodic drills to act in case of kick or blow out
can enhance confidence and proficiency of crews.
11) It is a recommended practice to keep the annulus always topped
to avoid considerable reduction in BHP when lost circulation is
encountered.
12) While carrying out tripping operation, especially in gas wells, the
intermittent flow checks to be carried out for detection of any gas
migration.
13) Always ensure that the well is full of brine/fluid while pulling
out of hole and to ensure the required volume of fluid/brine is
being filled in the well bore while tripping by using trip tank.
Accurate trip fill up records should be maintained in trip sheet.
14) If any well activity is observed while tripping in or out of hole, do
not try to run in pipe in the hole, shut the well immediately to
minimize the influx, which will help in regaining the control of
the well in less time.
15) Rig must be equipped with a FOSV and Inside BOP having
correct size thread connection for the tubing/drill pipe in use.
Anytime a trip is interrupted, install FOSV/Inside BOP.
16) Whenever well activity is observed the well closure procedure
should be followed as quickly as possible.
17) During workover/ completion operations, a kick always gives a
warning before it takes the form of blowout. Operator should
have sound knowledge about various kick indication and
warning sign.
18) To control the flow activity through tubing/drill pipe during
tripping a device like inside BOP/Kelly cock / NRV/ FOSV with
matching thread of tubular being handled should always be
available at the derrick floor.
19) Keep some trip margin to compensate the swab pressure during
pulling out.
20) During well control operations, to avoid further entry of
formation fluid, kicks should be circulated out at slow circulation
rates (minimum possible pump speed at which pump can run
smoothly without any knocking etc.)

21) Whenever the warning signs of kick are observed, the well should
be controlled according to correct procedure. If there is any doubt
as to whether the well is flowing, shut-in the well and check the
pressures.
22) Several types of shut in procedures are available for well control
depending upon the type of a rig in use and the activity occurring
when the kick is detected. Depending on the situation, operator
may opt to shut in a well by adopting hard shut in or soft shut in
procedure.
23) Many methods for well killing/ control are available. Select the
right procedures depending upon the well condition.
24) In bullheading, to prevent the contamination of the kill fluid by
oil/gas, pump rate should be high enough to ensure that the rate
the kill fluid is moving down the tubing is faster than it will free
fall.
25) Prior to initiating well killing operations, the well must be shut-in
in advance of operations to stabilize bottomhole pressure and
allow time to inspect and service the X-mas tree. The well shall
then be isolated from all external control systems, the lines
isolated by double barrier isolation and depressurized.
26) All the well control incident (minor & major) should be brought
to the notice of Head CMT Corporate and information flow
channels as per Disaster Management Plan (DMP) should be
followed strictly.
27) Area Managers, Rig In-charges, DIC, shift in-charges & Assistant
Shift in- charges should successfully complete the IWCF/ IADC
well control training course every two years.
8.9.2 DONT'S
1) Do not allow fluid level in annulus to drop down. Keep it always
full.
2) Never light match sticks in danger zone.
3) Do not pull out, if hole does not take proper amount of fluid.

CHAPTER – 9
DOWN HOLE COMPLICATIONS
9.0 GENERAL
Complications in the well bore prevent successful workover operations
and completion of a well. Common types of complications encountered
during workover operations are:
1. String Stuck up
2. String failure
3. Bit failure
4. Casing failure
9.1 STRING STUCK UP

Some of the causes of String stuck up are:
1. Mechanical sticking
2. Cement sticking
3. Differential sticking
9.1.1 MECHANICAL STICKING
Improper hole cleaning or presence of foreign objects or junk in the hole
leads to hole pack off and/ or mechanical sticking.
9.1.1.1 Hole Packoff
The behaviour of cuttings (formation/ cement cutting, debris or junk in
the well bore) varies according to the angle of the well bore. Vertical wells
are least difficult to clean as compared to inclined or horizontal wells.
Factors which affect the well cleaning are;
i. Workover Fluid Weight
It provides buoyancy to help lift the cuttings. Higher the weight,
greater is the buoyancy & lesser is the slip velocity.
ii. Annular velocity
Annular velocity is the most important factor in hole cleaning of
wells. The lifting force is directly proportional to annular velocity

in laminar flow. Rule of thumb for vertical wells – annular
velocity should be twice the cuttings settling rate.
iii. Fluid Flow regime
In laminar flow the flow regime is parabolic. Heavier cuttings are
pushed to the wall and subsequently fall back in the well. The
larger the cutting more is the force at which they are pushed to
the wall and fall into the well – this results in cuttings recycling.
Turbulent flow is better for hole cleaning as it has a flatter flow
profile, however turbulence increases hole erosion / pressure
drops.
iv. Cutting size, shape & quantity
Slip velocity increases with size and density of cuttings. Large
quantity of cuttings interferes with each other and flow profile
reducing the cleaning effect. This results in the flow profile
becoming more parabolic and cuttings stick to the wall.
v. Rate of penetration
Rate of penetration controls the size & quantity of cuttings. Drill
only as fast as the cuttings can be removed. Loading of the
annulus with drilled cuttings will result in hole pack off /
plugged nozzles.
vi. Pipe rotation & eccentricity
Pipe rotation improves the hole cleaning. While pipe eccentricity
(pipe sticking to the wall) leads to poor hole cleaning.
vii. Time
If sufficient time is not given to circulate out the cutting prior to
tripping out, it can result in stuck pipe. It takes more time to
transport cuttings along an inclined/horizontal well bore than a
vertical well.
viii. Hole inclination
As the angle increases to 300 the cuttings migrate to the bottom
wall. The re-cycling of cuttings is more severe as the angle
becomes greater than 300. As the angle approaches 450 the time
cuttings spend on the wall greatly increase. At angles between 450
- 650 the cuttings slide down even while circulating. At angles

above 650 cuttings form beds that are more packed and thus
harder to disturb / circulate out.
Water in turbulent flow provides the best hole cleaning in angles
more than 650.
Preventive measures
i. Circulate cuttings out prior to tripping out.
ii. Use high viscous pill sweep for vertical wells. Use low, high
viscous pills sweep combination for high angle wells
iii. Minimise connection time.
iv. Establish over-pull limits. Pulling too hard into a pack off will
prevent the pipe from being freed downward. Use small
increments of over-pull.
9.1.1.2 Freeing procedure
First action
o Bleed off pressure and apply 200- 500 psi and try to establish
circulation.
o Apply torque and slack off.
o Generally the string packs off during trip out- Jar down if jars are
in the string.
o In high angle wells it can get packed off during trip in – jar up in
this case.
o Jar with incremental increase in trip load.
Secondary freeing procedure
o Pulling hard – not the first choice. Only done when other things
fail.
o The driller must know the maximum amount of over-pull.
o Ensure that there is no torsion in the string while working or
jarring upward.
Fishing procedure
o Back off above free point & wash over.
o Carefully select the length of the wash over pipe.

o After wash over, run a fishing assembly with both up & down
fishing jars.
9.1.2 CEMENT STICKING
To place a cement plug, cement is pumped through a string of drill pipe
or tubing. Cement is displaced for a pre-determined length into the string
annulus and some quantity is left inside the pipe so that as the pipe is
pulled out, the cement inside fills the pipe displacement, leaving a clean
uncontaminated plug in the well. The cement is designed based on hole
conditions and should be retarded or accelerated as required. The
potential danger lies in the unlikely chance of flash set causing the cement
to set with string in the hole / within cement.
Identification / Indications
• Unable to reverse circulate.
• Unable to pull out the working string (drill pipe / tubing).
Immediate action
• Pull to the maximum safe limit of the string.
• Attempt to circulate at a higher pressure than that available with
rig pumps (use cementing/pumping unit).
Preventive action
• Technical water should be tested for designing cement slurry.
• Simulate downhole conditions prior to cement job.
• Make all arrangements for reversing out in advance.
• Cementing units and mud pumps should be checked prior to
taking up cementing job.
• Contamination of the cement with mud should be prevented by
using spacers.
• While carrying out a squeeze job, use an open end string to place
a balanced cement plug. Pull the string above the cement plug.
Reverse out 1-1/2 times the annular volume and then squeeze.
• While using a packer to squeeze, monitor the annulus pressure.
Any build up of annulus pressure will indicate a leaking packer.
Stop the squeeze job. Unseat the packer and reverse out the
annulus volume.

Recovery Process
1. During a cement squeeze job using a packer.
When a packer is utilized for a squeeze job, several problems may
arise namely packer can leak, the casing being squeezed can leak
from a point above the packer setting depth.
Both these instances can lead to the string getting stuck above the
packer. If a pressure gauge is installed on the annulus of the
cementing string, it allows close monitoring. Should there be a
leak anywhere, the pressure in the annulus will indicate it.
2. If the pipe is cemented in place inside a casing the following
factors will decide the recovery techniques to be adopted:
o The length of the cemented section.
o The depth at which the pipe is cemented.
o The strength of the cement bond.
o The annular clearance between the cementing string and the
casing.
3. Except in large size casings, the annular clearance between the
cemented string and the casing rules out wash over as a means of
recovery. One option, depending on techno economics, is to mill
out the cemented string. Another option is sidetracking from
above the stuck pipe or plug and abandon.
9.1.3 DIFFERENTIAL STICKING
The pipe stuck-up due to pressure differentials is known as ‘Differential
sticking”. Some of the common situations resulting in pipe stuck-up due
to pressure differential are:
(a) Use of very highly overbalanced drilling fluid in open holes
(b) Testing of high pressure zones where a large pressure differential
exists above and below the packer
9.2 STRING FAILURE

The main causes of drill/ tubing string failure are:
a. Fatigue failure.
b. Washout.
c. Twist off

d. Tensile failure.
e. Collapse.
f. Burst.
g. Down hole vibrations.
h. Slip crushing.
a) Fatigue failure
• Mostly drill pipe failures are caused by fatigue. Fatigue is the
combined effect of tension, torsion and bending. The cyclic
reversal of stress that results when the string is rotated also causes
fatigue failure.
• Failure of the pipe due to fatigue takes place in the pipe body
generally in the area where slip is set. Surface imperfections
caused by slip marks, cuts, tong marks, grooves caused by rubber
protectors, welding and downhole notches caused by junk greatly
affect the fatigue limit.
• Fatigue fractures are progressive beginning as micro cracks that
grow under the action of cyclic stress. The rate of propagation is
related to the applied cyclic load. Since the crack develops from
the inside of the drill pipe and no plastic deformation occurs,
these cracks are very difficult to detect.
• Fatigue results in washouts and twist off. In drill collars. It takes
place in the connection with the pin being left in the box.
• Fatigue also results in heat cracking of tool joints. Tool joints
which are rotated under high lateral force against the wall of the
hole may be damaged as a result of frictional heat cracking. The
heat generated at the surface of the tool joint by the friction with
the wall of the hole under high radial thrust may raise the
temperature of the tool joint steel above its critical temperature.
b) Washout
• A washout usually is the result of a fatigue crack penetrating the
wall of the pipe resulting in the fluid being forced out through a
small opening / pin hole in the pipe.
• Wash out may also be caused by a damaged shoulder of box
and/or a damaged pin.

• Tool joint/ tubing box may get worn out, if joints are not made up
to the recommended torque.
c) Twist off
• Most failures occur when rotating or when picking the pipe off
bottom immediately after drilling rather than pulling on stuck
pipe.
• Most failures occur within 1m of the tool joint on either end of the
pipe.
• Failures that originate from the outside of the pipe are usually
associated with slip marks or other surface damages such as
gouges, welding arc spots, marks made by drill pipe protectors,
etc.
• In case of stuck pipe, failure frequently occurs in a location where
a fatigue crack has developed but has not progressed to the point
of failure.
d) Tensile failure
• Tensile failure usually occurs due to:
o Erroneous reading in the weight indicator.
o Application of pull more than the rated capacity either
accidentally or purposely while pulling out.
o Use of pipes of different size, weight or grade in the same
string due to improper design or due to mix up during
tripping.
• The work string can fail due to tension alone i.e. the total weight
of the work string exceeds the pipe yield value. The design of the
tubular stem for static tensile load requires sufficient strength in
the top most member of each size, weight, grade and class of
work pipe to support the buoyed weight of all hanging load
below it.
• The tensile failure will in most cases be located between the
upsets.
• Although this type of failure is usually near the top of the string,
but variation in wall thickness and tensile strength between
different pipes can cause pipe to fail somewhere lower in the
string also.

• Tensile failure of the tool joint is rare because the tool joint has a
greater cross sectional area than the pipe body.
• In tensile failures the pipe body usually gets bottle necked near
the fracture.
e) Collapse failure:
Tubing/ Drill pipe may be subjected to an external pressure higher
than the internal pressure. This condition usually occurs during drill
stem testing or activation (creating draw down by applying nitrogen)
and may result in collapse of the pipe. The collapse pressure is the
maximum in the lower most pipe.
f) Burst failure:
This type of failure is extremely rare but it can occur in any operation
with a high differential pressure from inside the pipe, for example
when well testing or fracturing.
g) Downhole vibrations
• Although some downhole vibrations are inevitable, severe
downhole vibration can cause work string fatigue (washout /
twist off), crooked drill string, premature bit failure and reduced
penetration rates.
• These vibrations cause three component of motion in the drill
string and bit (axial, torsional and lateral).
• There are number of mechanisms which can cause severe
downhole vibrations. Such mechanisms, their symptoms and
methods of control are described below :
i) Slap stick
9 Non uniform bit rotation in which the bit slows or even
stops rotating momentarily, causing the drill string to torque
up and then spin free.
9 This can be controlled by reducing WOB & increasing RPM.
ii) Drill string whirl
9 The BHA (or drill pipe) gears around the hole. The violent
action slams the bit against the hole.
9 To control this, lift bit off bottom and stop rotation, drill
with reduced RPM,

iii) Bit whirl
9 Eccentric rotation of a bit about a point other than its
geometric centre.
9 To control bit whirl, lift bit off bottom and stop rotation,
then reduce RPM & increase WOB.
iv) Bit bounce
9 Large WOB fluctuations causing the bit to repeatedly lift off
& impact the formation.
9 To control this adjust WOB/RPM.
h) Slip crushing:
A majority of the pipe failures occur in the slip area. These types
of failures are caused by highly concentrated stresses originating
from axial and transverse loads that are not equally distributed
over the full gripping surface of the slip. Improper handling
methods result in abnormal markings and stressing in the slip
area.
9.3 BIT FAILURE

• Bits and other large pieces of junk are always removed. A number
of trips with a mill may be required to clear the junk.
• A junk sub should always be run with the mill. If the junk is small
enough to enter a junk sub, then run a junk basket.
• If the top of bit is a clean pin then run a matching box and screw
into the pin of the bit.
• A taper tap may be used to catch the bit which is lying with pin
up.
• The most common method of removing a bit which cannot be
removed by a matching box or a tap is to mill it into small pieces.
9.4 CASING FAILURE

Failure of casing is a matter of serious concern. Common type of casing
failure and their reasons are as described below:
9.4.1 Casing Leak
Casing leak is the most common failures and often occur in association
with most other failures. The major causes for leaks are:

• Improper make up during running.
• Drill pipe wear during drilling.
• Mechanical wear during fishing and specially milling.
• Corrosion and to a lesser extent erosion and mechanical wear
during production life of the well.
9.4.2 Casing Split or Burst
Casing split or burst occurs from many reasons;.
• Applying excess internal pressure sometimes in combination with
high tensile loading.
• Excess internal pressure may occur while testing liner top or
testing casing before drill out.
• Some failures that cause casing leaks may also cause split or burst
casing.
• Casing may split while hanging long, heavy liners.
• General causes include inadequate strength due to improper
design, or worn casing at the point where liner setting tool slips
engage the casing.
• Casings can also split due to high density perforation (especially
in the higher strength steels).
• Casing may also split due to structural defects.
9.4.3 PARTED CASING
These types of failures are caused mainly due to:
• Improper design.
• Operation or mechanical failures due to improper construction.
• Split or burst casing may also part due loss of structural integrity.
• Other causes can include excess wear and resulting loss of tensile
strength, pulling hard while working stuck casing and bumping
the plug too hard during cementation.
9.4.4 COLLAPSED CASING
Casing collapse due to various reasons
• Improper design.

• Wear reduces body strength so the external pressure may cause
the casing to collapse.
• Anything that reduces wall thickness, including wear or corrosion
increases susceptibility to collapse.
• Casing may collapse due to squeezing or treating below a packer
set in the casing.
• Worn or poorly designed production casing may collapse when
the hydrostatic head is reduced by compressor / nitrogen
application.
9.5 CASING REPAIR

9.5.1 FACTORS AFFECTING CASING REPAIRS
• Casing type, size & depth of failures.
• Whether the problem is in cemented or uncemented section.
• Whether the option of using extra string of casing is available.
• Formation type, pressure, fluid in the formation & transition
zone.
• Age of the well.
• Current status of the well (drilling or production).
• Productivity from the well.
• Severity of failure.
• Cost of repair
• Time required for repair
• Others
9.5.2 CASING REPAIRS ARE BEST REVIEWED & EVALUATED BY
CONSIDERING THE FOLLOWING
1. How does the failure affect future & current operations? The first
thing that needs to be evaluated is whether the failure needs to be
repaired. The failure may not have an adverse effect on
operations; if not, and no other hazardous conditions exist; do not
repair the casing.
2. Is the internal diameter restricted? An immediate repair may be
needed if the restriction is preventing the running of full gauge

tools / completion string and other operations. There are some
exceptions like a partially collapsed larger diameter casing above
a drilling liner which is not impeding the normal operations. A
partially collapsed casing above a conventional completion like an
intact packer and tubing with no annulus pressure build up may
not be repaired.
3. Can the failure be repaired by normal future operations? A casing
failure may not pose a problem in current operation and can be
effectively repaired or effectively eliminated by future operations.
4. Can the failure be patched off or the leak packed off? Some casing
repairs can be made by a simple casing patch or packing off the
leak.
5. Can the casing be plugged off and repaired later? This applies
mainly to production casing. If the casing fails in the lower
section, one procedure would be to set a plug and isolate the
failure. Production testing of the upper objects can be done. If the
well is deepened later, repair the failure.
6. Can an extra casing be run? It may be possible to repair the casing
by running another string of casing, a liner, or a stub liner.
9.5.3 CASING REPAIR METHODS
1. Squeeze and clean out: Generally this is the simplest method of
repairing a casing failure such as a leak. Squeeze the section and
run a full gauge tool through to ensure that the hole is full gauge.
The disadvantage of this method is that it leaves a potentially
weak section that must be considered during future operations.
Squeezing of cement can be done through open end tubing or
drill pipe, retrievable packer or cement retainer.
2. Pack off the failure: Pack off the failure by isolating it. A
damaged section can be isolated from the remaining well bore by
running a packer on tubing. Alternately, run two packers on
tubing separated by the length of damaged casing. Disadvantage
of this method is that it reduces the working inside diameter of
hole and usually restricts operations below the failure.
Nevertheless, it is the fastest and most economical type of repair.
3. Patch off the failure: Various types of inside casing patches are
available. Generally they include a ribbed or corrugated, thin wall
steel cylinder. Run it into the cased hole and position it over the

failure (usually a hole). Expand the sleeve by pulling the mandrel
through it to form a sheet of metal inside the casing. Inside patch
reduces the inside diameter of the casing by a small amount,
which can cause burst and collapse strength to reduce.
4. Repair parted casing in place: One of the best methods, where
ever it is possible, is to establish circulation through the failed
section and perform a primary cement job under a retrievable
packer or cement retainer. Alternately, perforate below the failed
section and perform a primary cement job in a similar manner. In
case of a retrievable packer or open end tubing or drill pipe, take
precautions to ensure that this assembly does not get stuck in
cement. Pull the cementing assembly above the damaged section
of casing and reverse out so that all excess cement is circulated
out. Pressurize the casing to ensure that the cement does not flow
back into the well.
Another method is to squeeze the section till it holds the desired
pressure. Clean out with bit.
5. Pull, repair, rerun and reconnect parted casing: This is one of the
best casing repairs, but it is not applicable in many cases. Back off
or cut the casing below the failed section and pull it. Replace the
damaged section and either screw back into the lower section or
connect it with an external casing patch. The external casing patch
can be a lead seal or lead seal cementing type.
6. Run another string of casing or stub casing or tie-back liner:
This method can be used :
(a) If the casing is large enough to run another casing or stub
casing or liner.
(b) If the failure is in the bottom of intermediate casing than by
covering it by production casing.
(c) Repair of a failure at the bottom of the hole above a liner with
a tie-back liner. If the failure creates an immediate hazard, it
may be squeezed off and covered by casing or a liner.
7. Failure in casing not cemented: When possible, pull the casing,
replace it, run and reconnect in a way similar to parted casing.
Otherwise try to cement the casing in place with a primary
cement job. Running another string of smaller diameter casing or
tie back or stub liner may be applicable.

8. Failure in cemented casing: This is one of the more difficult
casing repair jobs. Generally the cemented casing cannot be
repaired by replacing the casing above the point of failure. If the
failure is such that it restricts the inside diameter of the casing
then the diameter should be restored by rolling out or swaging or
milling out and squeezing if necessary. Running another string of
casing or liner may be a viable alternative.
9.6 FISHING
Fishing is any operation or procedure to release, remove or recover
tubular or any undesirable material left in the well bore. The key elements
of a fishing operation include an understanding of the dimensions and
nature of the fish to be removed, the wellbore conditions, the tools and
techniques employed. The fishing operations are performed in open hole,
cased hole and through tubing. Through-tubing fishing applications have
grown dramatically with the increased use of coiled tubing as a
conveyance method.
The exact sequence of job plan is very much dependent upon the
problem. The success of each operation is quite uncertain and it is a cost
intensive and time consuming operation
9.6.1 CAUSES LEADING TO FISHING OPERATIONS
Some of the common causes that result in fishing operations are:
Human error in majority of cases
Corroded tubing and equipment
Stuck packers.
Damaged casings above the packers that result in packer
stuck-up during pulling out the string.
Logging tool stuck-up in tubing/casing due to scale
deposition or damage
Premature setting.
Falling of slip dies or other items in the well bore during
tripping operation or otherwise resulting stuck up of pipes.
9.6.2 CONSIDERATIONS FOR FISHING
The key considerations for a fishing operation include:
i. Knowledge of down hole tool configuration

• An understanding of the dimensions and nature of the fish
to be removed is essential for designing a successful fishing
operation.
• Anything that is lowered into the hole must be accurately
measured and sketched so that appropriate fishing tools can
be used if required to fish out any item out of the hole.
ii. Well bore conditions
The well bore conditions need to be understood clearly to
determine the cause of stuck-up. Based on Hooke’s law that
stretch is proportional to strain, the free point/stuck point in the
string are determined.
iii. Well profile
Successful fishing is much easier in a relatively straight well than
in a highly deviated well bore. However, it is still quite possible to
perform a successful fishing job in a highly deviated or horizontal
well bore, if the proper approach is adopted. There are several
special considerations that should be taken into account when
planning a fishing job in a high-angle deviated or horizontal well.
For example:
o Hole drag in horizontal or highly deviated wells
inhibits good jarring action.
o Adding weight to the string for milling operations
can be a problem. Drill collars have to be run higher
up in the more vertical section of the hole to be
effective.
o It is difficult to get the required torque down and
around deviations when attempting to back off pipe
in highly deviated well.
iv. Fishing tools:
The choice of fishing tools and equipment is dictated by the size
and the shape of the fish, the anticipated severity of the problem,
and the experience of the fishing expert. In the past years, the tool
pusher and the drillers handled these problems almost
exclusively, their main tool being their own ingenuity. Much of
this work is currently handled by service companies, which offer

complete lines of fishing tools and experienced operators
(fisherman) on a rental basis.
The fishing tools are classified in to various categories:
External Catch:
o Overshot,
o Diecollar
Internal Catch:
o Taper Tap,
o Spear (mechanical, hydraulic)
Junk Catcher:
o Reverse circulating junk basket
o Junk basket,
o Fishing magnet,
o Ditch magnet
o Impression block
o Wireline spear
o Screw grab
Milling and Washover Equipment:
o Skirted junk basket,
o Combination mill,
o Pilot mill,
o Taper mill,
o Boot basket,
o Wash over pipe,
o Washover safety joint,
o Lift plug,
o Drive sub,
o Rotary shoes
o Junk mill

Accessories equipment:
o Fishing jar
o Bumper sub,
o Jet impact amplifier,
o Lubricated bumper sub,
o Drilling safety joint
Remedial and repair equipment:
o Casing roller,
o Casing scrapper,
o Crossover sub
o Casing patch
9.6.3 GENERAL GUIDELINES ON FISHING
1) Avoid using welded guide in the fishing assembly. Always use
threaded connection guide for centring of the fish.
2) While engaging fish with matching pin, the jar / bumper sub pin
should be protected by using an end connector.
3) Always use strongest catch tool available for the particular size of
the fish.
4) While using overshot with deflection tool like knuckle joint/bend
sub, the lip of the overshot should be in line of the direction of
deflection.
5) Standard fishing assembly should consist of :
a) Overshot or any other catching tool.
b) Bumper sub (min 18" stroke).
c) Hydraulic up jar.
d) 3-4 singles of drill collars.
6) In crooked hole for maximum effective jarring, use jar accelerator
along with the jar.
7) Jar accelerator should be placed above the drill collar which is put
above the jar for better impact.

8) Before lowering jar, make sure that I.D. of jar is sufficient to pass
string shot or free point indicator tool. Record all the dimensions
of all fishing tools lowered in the well.
9) Try to avoid using Rotary male tap as string shot tool cannot be
lowered through it.
10) Prior to starting fishing operation or engaging the fish always
circulate thoroughly.
11) In case of suspected mud cut or string failure, pull out the string
using pipe spinner or manila rope, never rotate the rotary to avoid
dropping of string.
12) In case of mechanical back off or string failure always count the
number of stands and singles pulled out.
13) While backing off keep the neutral point at the back off point. In
directional wells or when in doubt it is better to have the shot in
tension.
14) After string shot, before picking up the string ensure that all the
torque is consumed or neutralized.
15) After backing off, tag the fish top prior to pulling out so as to have
an idea of the hole size at the fish top.
16) Dress the over shot with the same size of grapple as the O.D. of
the fish. When reduction of tool joint is around 1/8”, use grapple
size 1/8" less than anticipated O.D. of fish.
17) After engaging fish with catching tool, reciprocate with gradually
increasing tension before trying to lift.
18) Before lowering junk basket, ensure that the catcher rotates freely.
19) In RCJB operation, before dropping the ball ensure that the hole
bottom is flushed.
20) Select the proper shoe for RCJB prior to assembling the tool. If the
junk is large & lying loose at the bottom, use finger shoe.
21) Cutting casing against joint must be avoided.
22) While fishing wire line inside casing, stop plate should be used
above wire line spear to avoid wire line coming above the spear
and getting stuck inside casing. The clearance between the stop
plate and I.D of casing should be half the diameter of wire line.

23) Be aware of the limitations of the fishing tools.
24) Use positive catching tools as far as possible. Non positive are to
be used only when positive catching tools cannot be used.
9.7 DO’S AND DON’T

1) Circulate cuttings out and keep away from the BHA prior to
commencing tripping out/ pipe breaking operation.
2) For efficient lifting of the cuttings, use high viscous pill sweep for
vertical wells. Use low, high viscous pills sweep combination for
high angle wells
3) Minimise connection time.
4) Establish over-pull limits. Pulling too hard into a pack off will
prevent the pipe from being freed downward. Use small
increments of over-pull.
5) Be alert to observe early warning signs to stay out of the trouble.
6) When wear or non uniform gripping of the slip dies is observed,
the entire set of dies on the slip must be changed. Never use re-
sharpened or combination of old and new dies.
7) To free a mechanically stuck string, first action should be to bleed
off pressure and try to establish circulation. Thereafter, apply
torque and slack off the string.
8) Generally the string packs off during trip out- Jar down if jars are
in the string. In high angle wells it can get packed off during trip
in – jar up in this case.
9) Pulling hard to free the string should be attempted as last resort.
10) The driller must know the maximum amount of over-pull which
can be given safely. Moreover, there should be no torsion in the
string while working or jarring upward.
11) To fish out a mechanically stuck string, back off above free point
& wash over. After wash over run a fishing assembly with both
up & down fishing jars.
CEMENT STICKING
12) The cement should be designed based on hole conditions and
should be retarded or accelerated as required to minimse the

unlikely chance of flash set causing the string to be cemented in
the hole.
13) In case of cement sticking, immediate action should be to apply
pull to the string to maximum but within safe limit. Attempt to
circulate at a higher pressure than that available with rig pumps
(use cementing unit).
14) As a preventive action, test the technical water to be used for
designing cement slurry, simulate downhole conditions prior to
cement job, make all arrangements for reversing out in advance,
check cementing units and mud pumps prior to taking up
cementing job, prevent contamination of the cement with mud by
using spacers etc.
15) While carrying out a squeeze job, use an open end string to place
a balanced cement plug. Pull the string above the cement plug.
Reverse out 1-1/2 times the annular volume and then squeeze.
16) When a packer is utilized for a squeeze job, monitor the annulus
pressure. Should there be a leak anywhere; the pressure in the
annulus will indicate it.
17) If the pipe is cemented in place inside a casing, length of the
cemented section, depth at which the pipe is cemented, strength
of the cement bond, and annular clearance between the cementing
string and the casing will decide the recovery techniques.
STRING FAILURE
18) Mostly drill pipe failures are caused by fatigue which is the
combined effect of tension, torsion and bending. The cyclic
reversal of stress that results when the string is rotated also causes
fatigue failure.
19) Failure of the pipe due to fatigue takes place in the pipe body
generally in the area where slip is set.
20) Tool joint/ tubing box may get wash/ worn out, if joints are not
made up to the recommended torque.
21) To avoid the tensile failure of the string don’t pull the string more
than the rated capacity.
22) Don’t mix up the different size, weight or grade of pipes during
tripping.

23) To avoid the failure of drill/tubing string due to tension alone,
while designing provide the top most pipe of each size, weight,
grade and class of the string of sufficient strength to support the
buoyed weight of all hanging load below it.
24) During testing/ activation/ stimulation operation, differential
pressure should be applied to the string within design limit to
avoid collapse / burst pressure failure.
25) Don’t use bend drill pipes/ string. NDT passed tubular should
only be used.
26) Avoid severe down hole vibration as they can cause drill string
fatigue (washout / twist off), crooked drill string, premature bit
failure and reduced penetration rates.
27) A majority of the pipe failures occur in the slip area as improper
handling methods result in abnormal markings and stressing in
the slip area.
CASING FAILURE AND REPAIR
28) Avoid splitting or bursting of casing by not subjecting the casing
to excessive internal pressure in combination with high tensile
load while testing liner top or testing casing before drill out.
29) High density perforation (especially in the higher strength steels)
and structural defects can lead to casing split.
30) Casing may part due to improper design, operations or
mechanical failures due to improper construction, excess wear
resulting in loss of tensile strength. Split or burst casing may also
occur due loss of structural integrity.
31) Casing may collapse due to improper design, reduction in wall
thickness/ body strength due to wear or corrosion, squeezing or
treating below a packer set in the casing etc.
32) Worn or poorly designed production casing may collapse when
the hydrostatic head is reduced by compressor / nitrogen
application.
33) Casing repair is a costly operation and many factors affect the
decision of casing repair. Decision to repair or not to repair casing
should best be taken after a thorough review and evaluation of
the facts considering a) how does the failure affect future &
current operations? Is the internal diameter restricted? Can the

failure be repaired by normal future operations? Can the failure
be patched off or the leak packed off? Can the casing be plugged
off and repaired later? Can an extra casing be run?
34) When the casing is damaged & cement behind the casing is poor,
this kind of well should either be abandoned or the casing
replacement/isolation should be done before going to put such
wells on production.

CHAPTER- 10
SECONDARY CEMENTATION
10.0 GENERAL
In an oil well, cementation of casing and liners is carried out to;
1. Restrict the fluid movement between permeable zones within a well.
2. Provide mechanical support for the casing/ liner.
3. Prevent corrosion of casing/ liner from sulphate rich formation
water
4. Arrest unwanted flow of fluids, mainly water and gas, in multi-
layered wells.
The cementation of casing / liner soon after it is lowered is called primary
cementation. Any subsequent cementation jobs carried out to improve the
cement bond behind the casing are called secondary cementation.
Subsequent to casing/ liner cementation, the hole is cleared to the
required depth and scraped to remove any cement on the casing wall.
Then CBL-VDL log is recorded to ensure that proper cement bond exists
between the various permeable zones. CBL stands for Cement Bond Log
and is recorded to determine the quality of cementation behind the
casing/liner. In case the cement bond is not up to the desired level, then
casing is perforated at a depth where cement bond is not good and
secondary cementation carried out to improve the bond. VDL refers to
Variable Density Log and is recorded to determine the quality of cement
to formation bond.
Secondary cementation is the operation performed to repair some
segments in the well bore having poor cement in annulus. Secondary
cementation jobs are mainly classified as plug cementing and squeeze
cementing.

10.1 PLUG CEMENTING
A column of cement of a specified length when placed across a selected
interval in an open hole or a cased hole is called “Plug Cementing”.
Cement plug is placed in the well bore for various purposes;
o To stop loss circulation during drilling.
o Directional drilling and side tracking
o To support the GP assembly.
o To plug back a depleted zone.
o Isolation of zones in production testing
o Well abandonment
o To provide anchor for open hole test tool.
10.1.1 PLUG PLACEMENT METHODS
There are two plug placement methods:
• Balance plug method
• Dump bailer method
A) Balance Plugs Method
This is the most commonly used technique for plug placement. Steps
involved are as follows;
1. Open end Drill pipe or tubing is run in the hole as far as the plug
base is desired.
2. The wash and spacers are pumped ahead and behind the cement
to avoid mud contamination. Volume of pre-flush & after flush
should be such that it makes equal height in annulus and inside
drill pipe after completion of displacement
3. Displacement is completed to the top of the calculated length and
allows reaching hydrostatic balance of cement slurry inside
tubing/drill pipe and annulus.
4. It is a common practice to under displace the slurry to avoid back
flow and facilitate the dry pull out.
5. Once the plug is balanced the pipe slowly pulled out up to the
plug’s desire top and excess slurry is reversed out.

B) Dump bailer method
In this method the cement is placed by running a dump bailer containing
a measured quantity of cement on a wireline. A permanent bridge plug
placed below the desired plug interval and the cement is dumped on the
plug by raising the bailer.
Usually this method is used for setting plug at shallow depth. Advantage
of this method is that depth of the cement plug can easily be controlled
and it is relatively cheap. However, the process of dumping the cement by
bailer may take longer time as quantity of cement is limited to volume of
dump bailer and therefore technique may not be adoptable to deeper
wells.
10.1.2 BEST PRACTICES TO PREVENT PLUG FAILURE
1) Select gauge section of a hole. Run a calliper log for selecting a
location to set a plug. Carefully calculate cement, water and
displacement volumes and always plan to use more than enough
cement (1.5 to 2 times the calculated volume) to compensate for
contamination effect so as to get the desired plug length. Always
use adequate spacer to reduce contamination.
2) Circulate long enough to condition the well so as to ensure that
the entire mud system is uniformly weighted. Check the mud
system carefully for loss of returns, fluid gain or gas entry. Any
movement of the plug after it is placed may cause the cement not
to set.
3) Plan for a plug length of minimum 100 m in open hole and 50 m in
cased hole.
4) A cement plug is best set in a competent hard rock. Shale should
be avoided as they are often caved and out of gauge. However, if
the kicking off is the objectives, the plug should not be set in an
excessively hard formation. Ideally, the plug should extend from
soft shale down to a hard formation. Logs and drilling rate record
should be consulted when selecting a location to set a plug for
kick-off.
5) Slurry design: Viscous slurries with high gel strength and low
density are needed for lost circulation plugs, to restrict flow into
voids or fractures.
6) Batch mix the cement slurry to ensure uniform slurry density.

7) Pump preflush that is compatible with workover fluid. Preflush
volume should be sufficient to cover an annular height of 150 to
250 m and the after flush volume should cover the same height in
the tubing string as that of the preflush.
8) Whenever possible preflush/ spacer should be pumped in
turbulent flow conditions.
9) Try to rotate or reciprocate string slowly till the completion of
displacement.
10) Under displace the plug by 200-300 litres to avoid any back flow.
11) Pull out the drill pipe/tubing slowly (30-50 ft/min) out of the
cement to minimize contamination.
12) Reverse wash twice the workstring volume to wash excess slurry
out of the hole.
13) Ample WOC time should be allocated as per the advice of
Cementing Engineer (12 to 24 hours) for a plug job. A common
practice is to allow for longer WOC time since well temperature
for a cement plug job is difficult to know accurately.
14) Always test the cement plug by tagging top of cement with bit and
apply required weight for “Hardness” test.
15) While placing a cement plug for kick-off, special measures as
depicted below are required to be followed for success at first
attempt
a. Use either a mechanical or chemical method to provide some
static barrier below the intended bottom of the plug
b. Typically 2-7/8 tubing should be used as tail pipe to minimize
contamination during pulling out as it will create less
disturbances of the cement plug when the pipe is being pulled
out. The length of tail pipe should be 1.5 - 2 times the plug
length.
c. At least provide 48 hrs. W.O.C for attaining sufficient hardness
/ strength for side- track plug.
10.2 SQUEEZE CEMENTING

Squeeze cementing is defined as the process of forcing cement slurry,
under pressure, through holes or splits in the casing to well bore annular
space and then allowing it to dehydrate by further application of

pressure. The key element of a squeeze cementing job is that of placement
of cement at the desired point or points necessary to accomplish the
purpose.
A basic fundamental of squeeze cementing is that regardless of the
technique used during a squeeze job, the cement slurry is subject to a
differential pressure against a filter of permeable rock. The resulting
physical phenomena are filtration, filter-cake deposition and, in some
cases, fracturing of the formation. The slurry, subject to a differential
pressure, loses part of its water to the porous medium, and a cake of
partially dehydrated cement is formed. As the filter cake builds, the pump
in pressure increase until a squeeze pressure less than fracturing pressure
is attained.
The squeeze job can be classified by pressure requirement:
High pressure squeezing: It involves breaking down the formation and
pumping down the cement slurry into the formation until a specific
surface pressure can be maintained without bleed off.
Low pressure squeezing: It involves placing of cement slurry over the
interval to be squeezed by applying a pressure sufficient to form a filter
cake of dehydrated cement in perforation, channels or fractures.
Squeeze cementing is useful/ necessary for many reasons
1. To repair primary cement job that failed due to cement bypassing
the mud (channelling) or insufficient cement height in the
annulus.
2. To eliminate water or gas intrusion from above or below the
hydrocarbons producing zone. Or to reduce producing gas oil
ratio by isolating gas zones from the adjacent oil intervals.
3. To repair casing leak due to corrosion or split pipe.
4. Plugging all or part of the zones in a multi-zone injection well so as
to direct the injection into the desire intervals.
5. Plug and abandoned a depleted or watered out producing zone.
1. Repair of primary cement job
The drilling mud, which the cement bypasses, may leave pockets
or channels behind the casing. These channels are repaired by
either low pressure or high pressure squeeze cementing
technique. At low pressure the channels connected to a permeable

formation will be cemented. High pressure squeezing may
improve the cement fill up, breaking weak nods in the set cement
structure.
2. To eliminate water or gas intrusion/ or to reduce producing gas
oil ratio.
Water or gas intrusion in the oil zone may occur as the oil zone
becomes depleted. Most important use is to segregate
hydrocarbon producing zones from those formations producing
other fluids.
Circulation of cement slurry between two perforations at the top
and bottom of the desired interval is another technique often used
for elimination of water intrusion or reduction gas oil ratio.
The usual procedure is to plug all the perforations in the oil,
water and gas zones and then re-perforate in the shorter oil
producing interval.
3. Repair of casing leaks:
This operation usually performed at very low pressure in order
not to extend the damage.
4. Plugging all or part of the zones in a multi-zone injection well
Diversion of injection fluid such as water, polymer solution or gas
to less permeable zones is difficult. If no vertical permeability
exists between the zones and isolation of zones is satisfactory,
plugging of the perforations in highly permeable zones will direct
the injected fluid to the others less permeable zones.
5. Plug and abandonment:
This job is done at low pressure to avoid damage to a zone, which
may be economically explorable in the future.
10.2.1 INJECTIVITY TEST PRIOR TO SQUEEZING
Prior to placement of cement slurry, conduct injectivity test against the
squeeze interval to determine if and at what rate below the fracture
gradient fluid can be placed against the formation. A rate sufficient to
allow adequate time for cement placement must be reached before
actually mixing the cement.
A high injection rate with a high pressure is almost never acceptable on a
squeeze job. A high injection rate with high pressure may induce high

fractures in the formation and will require a large volume of cement
slurry to fill these fractures before the actual squeeze job begins. When
obtaining an injection rate, consideration should be given to the
possibility of spotting a clear fluid such as water across the perforation, as
drilling mud contains solid and can enter the formation.
The injection test is performed for several reasons:
• To ensure that the perforations are open and ready to accept fluids.
• To obtain an estimate of the proper cement slurry injection rate.
• To estimate the pressure at which the squeeze job will be performed,
• To estimate the amount of slurry to be used.
If suitable injection rate could not be established at the desired injection
pressure, it may be necessary to re-perforate / use acid to clean up the
perforations, channel etc. Hydrochloric and hydrofluoric acids are
commonly used.
10.2.2 DESIGN OF CEMENT SLURRY FOR SQUEEZE JOB
The properties of cement slurry must be tailored according to the
characteristics of the formation to be squeezed, and the technique to be
used. Squeeze slurry should be designed to have the following general
attributes:
• Low viscosity: to allow the slurry to penetrate the small voids
• Low gel strength: a gelling system restricts slurry movement
• No free water
• Appropriate fluid loss control.
• Proper thickening time to safely meet the anticipated job time.
Following factors may be considered in designing the cement slurry for
any squeeze operation:
i) Fluid Loss Control
The designed slurry must fill the perforation cavities. Fluid loss and filter
cake growth rate vary directly i.e. higher the fluid loss, faster will be the
filter cake build up. As such, while designing the slurry, fluid loss must
be tailored to the formation type and the permeability so as to achieve a
uniform cake build up against the squeeze interval.
The generally accepted API fluid loss rates are listed below:-

Extremely low permeability formation - 200 ml/30min
Low permeability formation - 100 to 200ml/30min
High permeability formation (>100md) - 35 to 100 ml/30min
ii) Thickening Time
The temperatures encountered in squeezing can be higher than those of
primary jobs, because fluid circulation before the job is usually less. For
this reason, special API testing schedules exist for squeeze cement slurry
design and must be followed to prevent premature setting.
Thickening time must be sufficient to assure slurry placement and
reversing out of the excess cement slurry. For a hesitation squeeze
method, higher pumping time must be designed so that cement slurry
remains in fluid stage till squeeze pressure is achieved.
iii) Compressive Strength
High compressive strength although desirable but is not a primary
concern for squeeze slurry design as a partially dehydrated cement cake
of any normal cement slurry will develop sufficient compressive strength.
iv) Dispersion:
The capacity of slurry to flow into narrow small cracks is proportional to
its fluidity. Thick slurries although useful when cementing large voids but
will not flow in to narrow channels. Thin slurry should be prepared by
using dispersant.
v) Slurry Volume
For a successful job, the appropriate cement slurry volume depends upon
the length of interval, placement technique, the injection rate of a
particular formation and pumping of excess slurry. A low pressure
squeeze usually requires a very small volume of cement, whereas a high
pressure squeeze, in which the fractures are to be filled, requires a higher
volume of slurry. However, calculate the slurry volume as per the
injection rate of a particular formation and pumping of excess slurry is
always recommended for a successful job.
Control of the amount of cement squeezed is not precise and is more of
art than science. The slurry volume should not exceed the capacity of the
running string and the volume should not be so great as to form a column
that cannot be reversed out.

vi) Slurry Preparation
When preparing the slurry, the use of a re-circulating mixer or batch
mixer is strongly recommended (rather than by hopper method as in
primary cementing), because it ensures that the properties of the slurry
pumped in the well are as close as possible to those of the slurry designed
in the laboratory. On most squeeze jobs, the amount of slurry involved is
quite small, but the requirements of its quality are quite high, therefore
special care must be taken in preparing it.
10.2.3 SQUEEZE PRESSURE
Squeeze pressure is the pressure at the injection point. In most cases, if the
cement can be placed at the proper point, a successful squeeze can be
obtained with 500 to 1000 psi pressure above the injection pressure. The
pressure should be hold for 10 to 15 minutes with no flow back. Low-
pressure squeeze is recommended where possible.
After a squeeze is obtained, the pressure should be bled off and the
volume of fluid back flown is measured. The squeeze should then be re-
pressured and the volume measured again. If the volumes are equal, this
indicates that the squeeze has held and the volume of fluid pumped
compensated for tubular expansion.
10.2.4 POST JOB ANALYSIS
1. Evaluation of cement job is very crucial to determine the success
of a cement job objective. A complete post job analysis comparing
field job parameters with actual results is the best way to
reasonably understand what happened in down hole and
accordingly necessary corrective measures for future operation
may be applied.
2. CBL-VDL, CET or USIT logs can provide accurate and useful
information to evaluate post job success or failure. However,
production results are the actual proof of the acceptable quality of
cementation.
3. The general rule is that the cement bond log should not be run
until 48 hrs after the cementation in order to achieve the true
cement bond reading. This again is highly dependent on the
cement type and additives used in the slurry.
4. Field results show that more than 90% of wells exhibit a micro-
annulus on a primary cement job. Always record CBL-VDL
under 700-1000 psi pressure to eliminate micro-annulus effect.

10.2.5 EVALUATION OF SQUEEZE JOB
Pressure testing after clearing the cement inside casing is the most
common means of evaluating the success of the operation. Both positive
and negative test should be used. A squeeze job may appear successful
when pressure is applied to the well bore but may fail to hold back the
pressure from the zone into the casing. The universally recognized
technique for confirming whether the cement in place will hold the
formation fluids under producing conditions consist of applying a
negative differential pressure on the face of the plugged perforations.
Positive pressure test
After the W.O.C time, clear the cement and test the cement by applying
required surface pressure for checking integrity of the perforation
squeezed. The pressure applied at the face of the perforation is
predetermined at the job design stage. It may be the reservoir pressure or
pressure equal to future working pressure in the well from fracturing or
acidizing treatments but should not exceed the formation fracturing
pressure.
Negative pressure test
A negative test or differential pressure testing of the well bore may be
obtained either by swabbing or by displacing work over fluid with air or
nitrogen. Negative pressure test should be conducted using pressure no
greater than the expected maximum drawdown in the well when it is put
into production.
When the objective of the squeeze is to repair a primary cement job, the
normal cement log (CBL/VDL) should be run to evaluate the
effectiveness of the repair by comparing pre-squeeze and post squeeze
logs.
10.2.6 SQUEEZE TECHNIQUES
A) Bradenhead squeeze method
1) In this method open end drill pipe or tubing is lowered without
packer up to the perforations.
2) A predetermined amount of slurry is mixed, pumped and
displaced to the specific height outside the tubing or drill pipe to
make a balance plug.
3) The tubing or drill pipe then pulled out of the slurry and BOP is
closed at the surface.

4) The displacing fluid is pump down the tubing / drill pipe until
the desire squeeze pressure is reached or until a specific amount of
the fluid has been pumped.
5) Usually, this method is used for squeezing shallow wells.
B) Squeeze packer method
1) This method uses retrieval or non-retrievable tool run on tubing to
a position near the top of the zone to be squeezed.
2) It confines pressure to a specific point in the hole.
3) Before the cement is placed, a pressure test is conducted to
determine the formation injectivity pressure.
4) In certain cases the section below the perforation to be squeezed
must be isolated with a bridge plug.
5) When the desired squeeze pressure is obtained remaining slurry is
reversed out.
C) Building Squeezes Pressure/ Hesitation method:
1) One common denominator to successful squeezing is reduction of
the pump rate as cement slurry starts passing through the
perforation.
2) Hesitation technique involves alternation of pumping and
hesitation.
3) The hesitation encourages cement filter cake build up.
4) The alternation of pumping and hesitation is continued until the
desired final squeeze pressure is obtained. Once slurry enters the
perforation it can contact the face of the formation.
5) Depending upon the permeability, slurry cake can begin to build
immediately.
6) The rate should be reduced to allow this build up without un-
necessary fracturing.
7) A loose formation will need a long hesitation period to begin
building the squeeze pressure.
8) A first hesitation period of 30 minutes or more is not
unreasonable. When pumping is resumed after this period the
slurry should be moved as slowly as possible.

9) Monitor the pressure gauge on the cementing unit and continue
pumping as long as the pressure steadily increases.
10) If shut in pressure is not more than the first period, a longer
waiting period is needed.
11) As shut in pressure increases, hesitation period can be shortened,
continue pump hesitation- pump cycle until squeeze pressure is
attained.
12) A tight formation will need only short hesitation period, possibly
five minutes in first time.
13) When the pump is allowed while placing slurry against the
formation face, it is common to have shut in pressure on the first
hesitation that is higher than the injection pressure.
14) Again when pumping is resumed slowly pump the slurry while
monitoring the pressure.
15) In the event squeeze pressure is not attained when there is no
more slurry in the casing, the slurry inside that covers the
perforations should be left in place.
16) A successful squeeze could very well be achieved, if the
perforations were left covered.
10.2.7 SQUEEZE CEMENTING PROCEDURE
a) Low Pressure Squeeze Cementing
1. Consult a CBL / VDL log prior to squeeze job.
2. Decide the point of perforation and perforate against a permeable
formation at least 6 to 8 Shots per foot for achieving better intake.
3. Carry out injectivity test in water. If injectivity is found to be poor,
acid job may be required to improve injectivity.
4. For low pressure squeeze cementing, follow all the standards as
given for a normal cement plug job so as to spot the slurry against
the perforated interval.
5. Then pull out drill string sufficiently above the cement top.
6. Close BOP and apply pressure through drill string to squeeze
cement.
7. Squeeze calculated volume of slurry and close the well under
pressure for 4 hrs.

b) Block Squeeze Cementing
1. For block squeeze perforate 2 sets of perforation i.e. above and
below the cement retainer.
2. If the poor bondage is continuous for a longer section, decide to
carry out block squeeze using a cement retainer.
3. Establish circulation through cement retainer behind casing with
water or cleaned fluid to ensure good clean up of the channels.
4. Maintain the down hole treating pressure below the formation
fracture pressure when carrying out injectivity test or establishing
circulation behind casing.
5. Calculate slurry volume keeping into consideration the annular
volume and slurry required below cement retainer.
6. Use spacers ahead and behind cement slurry for a minimum
length of 50 to 75 m to avoid contamination.
7. While displacement in progress, monitor free falling /U tubing of
cement slurry by controlling through choke. Displace cement up
to the tip of cement retainer so as to keep the cement inside the
string and engage tubing string to retainer, and squeeze to
circulate out cement between the two perforations.
8. Disengage the string from retainer and balance the plug. Pull out
the string above the top of perforations, reverse wash and squeeze
cement in the upper perforation (optional) and keep the well
under final squeeze pressure.
c) Water/ Gas Shut Off Squeeze
1. For elimination of water intrusion or reduction of gas oil ratio this
squeeze cementing is carried out to seal all the perforations and
then re-perforate a selected interval.
2. All procedures that of low pressure squeeze cementing are to be
followed for placement of cement slurry against the perforated
interval.
3. In case of good injectivity, squeeze calculated volume of slurry
into the perforations leaving a cement plug inside the casing.
Squeezing to be done by hesitation method, so that final squeeze
pressure is achieved.

4. In case of no injectivity, squeeze cement slurry at the maximum
permissible squeezing pressure and close the well under squeeze
pressure for 4 hours.
10.2.8 MISCONCEPTION IN SQUEEZE CEMENTING
• The cement slurry penetrates the pores of the rock
Only the mix-water and dissolved substances penetrate the pores, while the
solids accumulate at the formation face and form the filter cake. The only way
for slurry to penetrate a formation is through fractures and large holes.
• High pressure is needed to obtain a good squeeze
If the formation fracturing pressure is exceeded, control of the placement of the
slurry is lost and the slurry enters unwanted areas. Once created, a fracture
may extend across various zones, and open unwanted channels of
communications between previously isolated zones. Pressure is of no help to
place the slurry in all the desired location.
• Plugged perforation
It is rare to find all perforations open and producing. Perforations will usually
have some degree of mud fill up, depending on the completion fluid. Mud filter
cake is capable of withstanding high pressure differentials especially in the
direction from the well bore to the formation and the high pressures may create
a fracture before accepting cement filtrate. Many squeeze failure may be
attributed to subsequent clean up of a previously plugged perforation which did
not accept the cement slurry during the squeeze job.
10.3 WELL PLUGGING AND ABANDONMENT

A time comes in the life of every well when it will never be produced
again or it will be uneconomical to continue production. OMR -1984
provide the following guidelines for temporary closure and abandoning
of the well.
10.3.1 GUIDELINES FOR CLOSURE OF PRODUCING WELLS - OMR (OIL
MINES REGULATION ACT -1984, INDIA)
A) Temporary Closure of Producing Well
1. (a) When it is intended to temporarily close any producing well
for a period exceeding 30 days, it shall be filled with mud or
water or oil so that the hydrostatic pressure of the fluid column
over-balances the formation pressure to prevent leakage of
petroleum at the wellhead.

(b)The control valves of the Christmas tree shall be completely
closed and control wheels shall be removed.
2. (a)The Christmas tree shall be examined for leakage once in 30
days by a competent person authorised for the purpose. In case
any leakage is detected during such examination the competent
person shall take immediate steps to stop it.
(b) A report of every such examination shall be recorded in a
bound paged book kept for the purpose and shall be signed and
dated by person making the examination.
B) Plugging requirements for abandoning a well
1. When it is intended to abandon a well -
(a) All permeable formations shall be isolated with cement.
(b) A cement plug of minimum length of 50 metres shall be placed
at the bottom of the well.
(c) A cement plug of a minimum length of 50 metres shall be
placed across the shoes of the surface casing;
(d) The cellar or pit around the well shall be filled up and the land
shall be restored to the original level; and
(e) Cased wells may be abandoned by placing a bridge-plug
above the top of perforations capped with a three meter cement
plug.
2. Every abandoned well shall be clearly identified at site.
10.3.2 OISD Std. 175 “Cementing Operations” provide following procedure for
open and cased hole well abandonment:
A) Open Hole Abandonment
I. Isolation plug: Where there is open hole below the casing, place a
cement plug of 50m in open hole and 50m inside the casing shoe.
II. Tag and test the plug prior to placing subsequent plugs.
III. Surface plug: Place a surface cement plug of 100m inside the
casing between depths of 200 to 300m.
B) Cased Hole Abandonment
I. A hydrocarbon producing zones should be isolated by cement
squeezing and plugging.

II. Last object tested should be squeezed with cement and leave a
cement plug of minimum 150 m above the zone of interest. Tag
the top of plug and test it to 500psi pressure.
III. Plugging of casing stub: If the casing is cut and recovered there by
leaving a stub inside the next larger string, abandonment cement
plug should be set so as to extend a minimum of 50 m above and
50 m below the stub.
IV. Surface Plug: A cement plug of at least 100 m with the top of the
plug 100 to 200m below the surface should be placed in the string.
10.3.3 Other Requirements
A. Casing Cuts
If the casing string is cut and recovered, a cement plug shall be
placed to extend at least 30 metres above and at least 30 metres
below the cut end of the casing string.
B. Behind Casing
• Minimum of 30 metres of good cement in the annulus is
required.
• Cement plugs shall be placed so as to provide a minimum of
30 metres of cement above and a minimum of 30 metres of
cement below any significant oil, gas or fresh water zones.
At least 30 metres of good cement should separate ‘Discrete
Permeable Zones’.
• Where the zones are less than 30 metres apart, then a
column of good cement extending 30m below the base of
the upper zone is sufficient. There should also be cement
extending at least 30 metres above the top of any transition
zone.
C. Where the casing string has been perforated
• A cement plug shall be placed opposite the perforations and
shall extend from at least 30 metres below to 30 metres
above the perforated interval; or
• The perforated interval may be plugged by means of a
cement retainer set in the casing string no more than 45
metres above the top of the perforated interval with a
cement plug extending at least 15 metres above the retainer,

provided the perforated interval is isolated from open hole
below; or
• where a succession of retainers are used to isolate a series of
perforated test intervals, only the topmost retainer need
have a minimum of 15 metres of cement plug placed above
it .
10.4 PRE-JOB SAFETY/ PLANNING MEETING

A pre-job safety/ planning meeting should be held to ensure proper job
layout and placement of cementing equipment following all safety
norms/ procedures.
During a pre-job safety meeting, cementing in-charge must outline the job
procedure, define pressure limits, discuss safety measures and additional
briefing on emergency procedure or any unsafe conditions to all
personnel designated to associate in the job. He should designate the
sequence and volume in which fluid will be pumped and at what
pumping rate and total time involved. Also duties of each person during
cementing job should be clearly defined including equipment operation,
mixing of chemical, operation of valves. He should also review
communication system which plays an important role in monitoring
cementing job execution.
The cementing operational in-charge must supervise line hook up work
and thoroughly inspect prior to testing lines.

10.5.1 DO’S
1) Follow the standardize cementing procedures and established
safety regulations with a view to improve planning, execution
and evaluation areas related to cementing services and to avoid
occurrences of any untoward accident during cementation.
2) Chemist must be present at site for preparing cement slurry of
correct specifications and to monitor the quality the well bore
conditions.
3) Ensure minimum spillage/ wastage of cement slurry during
cementation.

4) Run bare minimum engines during cementing operations as
simultaneous running of all equipment will create high level of
noise pollution.
5) Provide special attention when cementation is being carried out in
night time.
6) Use prescribed personal protective safety kits like overhaul,
hardhats, safety glasses, hard-toed shoes, hand gloves etc.
7) Simultaneous presence of a large crew of different disciplines
makes coordination extremely essential. Entire sequence of
operation should be controlled by cementing operational
in-charge (one single supervisor) to avoid any confusion in
following instructions during cementation.
8) A pre-job safety/ planning meeting should be held to ensure
proper job layout and placement of cementing equipment
following all safety procedures.
9) Mobile cementing equipment positioning should be planned for
quick removal from the work area in case of an emergency. All
vehicles should be placed with cabin facing away from the well
and wooden wedge support should be placed behind wheels to
minimise vibrations and movement of line while pumping
operation.
10) Place cementing pump / bunkers / mobile silos at least 1.5 - 2 m
apart from other cementing vehicles and at least 25 m distance
from the well head.
11) Park all vehicles, which are not required for the job, to safe areas
from the well head so as not to block the well site exits.
12) While hooking high pressure lines from cementing units, avoid
crossing of two discharge lines. Lines should not be run under
cementing trucks. Ensure proper anchoring of high pressure lines
to prevent accident in case of line failure.
13) Use sufficient number of chicksens to provide more flexibility to
discharge lines for reducing vibrations during cementing
operations.
14) Use only high pressure fittings and approved steel pipes which
are in good condition and thoroughly inspected.

15) Cementing heads, manifolds, valves and plugs should be
inspected, cleaned and lubricated prior to hooking up. The
cementing operational in-charge must supervise line hook up
work and thoroughly inspect prior to testing lines.
16) Care should be taken to avoid damage to the threaded pin end
and stopper of cementing head during handling and tightening to
the tubing. Cementing head must be secured to the links by safety
chains.
17) Thread protectors must be used on all exposed male threads of
circulating subs or cementing heads to avoid thread damage.
18) Only steel lines should be used for releasing pressure and
checking back flow from the wells.
19) Cementing head, safety valves and high pressure lines of
cementing units should be checked for operation at stipulated
pressure to ensure operational safety and NDT should be carried
out at an interval of 3 years.
20) High pressure lines should be tested with water at 1.5 times the
maximum pressure expected in pumping operations. The
pressure test will not exceed the safe working pressure of any
equipment
21) Before, testing all persons should be vacated from the vicinity of
high pressure line. No one will be permitted to step across, stand
on or straddle or hammer on any pressurised line.
22) Check all valves in discharge lines to ensure that they are open
before orders are given to start pumping.
23) A pressure-chart to record pumping pressure continuously
should be made available for all cementing jobs. Pressure chart
should be supplemented with pumping sequence volume, time
and rate.
24) Several liquid chemicals and cementing additives used in
cementation can cause safety hazards which needs proper
precautions while handling. During slurry mixing, chemical
preparations, adequate precautions must be taken to avoid
chemical / additive contact with skin, eyes and clothing.

25) When handling cement additives, appropriate safety goggles,
respirators, dust or vapour masks, face shield, rubber gloves,
shoes and hearing protection should be worn.
26) Material safety data sheet should be made available at work-
centre while handling cement additives.
27) After pumping has been completed, all pumps, lines and hoses
should be flushed before rigging down.
28) When transferring or venting material through an open ended
hose, a "T" shall be affixed to the end of the hose to prevent the
hose from whipping around. The end of the hose should be
secured tightly to a stationary object.
29) Proper illumination with adequate flame proof lighting
arrangements should be provided in the operational area
especially at slurry mixing point and additive mixing system to
ensure safe and effective job coordination during night time.
30) Prior to placement of cement slurry, conduct injectivity test
against the squeeze interval to determine if and at what rate
below the fracture gradient fluid can be placed against the
formation.
31) The properties of cement slurry must be tailored according to the
characteristics of the formation to be squeezed, and the technique
to be used.
32) Thickening time must be sufficient to assure slurry placement and
reversing out of the excess.
33) The slurry volume should not exceed the capacity of the running
string and the volume should not be so great as to form a column
that cannot be reversed out.
34) When preparing the slurry, the use of a re-circulating mixer or
batch mixer is strongly recommended because it ensures that the
properties of the slurry pumped in the well are as close as
possible to those of the slurry designed in the laboratory.
35) The general rule is that the cement bond log should not be run
until 48 hrs after the cementation in order to achieve the true
cement bond reading. This again is highly dependent on the
cement type and additives used in the slurry.

36) Field results show that more than 90% of wells exhibit a micro-
annulus on a primary cement job. Always record CBL-VDL
under 700-1000psi pressure to eliminate micro-annulus effect.
37) A squeeze job may appear successful when pressure is applied to
the well bore but may fail to hold back the pressure from the zone
into the casing. The universally recognized technique for
confirming whether the cement in place will hold the formation
fluids under producing conditions consist of applying a negative
differential pressure on the face of the plugged perforations.
10.5.2 DON’T
1) Don’t move out any mobile cementing equipment without
conducting pre-departure checks. Fire extinguishers spark
arrestor in engine's exhaust pipes and a first-aid kit should be
available in all cementing vehicles.
2) Don’t throw down the equipment from rig floor. Transfer
chicksans, high pressure lines, valves, swivels, hoses with end
connections from rig floor to ground by winch line only.
3) Do not suspend discharge lines from cementing head without
safety chains. Inclined or vertical discharge lines should be tied
off to prevent them from being dragged.
4) Don’t start dismantle the line before pressure is released to zero.
Pressurised line should not be hammered. Tightening or
loosening of connections under pressure is strictly prohibited.
5) Do not allow anyone to take up line leakage repair operation until
:
i) Particular well site personnel are notified by the cementing
supervisor with the repair plan
ii) Pressure has been released from the line.
iii) The release valve is left open during repairs.
iv) The flow has stopped from the bleed-off line.
v) The cementing supervisor has personally observed and
determined that the system is free of any pressure.
6) Don’t start pumping while any personnel is working on, above or
below floor level.

7) Don’t place flammable or combustible fluids in open
displacement tanks on cementing equipment.
8) Avoid acid pumping with cementing units. In case it cannot be
avoided, make extra sure that all the valves, caps, lines etc. are
fitted correctly and also the least number of people should be
present in the vicinity. After the job, the cementing unit and the
lines should be washed thoroughly so as to remove even traces of
acid.
9) Surface pumping pressure should not exceed the lowest pressure
rating of the union and / or whatever connections used such as
chicksans, valves, cross-over etc.

CHAPTER- 11
WELL LOGGING AND PERFORATION
11.0 GENERAL
Well logging is a technique to record geophysical properties of rock as a
function of depth. It is accomplished by moving a down hole logging
probe and recording its sensor output at the surface through an electrical
cable. The borehole logging probe or the well logging tool relates to a
particular physical property of the rock and mud system. The well
logging system consists of down hole-logging tool, surface computer
system and wire line cable for transmitting down hole signal to surface
system.
Majority of logs are recorded while pulling the tool upward in the
borehole. The logs are recorded both in the open hole as well as in the
cased hole, though with different objectives. There is a large variety of
logging tools meant for different types of measurements. Generally these
tools are named according to what parameter they measure or to the
physical process involved during their operation e.g. the tool which
measures resistivity of the formation is generally referred to as Resistivity
Tool.
Logging is conducted to locate reservoir rock and to evaluate its viability
as hydrocarbon producer. The most common reservoir rocks are
sandstones (elastic rocks) and limestone and dolomite (carbonate rocks).
The effectiveness of a rock as a commercial hydrocarbon producer
depends upon its following properties:
a) Reservoir properties - Porosity, permeability and fluid saturation,
which help in describing the texture and producibility of reservoir and are
essentially determined for estimation of oil and gas reserves.
b) Physical properties - Electrical resistivity, self-potential (SP),
radioactivity, elastic wave propagation etc. help in describing nature of
rock and its saturating fluids.
The well logging techniques are employed to measure these physical
properties of rocks directly in the borehole. The well log data
interpretation is the methodology to translate in-situ measured physical

properties into reservoir parameters, such as porosity, fluid saturation,
permeability and other geological parameters in a more realistic manner.
During workover operations, logs are recorded in cased hole. Perforation
of the casing is undertaken to connect the well with reservoir. Perforation
is an important activity and involves the risk of blowout and fire.
In this chapter general safety precautions/ recommended practices to be
undertaken during logging and perforation operations are mainly
covered.
11.1 PRE JOB SAFETY MEETING

Prior to commencing well perforation operations, a meeting shall be
held with all workover personnel involved, covering the procedures for
operations , hazards and risk involved. The meeting shall be conducted
by Officer-in-Charge of Logging Team.
11.2 SAFETY GUIDELINES FOR RIG CREW DURING

LOGGING/ PERFORATION OPERATION
1) Ensure that BOP is pressure tested above the expected surface
pressure.
2) No welding job should be carried out during perforation job.
3) There should not be any fire /flame producing devices near cat
walk.
4) Wireless set should be switched off, radio room must be locked.
Even mobile phones are to be switched off.
5) Any high tension line (over/under ground) in the vicinity of the
catwalk should be disconnected and ends should be insulated.
6) Pipe line with cathodic protection should be switched off.
7) Any electrical rig wiring which can make contact with the unit,
cable or explosive device should be removed before perforation
job.
8) A copy of electrical layout plan and communication network plan
should be briefed to logging engineer.
9) Derrick floor, cat walk and unit parking place should be cleared
for safe handling of explosive devices.
10) Logging unit parking place should be at a distance of thirty meter
plus from the well head.

11) No unauthorized person should be allowed in the vicinity of
thirty meters of working area.
12) No heavy equipment like crane, tractor should be allowed to
operate in the drill site area while logging.
13) No movement of tubular should be done during logging. BOP
must not be operated during logging.
14) Intimation of logging jobs involving explosives should be given
24 hours in advance to make proper arrangements.
15) Special care should be taken to avoid accidental firing of tool at
the surface when a failed ‘Tubing Conveyed Perforation’ tool is
pulled out to the surface.
16) A double ram i.e. a set of blind and pipe rams, preventer should
be installed and tested to the expected bottom hole pressure. In
addition, a master gate valve with tubing head and a short length
of tubing should be pre-assembled and kept readily available at
the site so that it can be used to control the well in case any sign of
activity in the well is noticed after perforation and while running
in tubing.
17) The blow-out preventer should be equipped for remote operation
with the hydraulic control unit located at a distance of not less
than 10 metres from the well.
18) When perforation is being done through the tubing, a wire line
blowout preventer should also be installed so that in case of a
kick, the well can be closed with the perforated wireline tool in
the hole, otherwise it may have to be snapped and allowed to
drop in the well if the wire line tool is not pulled out of the hole in
time. The master gate valve can be operated to close the well.
19) Before commencement of perforation operations, it should be
seen that :
I. The well is filled with mud or other suitable workover/
completion fluid up to such a level as to over balance the
expected bottom hole pressure.
II. The blowout prevention equipment is function and pressure
tested and is in safe working order.
III. The perforation gun can be safely lowered down the hole.

IV. In case of through - tubing perforation, a lubricator, duly
pressure tested, is installed. It should be provided with a
valve to release pressure before disconnection.
V. The Insulation resistance of the electro-logging cable is not
less than one mega ohm. After the check, the cable should
be shorted otherwise residual electric charges may detonate
the explosives
VI. Every person employed on a perforation job must have a
clear understanding of the warnings sign of a kick and be
able to operate the controls for blowout prevention.
VII. Standing orders are framed specifying the action to be taken
as soon as a kick is detected and the duties of each person
employed in the perforation job and the instructions are
clearly understood by all concerned for prompt action in
case of emergency.
11.3 GENERAL SAFETY PRECAUTIONS DURING

PERFORATION
1) Explosives used in well perforation shall be transported in
suitable containers.
2) No person other than a competent person authorised for the
purpose shall handle, transport and use explosives meant for well
perforation.
3) Well perforation operation shall be carried out under the direct
personnel supervision of the official authorized for the purpose.
4) Perforation should not be carried out during night hours or under
conditions of thunder, lightning, heavy rains.
5) At the well site, all operations not directly connected with
perforation, should be kept suspended till the perforation job is
satisfactorily completed.
6) All equipment including rig used for perforation should be
efficiently earthed and electric bonding should be established
between the equipment and well head before connecting
explosive charges.
7) Clear every one out of unit. No one be allowed to enter the
logging unit till the explosive device is lowered in the well.

8) Check again the voltage in casing to rig voltage monitor. It
should be less than 0.25 volt.
9) Clear all non essential personnel. Bring the explosive device/
charged gun at CAT-WALK. Keep every one else out of line of
fire.
10) Persons not directly connected with perforation job should
remain at a safe distance not less than 30 metres from the well. An
area within 30 metres of the well should be demarcated as danger
zone in which no smoking or open fire should be permitted and
all electric installations should be de-energised.
11) Effective means of communications between the derrick floor and
perforation unit should be provided.
12) Adequate number of self contained portable hand lamps of
approved type should be kept available for use in emergency.
13) Explosives should be primed with detonators only at the well site
and the place should be clean, dry and free from flammable
materials. It should also be ensured that there is no danger due to
falling material.
14) Explosives should not be primed under conditions of lightning
and thunder.
15) The explosives should be suitable for the temperature conditions
expected at the bottom of the hole.
16) Precaution against sources of stray current should be taken.
17) There should be no radiophone transmitter in operation when
perforation job is in progress. The perforating company should
provide appropriate warning signs. Such signs should be
conspicuously placed at the entrance(s) to worksite(s), near the
site of operation where perforation is being done.
18) Upon completion of perforation operation, the work area should
be inspected and all explosive material and scraps should be
placed in approved containers for removal from the site by
Service Company employees.
19) Whenever there is uncertainty of formation pressure and it is
expected that the gas may be present in the formation with oil
then one of the following recommendation should be followed.

a. Use lubricator/shooting nipple with wire line BOP when
normal perforation is planned.
b. Use of through tubing perforation technique
c. Use of tubing conveyed perforation technique
d. Use dual gradient fluid i.e. brine against the perforation zone
and mud or heavier fluid at top to ensure adequate
hydrostatic head to balance the formation pressure.

Safety guidelines for rig crew and general safety precautions during
perforation covered in Para 11.2 and 11.3 above should be read/ followed
as Do’s and Don’ts of ‘ Well Logging and Perforation’

CHAPTER – 12
WELL TESTING AND COMPLETIONS
12.0 GENERAL
Subsequent to drilling of a well to its target depth, the open hole is logged
and based on the log interpretation, the prospective layers/ intervals are
identified for testing. Accordingly, the open hole is first cased and
cemented. Well is then temporarily completed with down hole
completion string and surface well control & testing equipments so that
the well can be safely flowed back & tested to ascertain its reservoir
potential. The entire gamut of above operations is known as Well
Completion & Testing.
Well testing is the first major activity to be undertaken after drilling a well
in a field. Once well is drilled, it is so completed that the well can produce
oil/gas safely. Based on the data collected during the test, a reservoir
model is created which is then used to formulate the field development
strategy. The main objectives of well testing operations are to: -
1. Identify produced fluids and determine their respective ratios
2. Measure reservoir pressure & temperature
3. Determine well productivity
4. Obtain samples for analysis
5. Evaluate reservoir parameters
6. Estimate completion efficiency
12.1 STEPS IN WELL TEST PROGRAMME

The well testing operations commence after a well has been drilled to
target depth, logged, cased and cemented. After the well is cleaned and
scraped to the required depth, CBL-VDL log is recorded. In case, the
cement bondage is good then the well testing operations commence. The
major stages of a well test programme are:
• Hermetical testing of production casing and/or liner

• Perforation of prospective zone / layer to be tested.
• Testing of perforated interval involving following operations:
9 Temporary completion of well with down hole production
string
9 Installation of surface equipment set-up and its pressure
testing
9 Activation of the zone
9 Initial Flow for well cleaning
9 Reservoir Studies- Flow, Build-up, Gradient Survey, PVT
sampling etc.
9 Killing/ Subduing the well
9 Isolation of the zone tested
All the prospective layers identified in a well are tested one by one from
bottom to top. Subsequent to testing of all the prospective zones, the well
is completed in the best oil & gas producing layer for taking production
from that well.
12.1.1 HERMETICAL TESTING
The hermetical test is carried out to ensure the hermeticity or complete
sealing of production casing and / or liner to pressures exerted on it from
either inside of well or from reservoir side. The casing head and
production casing and/or liner should be pressure tested separately to
the maximum expected surface pressure during testing/ production.
The annular space between two consecutive casings should be connected
to a valve. It should not be plugged otherwise the casing may be
subjected to a pressure higher than the intended. The valves should be
tested to working pressure.
X-mas tree assembly should be complete in all respects as per
recommendations of the manufacturer. Pressure gauges with suitable
cocks should be installed for release of pressure during the test.
Every well head assembly should be provided with suitable arrangement
for recording tubing and annulus pressure.
The procedure for carrying out the hermetical test is as follows:
1. A tubing string with / without scraper is run to the bottom.

2. The drilling mud is displaced with water and thorough circulation is
carried out to ensure that the entire drilling fluid has been displaced
with clean water.
3. Negative test: The well is kept under observation for 1 hr to ensure
that there is no activity / flow back of water from the well thereby
indicating that the production casing / liner is hermetical to
formation pressures from behind it.
Initially there will be some flow back owing to thermal gradients
which should not be concluded as failure of negative test. As cold
water attains thermal equilibrium with the temperatures inside the
well (approximately in ½ hr), the flow stops provided the
production casing is hermetical.
Also, in case the hydrostatic head of water inside the casing is more
than the reservoir pressure then some of the water inside the well
needs to be knocked out using compressor and / or nitrogen to
create pressure differential across the casing for the negative test.
4. Positive test: In case the negative test is satisfactory then the well is
filled with clean water up to the surface. The pipe rams are closed on
the string.
A pressure equivalent to maximum expected surface pressure
during testing which will be equal to higher of shut-in tubing head
pressure assuming well flows only dry gas or maximum expected
surface pressure of nitrogen during activation or pressure required
to hydrostatically fire TCP guns is applied on casing through tubing.
The pressure is normally applied in stages / increments of 500 psi
initially up to 3000 psi and then in increments of 200 psi and held for
2 minutes to observe for any pressure drop. The pressure is held for
15 minutes at the final hermetical test pressure.
All the annular valves should be kept open during positive test and
any activity / flow from them should be closely monitored.
Since hermetical testing involves application of high pressures, it
must be ensured that:
• All the lines being subjected to pressure are properly secured /
anchored.
• Unnecessary personnel are removed /restricted from the area.

• People are made aware that pressure-testing operations are in
progress.
5. Subsequent to successful hermetical test, the well volume water is
displaced with drilling mud or solid-free completion fluid such as
brine of requisite specific gravity and the same is thoroughly
circulated & conditioned prior to pulling out the tubing string.
Now, the well is ready for perforation.
12.1.2 PERFORATION OF ZONE
The casing in the well is perforated by firing explosive charges at
appropriate horizon by means of a perforation gun, so that oil under
reservoir pressure can flow through the perforations into the well and
then to surface. Various perforation techniques are available such as:
(a) Conventional Perforation: Perforation guns are conveyed on wire line.
Use of conventional guns results in overbalanced perforation.
(b) Through Tubing Perforation (TTP): The formation is perforated using a
string of individually sealed explosive capsules that are lowered in to the
well on wire line through tubing. TTP can be employed for both
underbalanced and overbalanced perforation.
(c) Tubing Conveyed Perforation (TCP): In this technique, the guns are
lowered in to the well as the lower most assembly of completion /
production string. Both Overbalanced and under balanced perforations
are possible.
During perforation, the hazard is that of blow out if the formation fluids
entering the well are not kept under control. Hazards due to use of
explosives and danger of fire also exist.
Recommended safe practices during perforation, as covered in ‘Chapter–
11’ of this manual, should strictly be followed.
12.1.3 COMPLETION
A well completion is nothing but an arrangement that allows the well to
produce oil and gas from the reservoir to surface in an efficient and safe
manner.
The completion basically consists of:
¾ Bottom hole equipment to provide communication between
producing formation and well.

¾ Tubular and accessories to provide a means for the produced fluids
to flow from bottom to surface
¾ Well head equipment for control and monitoring of the produced
fluids.
The cased hole perforated completions that are mostly in vogue in
onshore are as follows:
9 Open end tubing
9 Packer & tubing
9 Packer, tubing & Gas Lift valves
9 Sucker rod completions
9 ESP completions
General Guidelines while running-in completion string:
1. Preparation of accurate tubing tally to ensure that tubing shoe is
above the perforations and packer/ other down hole completion
equipment are at desired depths.
2. Packer to be placed approximately 10 m above the top perforation.
3. All tubing & equipment to be properly go-gauged to ensure smooth
running of through tubing tools such as TTP guns, CTU etc, if
required subsequently.
4. Preparation of completion string diagram indicating the dimensions
and end connections of all downhole tools and cross overs used in
the string & their depths.
5. Use of minimum thread dope.
6. Application of optimum torque while making-up tubing.
7. X-mas tree assembly should be tested to a pressure equal to 1 ½

times the maximum expected surface pressure before installation as
well as prior to activation of well.
12.1.4 ACTIVATION OF WELLS
After a well is perforated and completion string lowered, well is activated
to induce flow of formation fluids into the well bore. In the process, the
hydrostatic head in the well is gradually reduced either by displacing the
column of fluids in the well with lighter fluid or by creating pressure
surges through injection of compressed air/ high pressure nitrogen gas or
by swabbing operation. Through this process, the hydrostatic head in the

well is gradually reduced thereby inducing the flow of formation fluids in
to the well bore and then into the production string to the surface.
A. Injection of compressed air down the annulus in wells completed
with open end tubing / packer & GLV.
In this technique, air is applied through mobile compressor in the
annulus i.e. space between tubing string and production casing which
by its pressure displaces fluid as well as mingles with tubing fluid
thereby reducing its head. In case required, prevailing pressure in the
annulus is reduced through a bean to induce formation fluids into the
well.
The maximum air pressure that can be applied is restricted to 200 ksc
(maximum capacity of available compressor) and the method is not
suitable for deeper wells or in wells requiring draw downs higher than
200 ksc.
B. Injection of nitrogen gas at high pressure down the annulus in wells
completed with open end tubing / tubing through CTU in wells
completed with packer.
In this method, nitrogen is applied in place of air and the same is
pumped through annulus in case of open tubing completion or
through CTU in wells with packer completion.
Higher draw down can be applied to the formation while activating the
well by applying nitrogen.
C. Swabbing Operation
As swabbing operation provides draw down to the formation, the
main hazard is a gas kick or blow out unless formation fluids entering
the well are kept under control. Therefore, swabbing should not be
attempted in gas wells. The other hazards are;
a. Fire, because gas is liberated during the operation particularly at
the point where the swab rod enters the X-mas tree valves
assembly.
b. Over winding, in which case the swab rod may hit the crown
block, snap and crash on derrick floor.
12.1.5 TESTING OF WELLS
All well test jobs are required to be planned and performed with major
emphasis on safety and environmental protection. This is most essential
since exploratory well testing operations are almost always carried out

under conditions of unknown pressures and temperatures with well
flowing highly inflammable and sometimes corrosive and poisonous/
toxic fluids.
After the well is perforated, temporarily completed for initial testing and
activated, the flow of formation fluids from well is initially led through a
bean in the flow line to an open pit. The bean regulates the flow and
pressure of formation fluids.
The well is flown for cleaning to eliminate all foreign fluids such as mud,
filtrate and completion fluids contained in the invaded zone and well bore
so that representative reservoir fluids are produced during test. The
following criteria are generally used to conclude that the well has
cleaned-up;
¾ Basic sediments and water (BS &W) are less than 1 percent.
¾ Flowing Tubing Head Pressure (FTHP) is constant.
¾ In case the well is flowing water along with oil & gas, then water
percentage and salinity are constant.
Once the well is cleaned up and start flowing clean oil & gas, the flow is
diverted through mobile test separator where oil & gas phases get
separated. The gas is diverted to the flare line and burnt. The oil, after
measurement of its rate, gets discharged into a tank.
Reservoir studies are performed by flowing the well through various
chokes and recording of flow rates and bottom hole flowing pressures,
Build-up studies, gradient survey, PVT sample collection etc.
Once testing of the zone is over, well is suitably completed or else killing/
subduing of the well is undertaken to isolate the tested zone and to
prepare the well for testing next zone. Well may require to be prepared
for abandonment after all the identified zones are conclusively tested.

During Compressor Application
1) The compressors should be located at a distance not less than 30
meters from the wellhead on the upwind side preferably.
2) An area within 30 meters of the wellhead should be treated as
danger zone in which no smoking or open flame should be
permitted and all electrical equipment should be de-energized.
3) Adequate arrangements for fire fighting should be made.

4) During the operation, a close watch should be maintained at the
pit or tank for fluids flowing out of the well. If there is any
indication of flow of fluids, the compressor should be stopped
and the well should be allowed to flow through a proper choke to
ensure controlled flow of fluids. If the bean is to be changed, the
pressure in the line should be released through the bleeding
valve.
5) The annulus pressure should be reduced gradually through a
bean otherwise a large volume of formation fluid may enter the
well and gush out of it.
6) In case of any interruption in injection of compressed air, the well
should be closed immediately.
7) The compressor discharge line should be provided with a gate
valve and also a non-return valve on upstream side to prevent
back flow of fluids from the well into the compressor. A pressure
gauge should also be provided on the discharge line. The line
should be securely anchored to the ground.
8) Before commencement of operation, it should be ensured that:
a) The safety valve of the compressor is in good working
order and it should be set to open at a pressure not
exceeding 10% of the maximum allowable working
pressure.
b) The discharge pipeline should be pressure tested to 1-
1/2 times the working pressure. The joints and
hammer union should not be opened or tightened
unless the pressure in the line is released.
During Handling of Nitrogen
9) Liquid nitrogen is stored at – 1950 C and requires extreme care in
handling it.
10) Frosted line should not be touched with bare hand.
11) Persons engaged in handling liquid nitrogen should be imparted
clear instructions in safe handling of nitrogen.
During Swabbing Operation
12) The operations should be carried out during day light hours.

13) An area within 30 meters of the well should be treated danger
zone in which no smoking or open flame should be permitted and
all electrical equipments should be de-energised.
14) While swabbing operation is being conducted, all engines, motors
and any other possible sources of ignition not essential to the
operation should be shut down.
15) The swabbing unit should be positioned upwind of any swab
tanks or pit, if feasible.
16) When swabbing is done through the Christmas - tree assembly,
wire line blow out preventer and an oil saver should be used at
the top to control the flow of fluids.
17) The valve assembly and flow lines should be checked carefully for
any leakage.
18) The swab rod should be run in or pulled out at a steady rate so as
to avoid pressure surges.
19) If during swabbing there is any indication of a kick, immediate
steps should be taken to keep the well under control.
20) Diesel engines, if in use, should be located outside the danger
zone on the upwind side.
21) At the point where the swab rod enters the valve assembly, a
guide/spool with inner lines of non sparking material should be
provided to prevent frictional spark. Gas may be liberated at the
point where the swab comes out of the valve and any frictional
spark produced at such a point may cause ignition of gas.
22) When the swab is being run in or pulled out, all persons should
remain at a safe distance from the well head because any
interruption may throw slack on the line and cause serious injury
to persons.
23) Suitable roller guides should be provided to ensure that the wire
rope coils or uncoils on the Winch drum uniformly without any
overlap.
24) If during pulling out the swab rod, the engine or the winch stops
due to any reason, immediate steps should be taken to keep the
well under control till the defect is rectified.

25) Adequate arrangements for fire fighting should be made and it
should be ensured that the persons are conversant with the use of
fire extinguishers.
During Well Testing
26) The separator should be located at a distance of not less than 10
metres from the well head.
27) The safety relief valve of the separator should be checked to
ensure that it is in a good working order.
28) The pipe line should be laid straight without any bends as far as
possible.
29) The open pit and flare should be located at a distance not less
than 45 metres from the well head.
30) An area within 30 meters of the well should be marked as danger
zone with proper warning signs at prominent places.
31) In the danger zone, no smoking or open flame should be
permitted; entry of unauthorised persons should be checked and
all electrical equipment(s) should be de-energised.
32) Testing of the well should be done during day - light hours, since
at night gases may settle near ground level and cause danger of
flash/ cloud fire. Flare should be lighted to burn the gases.
33) Adequate fire fighting arrangements should be made. It should be
ensured that persons deployed for well testing are conversant
with the use of fire extinguishers.
34) Before the gate valve of the well is opened, all persons should be
withdrawn to safety. The valve should be opened fully,
otherwise it may get damaged due to throttling and may leak
thereafter.
35) The layout of PTS (Production Testing Surface) equipment varies
considerably depending on the availability of space, environment,
well conditions and test objectives. However, safe conduct of
testing operations is a major factor and some of the considerations
that govern layout of PTS equipments in achieving this objective
are: -
a) Equipment layout and spacing must be in accordance
with classified zones.

b) All the PTS equipments must be properly grounded.
c) Piping used must be properly anchored.
d) Piping must be colour coded to identify the working
pressure of the pipe as well as identify the fluid flowing
through it.
e) The dominant wind direction must be identified to
properly orient equipment that vents or burns gas.
36) All the personnel must be well trained for the job. A perfect
understanding of all the operations, possible hazards, a
contingency plan is most essential and these procedures must be
discussed with all the concerned personnel before the job.
37) All equipments, downhole & surface, must be specifically
designed, manufactured, maintained & tested for the job.
38) The testing operation must be carried out as per the prevalent
applicable safety standards.
39) Advanced planning for safe well test operations must be done
taking in to consideration the various safety hazards, anticipated
pressures & temperatures, expected formation fluids, likely
production of H2S, CO2 & sand, need for special chemicals for
hydrate control, paraffin deposition control etc.
40) Appropriate distances between the various pieces of equipment
must be maintained as per recommended practices.
41) It must be ensured that the various responsibilities of the crew
members are clearly defined prior to the onset of operations and
the crew is aware/ conversant with their respective
responsibilities.
42) The onsite safety meetings with rig & test crews must be held to
review all operational steps, potential safety hazards etc.
43) Adequate number of self contained portable hand lamps of
approved type should be kept available at the site for use in case
of emergency.
44) All personnel must be made familiar with emergency procedures,
including fire drills, H2S drills etc.
45) Appropriate safety equipments such as safety boots, gloves, hard
hat and harness (when working at heights) must be worn.

46) Pressure tests must be performed only after all the equipments
have been connected. During pressure testing of the equipments,
it must be ensured that:
i. Unnecessary personnel are removed /restricted from the
area.
ii. People are made aware that pressure-testing operations
are in progress.
iii. All flow lines and relief lines are properly secured.
iv. Pressure tests are carried out using only water as testing
medium.
v. The entire system is flushed rapidly to eliminate trapped
air/ gas in high spots/ elbows.

CHAPTER – 13
WIRELINE OPERATIONS
13.0 GENERAL
Wireline is the oldest and most common type of well servicing method. It
is extremely efficient, economical and relatively easy to deploy and rig up.
Slickline is used to conduct mechanical operations utilising wire line tools
for various operations viz. tubing gauging; depth determination; pressure
and temperature surveys; bailing; paraffin cutting; to set & retrieve
chokes, circulating plugs; installing flow controls devices, safety valves
and gas lift valves; setting bridge plugs & packers etc.
The slickline unit can also be rigged up with stranded/ braided line for
heavy duty wireline operations such as swabbing, fishing operations.
13.1 WIRELINE EQUIPMENT AND TOOLS
13.1.1 WIRELINE SURFACE EQUIPMENTS
The truck with wire line winches is the primary transport vehicle for
wireline land operations. The surface equipment required to perform a
wireline operation depends largely on the well pressure, well depth and
tubing size.
A. Wireline
As the well depth increases, heavier loads are experienced on the
measuring line. The most commonly used diameter sizes of solid high
strength steel wireline are 0.066, 0.072, 0.082, 0.092, 0.105, 0.108 and 0.125
inch. Measuring lines are available in standard lengths of 10,000, 12,000,
15,000, 18,000, 20,000 and 25,000 feet.
When corrosive environment is likely to be encountered in a well, wire &
other tools made of type 316 stainless steel is recommended because of its
resistance to hydrogen embrittlement.
Stranded line is commonly used when added strength is required. This
line is available in the sizes; 1/8 inch (0.125), 9/64 inch (0.141), 5/32 inch
(0.156), 3/16 inch (0.187), ¼ inch (0.250), and 5/16 inch (0.312).

Precautions in Wireline Handling
1. Proper transfer of measuring line from shipping spool to the reel for
extending the performance and service life of the line. Improper
winding causes reverse bending of the line, making the line more
difficult to handle, and causing it to kink and tangle.
Best results are obtained when both spool and reel are mounted on
horizontal shafts and spaced far enough apart to make level winding
easier.
2. Avoid gripping the line with tools, such as pliers or hardened jaws.
Nicking or gouging the surface of the wire can cause failure when the
line is subjected to tensile and bending stresses.
3. Uncontrolled slack and resultant kinking must be avoided.
4. When retrieving the line from the well, clean the line of well fluids and
give it a protective coat of oil as it is reeled on to the drum.
5. Do not pull a line beyond its elastic limit.
6. Before commencing the wireline job or at frequent intervals during
extended work periods, cut 15 to 20 ft. of line off the spool and tie
another Knot.
Ways of Detecting Bad line are:
1. When a line is laid out on the ground and does not form a coil or loop
as on the drum. This indicates the line has exceeded its elastic limit and
is considered a “dead line”
2. When tying a knot, the wireline breaks easily. Remove a few feet of line
and tie a new knot.
3. When kinks will not straighten out. This indicates the line has been
subjected to extreme tensions or stress. Change the wireline.
B Measuring Devices
In order to perform the wireline operations efficiently and safely, operator
uses measuring device to know the exact location of the tool so as to
control the speed while retrieving the wireline tools from the well and
thus avoid any damage by way of hitting the tool at the wellhead.

C. Weight Indicators
Various types of weight indicators (mechanical, hydraulic and electronic)
are used to know the load on the measuring line and to ensure that wire
line does not exceed the maximum safe load.
D. Reel Systems
Wireline reel is a spool of sufficient size to accommodate the required
length of line to perform the job. Double drum wireline units (two reels)
are used on most of the wireline jobs. One is for routine wireline job and
has 20000 ft. of 0.082 / 0.092 inch diameter solid line. On the other reel is
approximately 20,000 ft. of 3/16 inch stranded line that is used for heavy
wireline job such as swabbing or fishing operations.
E. Floor Block Or Pulleys
When the wireline is routed from the reel to the stuffing-box
sheave, conditions may require changing the direction of the line
several times. Floor blocks or pulleys with sheaves, properly
sized to prevent over stress in bending are used for this purpose.
F. Stuffing Boxes
Wireline stuffing boxes are used to perform work on a live well. The
stuffing box is so designed with suitable packing to minimize leakage
around the line resulting from the well pressure. The stuffing box
provides a swivel bracket and sheave that guides the measuring line
down into the packing gland.
G. Lubricators
A lubricator is made up of number of tubular sections assembled together
with a stuffing box to pack off the wireline on top. The lubricator is first
made up at ground / rig floor and then erected vertically with quick
unions above the wireline valve. The size and length of the pipe
assembled must accommodate the working tools and have a working
pressure rating equal to or higher than the string of pipe through which
the tools are lowered.

H. Wireline Valves
Wireline valve/ Blowout Preventer is a ram-equipped device installed at
the surface to prevent and control unwanted flow of fluids. The wireline
valve is a means of isolating the well pressure from the lubricator without
cutting and damaging the line.
I. Line Wipers
Line wipers are used during retrieving the wireline from a well for
effective cleaning the line at the wellhead. The fluid clinging to the line
drips or thrown off the floor blocks and pulleys, creating safety,
maintenance and housekeeping problems.
J. Gin Poles Or Mast
When it is necessary to use tall high-pressure lubricators to accommodate
long and heavy tool string, removing and replacing the lubricator off and
on the wellhead is a problem. A stiff leg with a block and tackle, electric
hoist or mast type structure is sometimes used to handle the lubricator.
13.1.2 WIRELINE TOOL STRINGS & SERVICE TOOLS
A. Wireline Socket
The wireline (rope) socket fastens the wire to the tool string. In wire line
operations one must know the knot – tying techniques and the knot
fastening the wire to the disc must be tied carefully.
B. Wireline Stem (Weight Bars)
The stem provides the weight to run the wireline tool string into the well
as well as adds weight in jarring operations. The stems are made by using
good grade steel tubes and filling them with lead. A stem is essentially a
round rod with a pin connection and fishing neck at the upper end and a
box connection at the lower end. Stems are available in various diameters
such as 3 /4”, 1 ¼”, 1 ½” and 1 ¾”, usually made in 2 ft., 3 ft, or 5 ft.
length.
C. Knuckle Joint
The knuckle joint is almost similar to the stem but has a ball swivel in its
mid section. It provides flexibility in the string of tools to facilitate taking
hold of various tools and also to enable the tools to pass through crooked
tubing.

D. Wireline Jars
The purpose of wireline jars is to provide a means of striking the wirleline
tools when they are in the well. The striking force can be either up or
down. The jars are available in various sizes and strokes. Most commonly
available jars are stroke jars, tubular jars and hydraulic jars.
E. Tubing Conditioning Tools
Large variety of tubing conditioning tools are available in the market used
for different purposes namely Tubing Gauge, Paraffin scratcher , Tubing
swage, Impression Block, Locator Tools, Bailer, Wireline Spear, Magnetic
Fishing Tool, Kick over Tool, Cutter Bar, Wireline Cutter, Shifting or
Positioning Tools, Tubing and casing Caliper, Bottom Hole Pressure
Gauge , Choke Extractor, Tubing Perforator etc.
13.1.3 SUBSURFACE COMPLETION EQUIPMENTS
A. Landing Nipple
A landing nipple is a short tubular nipple with tubing threads that is run in
the well on tubing string to a predetermined depth. Landing nipples are
internally machined to receive a locking device that has a precision-machined
profile that locks a production control in the tubing string.
B. Polished Nipples
A polished nipple is a short tubular structure of the same materials as the
landing nipple. A polished nipple does not contain locking recesses, but is
machined and internally honed to receive a sealing section
C. Flow Couplings
A flow coupling is tubular in construction, normally 2 to 4 ft long and usually
made of high-grade alloy steel. The flow coupling is machined with
coupling-size outside dimensions and full tubing inside dimensions that
furnish a greater wall thickness as protection against possible internal erosion
and corrosion. Flow couplings are positioned immediately above and, on
some occasions, below a landing nipple designed to receive production
control equipment such as a tubing safety valve, bottom-hole regulator,
bottom-hole choke etc.
D. Blast Nipples & Joints
They are constructed of various types of materials, with external and internal
dimensions similar to those of flow couplings.

Blast joints are usually manufactured in lengths of 10, 20, and 30 ft, and
are run in the tubing string and positioned opposite perforated intervals
in multiple completions. This gives added protection against erosion
resulting from jetting actions of producing perforations.
E. Equalizing Subs
Equalizing subs provide a means of equalizing differential across
subsurface controls prior to reopening or retrieving them from the tubing
string. .
F. Safety Valves
Safety valves are designed to automatically shut in the flow of a well in
the event of surface controls failure or surface equipment get damaged.
The surface controlled subsurface safety valve (SCSSV) is a device which
shuts off well flow in response to a manual or automatic signal from a
surface source. A certain amount of pressure is applied at the control
source to keep the valve open. The valves are either tubing retrievable or
wireline retrievable.
G. Standing Valves & Tubing Stops
Standing valves are used mostly in intermitting gas lift wells to contain
fluid in the tubing string during an injection cycle. Standing valves can be
set in landing nipples, pump seating nipples, and on tubing ID locking
devices.
13.1.4 TOOLS FOR TYPICAL WIRELINE OPERATIONS
Wireline operations are being carried out with the use of running tools,
pulling tools in conjunction with various devices.
A. Running Tools
There are various types of running tools available in market and each has
different function such as to run and set slip type lock mandrel, to place a
collar lock mandrel, to set a tubing collar stop, to run and set slip type
locks, some collar stops and circulating devices etc.
Some running tools perform both functions of setting and releasing from
the lock and mandrel.
B. Pulling Tools
The tools are more or less universal in design, and all have virtually the
same principle of operation. Tools are used to pull locks that have outside
pulling flanges. The engaging dogs of these tools are designed to latch

the pulling flange of the lock mandrel, with matching bevels to ensure
firm contact. These pulling tools are designed to be released from the
pulling flange, should the device be stuck, by shearing a pin in the upper
part of the tool.
Tools to engage internal pulling necks are equipped with a set of spring
loaded dogs that retract on a tapered inner mandrel as the tools are set
down on a lock mandrel, and are forced downward by the spring out into
a groove at the top of the mandrel. These tools are also equipped with a
shear pin that requires downward driving action to shear which allows
the dogs to move back up on the inner mandrel and release from the
pulling neck of the lock mandrel.
C. Positioning/ Shifting Tools
Sliding sleeves are designed to be operated from the closed position to the
open position or vice versa using wireline methods. The tools used to
perform these operations are referred to as positioning or shifting tools.
D. Tubing Conditioning Tools
Tubing conditioning tools are run before installation of any subsurface
flow control devices in the tubing to ensure that the control device will
pass uninterrupted to the desired depth. Normally, a tubing gauge is
recommended to be run to make this determination. In case this tool finds
any obstruction in the tubing, an impression block is run to know the type
of obstruction and accordingly steps to be taken to remove the object. In
case of paraffin deposition along with the wall of tubing, paraffin
scratcher or gauge cutter are used to remove the deposits and obstruction.
Oil and gas production may be interrupted by sand deposition in the well
bore, which almost sometimes completely plug off flow. Such sand plug
can safely be removed with sand bailers to be operated by wireline
methods.
13.2 WIRELINE JOB PLANNING / OPERATING PRACTICES

For any wireline operation the following factors should be taken into
consideration in planning/ before performing a job:
a) Due consideration should be given to following points at
planning stage
• Set flow control equipment below paraffin line, if possible.
• Annular fluid weight: If tubing is plugged and pressure bled to
zero, differential may collapse tubing.

• Temperature: Flow control equipment should be set deep enough
to prevent freezing due to pressure drop through bottomhole
choke or regulator, etc.
• Space limitations: Vertical or Arial
• Surface controlled subsurface safety valves (SCSSV), if any,
should be temporarily placed out of service before performing
any wireline work.
• Sour & corrosive environment.
• Status & Record of sub-surface completion, drift diameter of
tubing string, drift diameter through packer bore, christmas tree
assembly, hanger flange and through other sub-surface
completion equipment (if any).
b) Well survey
• A dummy wireline operation should be made up to the planned
operating depth to ensure absence of any restriction.
• In case of gas lift wells, injection of gas should be stopped during
running in/ pulling out of any wireline tool.
• Nominal internal diameter of tubing, christmas tree, tubing
hanger, packers, packer stringers etc., should be checked for full
or compatible bores and proper bevel on inside.
• Packer and stringer bores restrictions may often necessitate
changing internal diameter of landing nipple and other
completion equipment.
• Blast joint bores may be restrictive and should be considered in
multiple combination tubing string wells.
c) Crooked tubing or deviated hole
• Selection of wireline service tools is affected by deviated holes or
severely crooked tubing strings. If this is anticipated, landing
nipples should be placed higher in the tubing string than normal
in order to service them properly and safely.
• In highly deviated shallow wells or slightly deviated deep wells,
substantial friction drag can occur. The overall effect of friction
will greatly limit the jarring action of the wireline tools.

• In a highly deviated hole, care should be taken when working
out of the end of the tubing.
d) Wellhead pressure
All wireline tools/equipment should be rated to handle maximum
anticipated well head pressure.
e) Support facilities
Appropriate crane service or suitable and properly anchored gin
pole should be made available at site for erecting and dismantling
the lubricator assembly.
f) Timing for wireline operation
Wireline operations should be planned in such a way that it shall be
completed in daylight itself. However, if it is to be continued
beyond day light hours sufficient illumination facilities should be
ensured at operating areas.
g) Logistics and considerations
In remote location (i.e. in offshore/desert locations) provision for
additional or back up equipment/tools should be made to avoid
waiting.
h) Sand production history:
Sand hinders wireline-servicing severely. Due care should be taken
prior to and while performing any wireline jobs in sand producing
wells.
i) Deviated wells:
In a deviated well provision of knuckle joint or similar flexible joints
should be made to provide flexibility in the string of wireline tools
to facilitate smooth running-in/ pulling out operation inside the
tubing string.
j) Wireline unit, Equipment and Tools:
• Wireline unit must be securely anchored before starting
operations.
• Wireline equipment and tools must be checked to ensure that the
following items are included:
− Necessary fishing tools to recover any tools that may be lost
in the hole during operation.

− Wireline blow-out preventer [BOP]
− Adequate length of lubricator assembly to accommodate all
tools (including fishing tools) on a trip, and of adequate
pressure rating to withstand maximum anticipated well
pressure.
− Stuffing box.
− Weight indicator.
− Odometer [depth counter]
− Jars
− Appropriate knuckle joints to ensure flexibility of the work
string in deviated holes.
k) Before starting of the job and during operations, following points
should be taken into consideration
• After installing wireline valve (BOP) and lubricator, testing of
the lubricator should be done to the maximum anticipated well
pressure.
• In case the well pressure is not available at well head, (in case
of a plug tubing or subdued well conditions) testing of
lubricator and BOP assembly should be done up to anticipated
wellhead pressure by external means.
• Wireline valve, blow-out preventer, lubricator, stuffing box,
depth-o-meter and weight indicator must be in good operating
condition at all times. Failure of any item that could adversely
affect the operations should be corrected before proceeding
with down hole wireline job.
• Wireline should not be left in the hole unattended. If the
wireline need to be kept in the hole overnight during BHP
surveys etc., it should be ensured to shut wireline B.O.P. ram
with close surveillance for any leakage through stuffing box,
glands or elsewhere in which case immediate remedial
measures should be taken.
• The rope socket knot should be closely monitored for any
possible damage and should be remade, if required.

• On every run into the well, check drag on tools at least every
1000 ft (305 m). More frequent checks may be necessary on
initial runs in tubing of unknown condition.
• While coming out of hole, the speed should be reduced to safe
limits when approaching any restriction in the tubing string
and when within 500 ft of the surface.
• Once the tools are in the lubricator, the wireline valve/ BOP
should be closed. All pressure trapped in the lubricator must
be bled-off before attempting to remove tools. The person
engaged in this operation should position himself away from
the direction of the flow.
• Pressure should be equalized before performing any operations
that may result in blowing the wireline tools up the hole, e.g.,
paraffin scraping operations, fish recovery operations, sand
bailing, retrieving/re-installation of standing valve/sub-
surface safety valve etc.
• On the wells with pressure exceeding 10,000 PSI, it is
recommended that the stuffing box be re-packed before each
trip into the hole. Also, a crown or swab valve should be
included with the blow-out preventer and wireline valve.
• In special situations where unusual pressures or safety
requirement exist the following should be considered;
i. Dual wireline blow-out preventer for an added degree of
safety while performing wireline operations.
ii. A wireline valve between the wireline BOP and the
wellhead swab valve can be used for added safety during
wireline operations.
iii. If a braided wireline is used, proper greasing of the
wireline should be ensured.
iv. Do not loosen any hydraulic connection or part before
assuring that the unit is not pressured with hydraulic oil.
v. Do not operate without protective equipment and if
visibility is obstructed.

l) Before closing the operation ensure the following:
• Check all controls are in neutral positions on the operator’s
console (Gear lever, Direction control valve, the hand brake
release).
• Open remote control valve & two way valve fully.
WIRELINE OPERATION CHECK LIST
Well No._____________ Date __________
YES / SATISFACTORY
S.NO ITEMS
NO /UNSATISFACTORY
A
GENERAL
Work area cleanliness

1.
Personnel Protective Equipment

2.
Portable Fire Extinguisher

3.
First –Aid Box

4.
Well Record Sheet

5.
B
WINCH & ENGINE
Air inlet slam shut valve

6.
Engine over speed shut down

7.
Oil pressure safety shut down

8.
Water temperature safety shut down

9.
Exhaust gas cooler ( Integral)

10.
Exhaust gas flame arrestor

11.
Anti-static fan belts

12.
Engine oil
13.
Gear box oil

14.
Hydraulic oil
15.

YES / SATISFACTORY
S.NO ITEMS
NO /UNSATISFACTORY
16. Diesel /Petrol
17. Coolant
18. Reel shaft pillow block bearings
19. All other moving joints and connectors
20. Brake Condition
21. Safety Guard of moving parts
22. Battery terminal connections
23. Starter / Dynamo cover in place
24. Leakages in hydraulic / fuel system
25. All controls in position (Gear lever, direction valve,

hand brake release, accelerator knob, remote control
valve, floor control valve of oil cooler )
26. Relief valve setting pressure
C
WIRE LINE & TOOLS
27. Condition of pulley / sheave groove
28. Size of pulley w.r.t. wire line
29. Condition of Rubber seals of Stuffing box
30. Measuring device condition
31. Weight indicator condition
32. Pressure test of lubricator to maximum of well pressure

.
33. Pressure test of wireline BOP
34. Wireline work string adequacy and condition
Checked By (Name/Designation ) _________________________ Signature ___________

13.3 GENERAL SAFETY CONSIDERATION:
The most important part of any wireline operation is the practice of safe
work habits. Following points should be adopted:
a) Use of appropriate tools and equipment for the specified jobs
along with ensuring the safe and clean working area.
b) Safety of personnel, environment and equipment should be the
prime consideration.
c) Before beginning any wireline operation, the wireline operator
must familiarize himself with all posted facility and safety
regulations. He should also ensure that his co-workers have full
knowledge of their designated jobs.
d) Place the wireline unit upwind from the wellhead.
e) Advise process control room at GGS before entering and
departing the location.
f) During the operation, one of the crew members should be
assigned the responsibility of observing for any unusual
occurrences which he should report to the operator immediately.
g) Make sure all personnel understand the actions to be taken in an
emergency, especially in case evacuation is required. Hold a
meeting before the job starts.
13.4 OPERATIONAL PROCEDURES

1) Clear the area around the wellhead of any hazardous objects that
can be moved.
2) Note the shut-in well pressure and enquire as to whether or not it is
the maximum shut-in pressure. Be sure that the surface equipment
on location are designed to withstand the maximum anticipated
wellhead pressure.
3) Check the wellhead top connection to ensure that the proper
matching connection is on location.
4) Place the truck or the trailer in to a convenient location and unload
the heavy equipment needed for rig up such as gin pole, lubricator,
wireline valve etc.

5) Move the truck or trailer out to a minimum distance of 50’ from the
wellhead if possible. Truck should be parked opposite to the direction
of wind on hard surface. Before rigging up the surface equipment,
truck should be securely blocked/ anchored so that it will not roll.
6) Close the top wellhead valve. If it is gate valve, count the number of
rounds the wheel or handle makes to fully close the valve. Never
operate the master valve except in an emergency.
7) Remove the connection and install the necessary adapter to fit the
bottom connection of the wireline valve.
8) If the gin pole is used, it should be raised and secured to the wellhead
with a 5/16 inch or larger steel chain and tightened with ratchet type
chain binder.
9) Hook up the top block in to top of the gin pole and scope out the pole,
inserting pins through the holes provided to support each section. The
pins should have a small hole in one end for safety pins.
10) Pick up the wireline valve and install it on wellhead. Never attempt to
manhandle the valve.
11) At this time, inspect the stuffing box and repack it, if necessary. Insert
the wireline through the stuffing box and through the rope socket.
With the wireline disc clamped in the vice, run the wire though the
rope socket, around the disc and tie the knot.
12) Assemble the lubricator sections and the wireline tool string, which
may consist of stems, jars and knuckle joint. Insert all but 12 in. of the
tool string into the lubricator.
13) Carry the stuffing box with the rope socket and wireline from the truck
to the wellhead, using every precaution not to kink the line. Screw the
rope socket to the wireline stem and make up tight with two pipe
wrenches.
14) Push the wireline tool string into the lubricator and make up the
stuffing box union on to the top of the lubricator. Guide the wireline
over the stuffing box sheave and pull it to the bottom end of the
lubricator and place it in the wire line clamp. This clamp keeps the
tools from falling out as the lubricator is raised.
15) Place the lubricator assembly so that the pick-up eye will be as close to
the gin pole as possible to minimize any side load on the gin pole.

16) Guide the lubricator during pick-up to prevent hitting any
wellhead fittings.
17) When the bottom of the lubricator is on the top of wireline valve,
tie off the pull rope to the flow line or other piece of heavy
equipment on the wellhead. .
18) Secure the hay pulley with the weight indicator, to the wellhead
with ¼” steel chain or steel cable. Place the wireline in hay pulley
and pull up the slack line with the unit on the truck. The hay
pulley should be mounted with the head of the latch pin on the up
side.
19) When all the slack line has been taken up, the wireline clamp can
be released and removed from the lubricator.
20) Lower the wireline tool string until the bottom protrudes from the
lubricator at a convenient working level. The remainder of the
wireline tool string is then made-up on to the upper portion.
21) Set the odometer of the counter assembly to zero, with the bottom
of the tool string as near the tubing hanger as possible. This point
should be used as zero point for all subsequent trips of the
wireline tool string.
22) Pull the tool string back up into the lubricator, and set the
lubricator on the wireline valve. Make up the lubricator union
onto the wireline valve and close the bleeder valve.
23) Open the closed valve on the wellhead very slowly until the
pressure has equalized into the lubricator. Check carefully for any
leaks then open the valve fully.
24) At this point, the wireline valve should be tested. Close the rams
of the valve and release the pressure from the lubricator through
the valve rams or the equalizing valve.
25) Close the bleeder valve and open the equalizing valve. When the
pressure has been equalized in the lubricator, close the equalizing
valve, open the wireline valve rams and lower the wireline tool
string into tubing.
26) When the trip with the tools has been completed and the bottom
of the wireline tools are above the top valve on the wellhead, close
the upper wellhead valve, then release the pressure from the
lubricator through the bleeder valve.

27) On all locations, ensure that all the well fluids bled from the
lubricator are contained and not allowed to contaminate the area.
28) Unscrew the lubricator union and pick up the lubricator with the
rope falls. The helper will swing the lubricator to one side and the
wireline operator will slack off the tool string to a convenient
working level to change tools.
29) When the wireline operations have been completed, lower the tool
string out of the lubricator. Have the helper close the jar and walk
out with them. He will cut the line 6” from the rope socket,
holding on to the cut end of the line until the wireline operator
has pulled it up in to the lubricator, step back in the clear until the
end has been pulled clear of the hay pulley. The 6” of the line left
on the rope socket must be bent 1800 , with the end resting as close
to the remaining line as possible.
30) The rigging up procedure is reversed for rigging down.
31) Replace the wellhead connection and pressure gauge. The
wellhead valve should be opened to check for any leak in the
connections. When all the tools have been reloaded on the wireline
unit, wellhead should be wiped clean and surrounding area
cleaned for any trash or debris that might have accumulated
during the operations.
32) Replace any objects which were moved in step 1.
13.5 WIRELINE JOB RECORDS

Upon completion of the wireline operation, a report signed by a qualified
person [wireline operator/production engineer] must be submitted to the
operating departmental in-charge. The report should include:
i) Date
ii) Well identification
iii) Chronology of operation performed including depth, pressures
and equipment involved.
iv) Sub-surface equipment removed, installed or replaced etc.
v) Any equipment lost/ left in the hole or any restriction not
previously reported.
vi) Information required to complete failure analysis reports.

1) Before beginning any wireline operation, operator must
familiarize himself with all posted facility and safety regulations.
He should also ensure that his co-workers have full knowledge of
their designated jobs.
2) Safety must always be of prime importance. Operator and all his
personnel should act in a manner, which should foster a safe
working environment for the protection of both personnel,
environment and the well.
3) Measuring line should be properly transferred from shipping
spool to the reel by mounting both spool and reel on horizontal
shafts and spacing them far enough apart to make level winding
easier.
4) When retrieving the line from the well, clean the line of well fluids
by using line wipers. Otherwise, the fluid clinging to the line drips
or thrown off the floor blocks and pulleys, creating safety,
maintenance and housekeeping problems.
5) Avoid gripping the line with tools, such as pliers or hardened jaws
as nicking or gouging the surface of the wire can cause failure of
line when subjected to tensile and bending stresses.
6) Give a protective coat of oil as wire is reeled on to the drum.
7) Before commencing the wireline job, cut 15 to 20 ft. of line off the
spool and tie another Knot.
8) Uncontrolled slack and resultant kinking must be avoided.
9) Do not pull a line beyond its elastic limit. Use a good weight
indicators to ensure that wire line does not exceed the maximum
safe load.
10) Line should be replaced
a. When a line is laid out on the ground and does not form a
coil or loop as on the drum.
b. When tying a knot, the wireline breaks easily.
c. When kinks will not straighten out.

11) All wireline tools/equipment should be rated to handle maximum
anticipated well head pressure.
12) Nominal internal diameter of tubing, christmas tree, tubing
hanger, packers, packer stringers etc., should be checked for full or
compatible bores and proper bevel on inside.
13) In case of gas lift wells, injection of gas should be stopped during
running in/ pulling out of any wireline tool.
14) A dummy wireline operation should be made up to the planned
operating depth to ensure absence of any restriction.
15) In deviated holes or severely crooked tubing strings, landing
nipples should be placed higher in the tubing string.
16) Flow control equipment should be set deep enough to prevent
freezing due to pressure drop through bottomhole choke or
regulator, etc.
17) Lubricators must be tested to twice the expected well working
pressure for each job as a safety measure.
18) Before dismantling the lubricator, it should be ensured that the
pressure the pressure inside it is released through the release
valve.
19) When it is necessary to use tall high pressure lubricators, and the
work is not performed on the rig, a gin pole, a block and tackle
should be used.
20) During the time any wire line operation is in progress, a warning
sign should be displayed at the X-mas tree with the following
inscriptions "Wire Line Operation On, Do not Operate Valves."
21) Equipment tools and small objects and other loose materials
which are not required for use should not be left lying on the
derrick floor when rig is in place so as to dangerously obstruct
work places and passage ways.
22) There should be at least two persons at the site during wire line
operation - one person at the controls and one person at the well
should always be present.
23) The winch mounted vehicle for wire line jobs should be secured to
the ground to prevent it from skidding forward.

24) Place the wireline unit upwind from the wellhead (at least 30
meters from the well head). This can be determined by noting the
position of the windsock.
25) All persons should stay away from the wire line when it is in
motion.
26) It should be ensured that the wire line tools, the wireline and the
brakes of the wire line unit are in good working order. In case any
defect is noticed, it should not be put into use until such a defect
has been rectified.
27) Wireline operations should be planned in such a way that it shall
be completed in daylight itself. However, if it is to be continued
beyond day light hours sufficient illumination facilities should be
ensured at operating areas.
28) In remote location (i.e. in offshore/desert locations) provision for
additional or back up equipment/tools should be made to avoid
waiting.
29) Wireline should not be left in the hole unattended. If the wireline
need to be kept in the hole overnight, it should be ensured to
shut wireline B.O.P. ram with close surveillance for any leakage
through stuffing box, glands or elsewhere.
30) On every run into the well, check drag on tools at least every
1000 ft (305 m). More frequent checks may be necessary on initial
runs in tubing of unknown condition.
31) While coming out of hole, the speed should be reduced to safe
limits when approaching any restriction in the tubing string and
when within 500 ft of the surface to avoid any damage by way of
hitting the tool at the wellhead.
32) Pressure should be equalized before performing any operations
that may result in blowing the wireline tools up the hole, e.g.,
paraffin scraping operations, fish recovery operations, sand
bailing, retrieving/re-installation of standing valve/sub-surface
safety valve etc.

33) Make sure all personnel understand the actions to be taken in an
emergency, especially in case evacuation is required. Hold a
meeting before the job starts.
34) In case well is expected to produce sour gas, the following special
safety recommendations are proposed;
a. In corrosive environment use tools made from type 316
stainless steel which is resistant to hydrogen embrittlement.
b. Make sure all personnel understand the actions to be taken
in an emergency, especially in case evacuation is required.
Hold a meeting before the job starts.
c. Only H2S rated equipment should be used.
d. The wireline and wireline tools should be suitably protected
against corrosion.
e. H2S detection and alarm equipment should be properly
selected and located.
f. Breathing apparatus must be worn during all operations
where personnel may be in contact with well effluents.

CHAPTER- 14
SAFETY
14.0 GENERAL
The most important part of any well servicing operation is the practice of
safe work habits. Safety is more than a set of rules to be followed. Rather,
it is an attitude that is practiced daily and applied not just in the
workplace, but in all situations. Being able to recognize and avoid hazards
is of primary importance. Safety rules are written to help personnel to
avoid hazardous situations and to protect them from hazards that cannot
be avoided. The enforcement of safety rules and regulations involves
making personnel aware of why the rules were written. Without this
awareness, rules tend to be ignored or, at best, selectively enforced.
Work-over operations are carried out on wells for maintaining, restoring
or increasing the productivity of well. Work-over operations should be
aimed at protection against damage to human, environment and property
and therefore operational safety is the foremost concern on work-over
rigs.
DGMS is the regulating agency for all onshore oil mines. Regulations
called the ‘Oil Mines Regulations, 1984’ extend to the whole of India. Oil
Industry Safety Directorate (OISD) is the regulating agency for all the oil
mines located in offshore (Indian water).
OISD has done substantial work and has published number of standard
related to safe operations of onshore oil mines. They are undertaking
safety audits of onshore oil field installations including workover over
rigs, on regular basis. OISD safety check list for workover rig is placed at
Annexure 1 at the end of this chapter.
It is recognised that the safety guidelines compiled in this section cannot
possibly mitigates all the hazardous situations which may arise during
the vast variety of workover operations. However, these guidelines will
definitely assist each individual worker to improve his work methods and
reduce accidents.
Safe and healthy working conditions, quality of equipment, safe
transportation of equipment / personnel to the well-site, safe operating

procedures, proper training, compliance with safety regulations,
company-wide commitment to safety, periodic safety audits, timely
inspection and appropriate repair /maintenance play a major role in
safety management and key factors in avoiding accidents. However, the
human factor plays the most vital role as most of the accidents are caused
due to human failure.
14.1 GENERAL OPERATING PRACTICES IN WORKOVER

OPERATIONS
14.1.1 HOUSE KEEPING
1. Good housekeeping on the job is essential to successful accident
control and fire prevention. Keeping everything in its place
promotes efficiency, quality and good work. Tools, equipment
and working areas should be kept clean, neat and orderly.
2. Work places and stairs with handrails should be maintained
reasonably clean and free of debris, mud, oil or stumbling
hazards.
3. Scrap, waste and rubbish shall not be allowed to accumulate in
work places of access or egress.
4. Hazardous leaks should be immediately stopped or spills should
be promptly cleaned up to eliminate personnel slipping and fire
hazard.
5. If employees are required to work in a cellar pit, it should be kept
reasonably clean of water, oil or drilling fluid accumulation.
6. Loose materials that are not required for use should not be placed
or left so as to dangerously obstruct work places and passage
way.
7. All projecting sharp edges and railing ends shall be properly bend
over to prevent possible injury.
8. When placing equipment and tools on or around the rig floor and
location, care should be taken to leave egress routes open. Tools
and equipment should be securely placed and stored in a manner
so that they may not fall.
9. Portable equipment shall be returned after use to its designated
storage place.

10. Equipment, tools and small objects shall not be left lying about
where they could cause an accident either by falling or causing
person to trip.
11. Safe storage and location of combustible and flammable materials
and the prevention of accumulation of rubbish are important to
fire prevention.
12. Separate dustbins for biodegradable and non–biodegradable
waste should be made available.
13. Smoking shall be prohibited at or in the vicinity of operations that
constitute a fire hazard. Such locations should be conspicuously
posted with a sign, “NO SMOKING OR OPEN FLAME,” or
equivalent.
14. Display of various sign boards (e.g. safety signboards,
contingency plan, zone diagram, first aid chart, mines structure
etc.) as required by different regulating agenises.
14.1.2 WORK-OVER OPERATION
1. Tool Box meeting must be conducted including all personnel
involved in the operation prior to appropriate stages in the
process e.g. at start of operation, at shift change, or when any new
members join the crew and when conditions change for any
reason.
2. At the beginning of every shift, the instruments and controls at
Driller’s stand, draw works, mud pump, casing line, cat-line,
blowout preventer assembly etc. shall be examined by the Shift in
charge and he shall satisfy himself that these are in good working
condition. In case of any instrument found non operational,
corrective action should be taken immediately.
3. Tools or other materials shall not be carried up or down a ladder
unless properly secured to the body leaving both hands free for
climbing.
4. The Shift in charge shall see that no person remains in a position
of danger at or near the rotary table when set in motion.
5. The casing line shall not be in direct contact with any derrick
member.

6. All high-pressure pipes fitted with flexible joints shall be suitably
anchored and pressure tested before commencement of any
operation.
7. A safety program should be established and maintained. Such
safety programs should include, but not he limited to, the
following:
i. Driller’s responsibility for the safety of the crew and
equipment during normal operations and possible
emergencies.
ii. New rig personnel, regardless of prior experience, should
have the job outlined, explained, and demonstrated by the
driller.
iii. Instructions on work procedures and safe practices.
iv. Regularly scheduled and impromptu meetings of the crew,
in which the probable hazards, problems of the job, and
related safe practices are emphasized and discussed.
v. Good housekeeping practices.
vi. Use and maintenance of personal protective equipment.
vii. General safety education through safety meetings, company
publications, and other educational media.
8. All unsafe and potentially dangerous conditions should be
rectified and reported immediately to his immediate supervisors/
In-charge for further suitable action.
9. The off-going shift in-charge shall inform the incoming shift in-
charge for any known special hazards on ongoing work that may
affect safety of the crew and rig. Accordingly brief note should
also be recorded.
10. Hazardous substances shall be stored at proper place, in proper
containers and properly labelled.
11. Hazardous waste materials shall be appropriately stored, labelled,
and disposed. Hazardous waste materials should not be mixed
with non-hazardous wastes because the entire mixture is then
considered hazardous and subject to hazardous waste disposal
requirements.

12. Employees required to handle or use hazardous substances shall
be instructed regarding their safe handling and use and are made
aware of the potential hazards and personnel protection measures
required. Material safety data sheets (MSDSs) shall be available to
the personnel at the workplace prior to and during chemical
usage.
13. Smoking and naked light shall be prohibited at or in the vicinity
of operations that constitute a fire hazard. No person shall smoke
or carry naked light within 30-m radius of a well. In cluster
locations prohibition should be enforced for all operations.
Locations should be conspicuously posted with a sign, “NO
SMOKING OR NAKED LIGHT” or equivalent.
14. Field welding shall not be permitted on tongs, elevators or any
other heat-treated rig equipment.
15. Never leave well unattended unless it is safely shut in. At least
one trained person, qualified in well control procedures, should
always be present on derrick floor to observe the well particularly
when BOP is not closed.
16. Personnel should be trained in basic well control, as needed, in
relation to their job duties.
17. Pipe threads should be cleaned with a wire brush.
18. Hand gloves should always be used for working on Rig floor,
while handling of wire ropes and tubular.
19. Thorough safety inspection should be made of well servicing
equipment and foundation before starting job.
20. Men on the floor should stand clear when rigging up or repair
work is in progress overhead.
21. When drinking water is transported and stored for use of crew on
location, it should be in a clean shatterproof container and
individual drinking cups provided. Drinking water should be
labelled "Drinking Water only".
22. Unsafe or otherwise dangerous conditions, no matter how small,
should immediately be reported to supervisor in charge for
corrective action. Correction of unsafe condition may take one of
three forms - remove, guard or warn.

23. Upon completion of job, clean equipment and load neatly and
safely in tool box/ store.
24. Practical joking, cards playing or horseplay of any nature among
employees on duty is inconsistent with safety and is positively
prohibited.
25. Control must be maintained over leaks and spills; however, if
they occur, they should be cleaned up promptly to eliminate
slipping hazard to personnel as well as fire hazard.
26. Well control shall be maintained at all times. Consideration shall
be made to ensure appropriate equipment and materials are on
location and operational before work commences.
27. Crews should conduct well control drills. When well servicing
operations are in progress on a well, the rig shall have on the rig
floor a safety valve (stabbing valve)/ FOSV with connections
suitable for use with each size and type tool joint or tubing
connection being used on the job.
28. All employees are responsible for prevention of accidents to men
working with them. Any employee using unsafe tools or work
practices or encourage other employees to do so should be
prohibited.
29. Lift weights properly, with your legs and not with your back. If
the load is beyond your safe capacity, get help.
30. In the event of a personal/ occupational injury, no matter how
small, shall be reported promptly to the supervisor in charge.
Supervisor is to make out a full report at the end of the shift on an
approved accident form and handover to the Driller I/C.
31. Hair of such length that it might become entangled in moving or
rotating machinery should be contained in a suitable manner.
Beards and sideburns of employees should be kept in such
conditions and of such lengths so as not to interfere with the
proper use of gas masks, air masks, or other safety apparel or
equipment.
32. Drinking alcohol/ intoxicated substance on the job or to and from
the work is prohibited.
33. It is the responsibility of all employees to train men under their
supervision, in the safest and most efficient way to work.

34. An employee should never operate any machinery, including a
cathead, until he is well acquainted with the operation.
35. As servicing jobs are frequently done at remote areas where
medical aid is not readily available, it is strongly recommended
that all employees take a course in first aid.
36. Unauthorized personnel should not be permitted at the work
location.
37. There will be no smoking at the well-site. All smoking materials,
matches, lighters, etc., are to be left in a pre-determined safe area.
38. Each employee should exercise caution to avoid falling,
stumbling, or moving into or against moving machinery.
39. Adequate general lighting arrangement shall be provided during
working.
40. On land locations, vehicles not involved in the immediate rig
operations should be located a minimum distance of 100 feet (30
m) from the wellbore or a distance equal to the height of the
derrick or mast (including attachments), whichever is greater.
Appropriate safety measures should be taken where terrain,
location, or other conditions do not permit this spacing.
41. The rig substructure, derrick, mast, and other equipment, bunk
houses etc. as appropriate, shall be grounded to prevent
accumulation of a static charge.
42. Rig engine must have safety devices like over sped trip, provision
for emergency stop from driller console panel and add on facility
like automatic hook load limiting device.
14.2 SAFETY EQUIPMENT

14.2.1 Following Critical safety equipments must be available in operating
conditions at all times near by /at rig site;
• Trip Tank
• Drillometer
• Twin stop safety system in order to prevent travelling block from
hitting on the derrick floor and the crown block.
• Tubing safety valve (Quick Shut off Valve).
• Suitable BOP stack and its accumulator unit.

• Spark arresters in exhaust of all the diesel engines which are placed
within 30 meters of well.
• Fall preventation device for monkey board approach ladder.
• Topman escape device from monkey board.
• Flame proof electrical fittings/junctions box for use of the same
within 30 meters of well.
• Emergency kill for shutting of the rig engine from derrick floor as
well as at the rig trailer. Air intake shut off valve for rig engine.
• Adequate number of DCP, foam and CO2 fire extinguishers.
• Sand buckets and fire bell/ hooters.

• Portable hydrocarbon gas detector. H2S gas detector. (Wherever
required)
• First aid box and ambulance cum emergency vehicle.
14.2.2 PERSONAL PROTECTIVE EQUIPMENT (PPE)
The personal protective equipment (PPE) are primarily required for the
personal protection and these are the secondary means of protection, the
primary protection being the engineering controls.
PPE should be made available inline with standard specifications
approved by ONGC and should be replaced as per norms/ OISD STD
184: Standard on Replacement of Personal Protective Equipment and Life Saving
Appliances.
Protectors should meet the following minimum requirements:
1. It should provide adequate protection against the particular hazard
for which they are being used.
2. It should be reasonably comfortable when worn under the
designated conditions.
3. It should fit snugly and should not unduly interfere with the
movement of the wearer.
4. It should be durable.
5. It should be capable of being disinfected and cleaned (unless they
are disposable.)
For selection, use and maintenance of PPE OISD STD-155 (Part 1 and 2)
may be referred

1. Head protection
a. No person shall be allowed to go into work in a drilling rig or
workover rig site or at such other place of work where there is a
hazard/ danger from impact or penetration from flying or falling
objects or from limited electric shock or burn, unless he wears a
helmet of such type as may be approved by the Chief Inspector by
a general or special order in writing.
b. The helmet shall be supplied free of cost at interval not exceeding
three years by the owner, agent or manager who shall at all times
maintain a sufficient stock of helmets in order to ensure
immediate supply as and when need for the same arise.
c. Provided that when a helmet is damaged during its legitimate
use, it shall be immediately replaced free of cost.
d. Safety helmets shall be worn by all personnel at all times while
working within working areas, outside accommodation and
offices.
e. Safety helmets shall be fitted with chin strap and shall be made of
non conductive material.
f. Personnel with hair of such length as to be a hazard in work areas
should keep it contained in a suitable manner while performing
their duties. Hair and beard styles shall not interfere with the
effective functioning of head, eye, face, or respiratory protective
equipment.
2. Clothing
a. Cotton overalls shall be worn by all personnel working on rig. .
Wind cheaters and rains coats should also be used in extreme
weather conditions.
b. Employees should wear protective gloves, protective apron, or
other protective equipment, as appropriate.
c. The unreasonably loose, poorly fitted or torn clothing should not
be worn.
d. Employees should not wear jewellery or other ornament causing
injury while in the work area.

e. Personnel clothing, which has been saturated with flammable or
toxic substances, should be removed and effected skin area
thoroughly washed.
3. Hand Protection
a. Hand protection should be used where there is danger of cuts
such as handling knives or slicing equipment, or danger from
handling corrosive materials, such as cleaning chemicals or
solvents, acids, alkalis, scale inhibitors, bactericides. These should
also be used where there is risk from hot surfaces or electrical
shocks.
Cotton, leather, asbestos or rubber gloves; gauntlets; heat resistant
gloves; are typical hand protection devices.
b. Safety gloves shall be provided to all personnel and worn as
appropriate.
c. Rubber gloves shall be available and worn by electrician while
working
4. Foot protection
a. No person shall go into work or be allowed to go into work in a
mine unless he wears a protective footwear of such type as may be
approved by the Chief Inspector may specify by a general or special
order in writing.
b. Foot protection should be provided where there is a potential for
foot, toe or instep injuries from external forces.
c. Safety shoes/ gum boots shall be worn by personnel in working
areas for foot protection
d. Protective footwear shall be supplied free of cost by the owner,
agent or manager at interval not exceeding one year.
e. The owner, agent or manager shall at all times maintain a sufficient
stock of protective footwear in order to ensure immediate supply as
and when need for the same arises.
5. Eye protection
a. Safety glasses, shields and goggles shall be worn anytime eye
hazard exist like when flash lights & glares, chipping, grinding,
hammering, cutting wireline, changing tong dies, scrapping paint,

using a drill machine, operating a press, a lathe machine, and for
any other activity which may result foreign body in the eye.
b. Suitable eye protection should be used where machines or
operations present danger from flying objects and hazardous
liquids injurious radiation or a combination of these hazards.
c. In addition to the safety goggles, a face shield shall be worn when
handling corrosive or harmful products (solids or liquids).
d. Welding helmet or hand-held shield shall be used when
performing welding rather than welding goggles.
e. Welding goggles shall be worn when using a cutting torch.
f. Provision for eye wash with potable water shall be available at
least in the mud/workover fluid mixing area.
g. Personnel using these eye protectors should undergo examination
for visual acuity and depth perception.
6. Hearing Protection
a. Protection against the effects of noise exposure shall be provided
when the sound levels exceed those shown in the table below.
Maximum Permissible Noise Exposures
Duration per day,

hours Sound level, dBA
slow response
12 85
8 90
6 92
4 95
3 97
2 100
11/2 102
1 105
1/2 110
1/4 or less 115
Note: When the daily noise exposure is composed of two or more

periods of noise exposure of different levels, their combined
effect shall be considered rather than the individual effect of
each. Exposure to impulsive or impact noise should not
exceed 140 dB peak sound pressure level.

b. When personnel are subjected to sound levels exceeding those
listed in above table, feasible administrative or engineering
controls shall be utilized. If such controls fail to reduce sound
levels within the prescribed levels, personal protective equipment
shall be provided and used to reduce sound levels within the
levels of the table.
c. A hearing conservation system including PPE, noise monitoring,
periodic audiometric testing and employee education shall be
initiated wherever the noise exposures equal to or exceed an 8-
hour time weighted average of 85 dBA.
Ear plugs, ear muffs, Swedish wool, disposable plugs etc. are
used for hearing protection.
d. The owner, agent or manager shall take reasonably practicable
means to reduce the noise level and to reduce the exposure of
work persons to noise.
e. Persons entering high noise areas should wear ear/ hearing
protection equipment
f. No person shall enter or be allowed to enter an area in which the
sound level is 140 dB(A) or more.
g. The Chief Inspector may, from time to time by notification in the
Official Gazette, specify the permissible noise exposure in any
area or place in a mine.
7. Respiratory Protection
Air purifying respirators, chemical cartridge respirators, air supplied
respirators, combination respirators, self contained breathing apparatus
(SCBA). escape masks, canisters etc. are used for protection in
irrespirable and toxic atmospheres.
These are required particularly in those areas which present limited
breathable environment, where the possibility of an oxygen deficient
environment exists or where there is air contamination. These protectors
have significant fitting requirements based on the facial bone structure of
the user and for spectacled as well as bearded users.
The use of breathing apparatus shall be demonstrated in the group safety
meetings covering,
• Respiratory hazards and availability of breathing apparatus at
various locations.

• Controls being used for respirators.
• Reasons for selecting particular type of respirator.
• Functions, capabilities and limitations of respirators.
• Methods of donning respirators.
8. Fall Protection
a. All personnel, when engaged in work ten feet above the rig floor
or other working surfaces, shall be protected at all times from
falling by guardrail systems, safety net systems, or personal fall
arrest systems (PFAS).
b. An anti-fall coupled with safety harness/ belt shall be worn by
personnel working on mast while exposed to a fall of 3 meters or
greater or climbing unprotected vertical monkey ladder with
same exposure.
c. Where any person cannot be protected against falls from heights
by other means, the owner, agent or manager shall provide an
approved safety belt suitable for the hazard exposure which shall
be attached by means of a lifeline to a fixed anchor and adjusted
to allow a drop not exceeding 1.8 metres in case of fall.
d. All personal working at Monkey Board should wear an approved
safety belt while working.
e. Safety belts, life-liners & tail ropes should be maintained in good
condition.
f. The topman leaving the monkey-board shall take off his harness
only when reaching the exit of the monkey-board.
g. When the topman is changing out, the blocks shall be lowered
and remain in vicinity of the drill floor.
h. The topman's safety harness(es), when not used, shall always be
located at the entrance of the monkey-board, to allow the topman
to put it on before starting to walk on the platform.
9. Auxiliary Escape/ Topman Emergency Escape Device (TEED)
a. On all land rigs, the derrick or mast shall have an auxiliary means
of escape installed. The auxiliary escape route should use a
specially rigged and securely anchored escape line attached to the
mast so as to provide a ready and convenient means of escape
from the monkey board.

b. The escape line route should be kept clear of obstructions. The
escape line on derricks should be a 7/16-in. (11.5-mm) minimum
diameter wire rope in good condition. A safety buggy equipped
with an adequate braking or controlled descent device should be
installed on the wire rope, kept at the monkey board, and secured
in a manner that will release when weight is applied.
c. Tension on the escape line should be periodically checked and
adjusted to enhance safe landing of the user.
d. The ground anchor point should be able to withstand a pull of at
least 3,000 lb. If the rig or location configuration will not permit
use of the escape system, an alternate means of fast emergency
exit from the monkey board to a safe place should be provided.
e. Personnel shall be trained in the proper procedure(s) for escaping
the derrick or mast.
f. Personnel shall not ride the safety buggy or escape equipment
except in an emergency.
g. Escape line shall be securely fastened to the grit immediately
above the monkey board. The angle of the anchored escape line
should be in accordance with manufacturer's specification.
API RP 54 recommend that the ground anchor point of the escape
line should be located a minimum lateral distance from the
derrick or mast equal to two times the height of the work
platform.
h. Escape device for derricks should have a seat (T Bar) and a spring
actuated cam brake which can be applied at any height with
finger tip pressure, both in good working condition to control the
descent.
i. Path of escape line should be free of obstruction.
j. Sand cushion should be provided in landing area of the TEED.
k. A competent person shall inspect every part of Emergency escape
device/ Braking system once at least every day. Record of such
inspection be maintained.
14.2.3 FIRE FIGHTING FACILITIES
Fire fighting facilities should be made available as per OISD-STD-189:
Standard on Fire Fighting Equipment for Drilling Rigs, Workover Rigs and

Production Installations. For safe and efficient operation, fire fighting
system should be inspected as per standard engineering practice/ laid
down approved procedure and OISD STD:142; Inspection of Fire Fighting
Equipment And Systems.
a. Fire Water Storage with fire pump:
i. One 40.0 KL capacity water storage tank should be provided at
the approach area and it should be connected with a trailer/skid
mounted diesel engine driven fire water pump of capacity 1800
LPM at 7.0 kg/cm2 pressure. The water storage tank should be
skid mounted, welded type of adequate thickness. Minimum 4”
hydrant line/hoses to cover well head and hazardous area form
approach side (Single line) should be provided with one monitor
and one hydrant point. One point near approach should be
provided for connecting fire tender. Tank available for
preparation of well workover fluid can also be used for fire
fighting purpose, provided it is kept at safe place and always kept
full.
ii. One additional TPC connection should be provided with the fire
water storage tank for connection of the fire tender in case of
emergency. Regular filling arrangement of the above mentioned
tank should be provided.
iii. Necessary hose storage facilities should be provided for keeping 4
nos. Fire hose of full length with 2 nos. branch pipe.
iv. In case more number of WORs are operating in same area and fire
fighting facilities are available within 15 minutes from nearby
GGS/CTF/WOR/Drilling rig than pumps and water tankers can
be pooled suitably for WORs so that resources are available
during critical operations.
b. Portable Fire Extinguishers
i. Fire fighting equipment, suitable for fire hazards involved, should
be provided at location. All fire protection equipment should be
maintained for ready to use condition and should be easily
accessible at all times.
ii. All fire extinguishers shall be maintained, inspected &
hydrostatically tested in accordance with standards & tagged
showing the date of inspection & date due for next
inspection/servicing.

iii. Every person employed at work-over rig shall be trained in the
use of such equipment; regular fire drills shall be held for this
purpose.
iv. The fire extinguishers shall be marked with an identification
symbol and the letter(s) that indicate the class of fires they shall be
used for.
v. Sufficient safety precaution should be taken while transporting
the Extinguisher from location to location.
vi. First Aid Fire Fighting Equipment at Workover Rig ( As per OISD
189)
1) Workover rig’s engine area - 1 No. 10 kg DCP
2) Rig’s compressor area - 1 No. 10 kg DCP
3) Rig floor area - 2 No. 10 kg DCP
4) Electrical generator house - 1 No. 10 kg DCP
-1 No. 6.8 kg CO2
5) Mud Water Pump/motor area - 1 No. 10 kg DCP
6) Near DIC office area - 2 No. 10 kg DCP
- 2 Nos. Sand bucket
7) Fire bell near office cabin - 1 No.
8) Lube. Oil area - 2 No. 10 kg DCP
- 2 Nos sand bucket
vii. A competent person shall once at least in every three months
examine every fire extinguisher and shall discharge and refill it as
often as may be necessary to ensure that is in proper working
order.
viii. A report of every such examination or refilling shall be kept in a
dated by the person making the examination or refilling
c. The fires shall be treated depending on their class :
Class A fires: occur in common materials. The quenching and
cooling effect of water or water solutions is recommended.
Class B fires: occur in the vapour-air-mixture over the surface of
flammable liquids such as gasoline, oil, grease, paints and

thinners. Class B fires are extinguished by limiting air (oxygen) or
by providing combustion-inhibiting agents.
Class C fires: occur in or near electrical equipment, Non-
conducting extinguishing agents must be used
Class D fires: occur in combustible metals such as magnesium,
titanium, zirconium, lithium and sodium. Specialized techniques,
extinguishing agents and equipment must be used to control this
type of fire.
14.2.4 FIRE PREVENTION AND PROTECTION (EXCEPT WHILE RIGGING
UP, RIGGING DOWN AND MOVING)
a. A portable gas detector capable of determining monitoring level
of combustible gases in air should be made available at site.
b. The detector shall be regularly inspected and maintained in ready
to use at all times and should be calibrated regularly.
c. Fire fighting equipment should not be tampered with and should
not be removed for other than its intended purpose.
d. Fire extinguishers and other fire fighting equipment should be
suitably located and plainly labelled as to their type and method
of operation.
e. Used cleaning rags and combusting waste materials are kept to a
minimum stored in a metal container and disposed of regularly.
f. Access to exits or fire extinguishers are not blocked or obscured
by clothing, materials or equipment.
g. Well cellars, rig floors and ground areas adjacent to derricks
should be kept reasonably free from accumulation of oil which
might create or aggravate fire hazards.
h. Fire protection and fire fighting equipment are maintained in a
serviceable condition at all time.
i. All fire extinguishers are maintained, inspected and
hydrostatically tested in accordance with standards.
j. A competent person shall once at least in every three months
examine every fire extinguisher and shall discharge and refill it as
often as may be necessary to ensure that is in proper working
order.

k. Records be kept showing the date fire extinguishers were last
inspected, tested or refilled and by whom.
l. A report of every such examination or refilling shall be kept in a
dated by the person making the examination or refilling.
m. During welding operation, keep suitable portable fire
extinguishers in the vicinity.
n. Any engine being refuelled should be shut off during refuelling.
o. No smoking should be allowed within 30 meters of any
flammable storage area, or within 30 meters of the handling of
flammable liquids.
p. There should be an adequate number of "No Smoking" signs
conspicuously displayed at each well location while well service
work is in progress.
q. Personnel shall be instructed for the use of fire fighting
equipment during fire drills and training exercises.
14.2.5 INJURIES/ ILLNESS AND FIRST AID
a. Telephone numbers, location and other related information
pertaining to availability of medical personnel, transportation and
medical facilities shall be available at all well servicing sites.
Prior to commencement of work in an area, provisions should be
made for prompt medical attention in case of serious injury.
b. Every occupational injury or illness shall be immediately reported
to the supervisor. The supervisor shall arrange for any necessary
medical or first aid treatment.
c. A report should be prepared as soon as practical, to record
information (or the circumstances) surrounding the injury or
illness. Additional reports to regulatory agencies and others may
be required.
d. The cause of the injury or illness should be investigated and steps
taken to prevent a recurrence.
e. The information regarding availability of first aid kit should be
made known to each member.
f. An adequate and approved first aid kit should be provided on
each rig and should be conspicuously located.

g. At least one person who is trained and certified in first aid and
basic rescue techniques shall be available in each shift.
h. Posters demonstrating rescue, breathing & first aid should be
displayed at work place.
i. First aid kit shall be maintained at the worksite. The first aid kit
shall have all medicines as recommended by John Ambulance. The
kit should contain appropriate materials for the potential injuries,
and should be inspected at frequent intervals, replenished as
necessary, and be immediately available at all times.
j. Where the eyes or body of personnel may be exposed to injurious
materials, eyewash and shower equipment for emergency use
should be provided.
k. Emergency contingency plan should be available at site.
l. Emergency vehicle/ ambulance should always be available at site
during operations.
14.3 RIG COMPONENTS AND WELL SERVICING

EQUIPMENT
Operation, maintenance and inspection of hoisting equipment should be
done as per guidelines contained in OISD GDN 203.
14.3.1 DERRICK FLOOR
a. Derrick floor chequered plates should be placed firmly and in
such a way that there should be no gap between them.
b. Any opening in chequered plate like mouse hole etc, should
always be protected to avoid injury to person. Plain and slippery
chequered plate should be replaced immediately.
c. Grease, dirt or mud spillage on the derrick floor be cleaned with
water jet or surfactant during and after any operation on the floor.
Grease, dirt, mud also be cleaned from the steps of
stairways/ladder to avoid slipping.
d. Used cotton waste and all other dirty substance should be stored
in the dustbin.
e. Stands of tubular racked in the derrick or mast should be rested
on wooden raft and properly secured to prevent them from
falling.

f. Proper stopper arrangement like steel chain shall also be provided
at the end of the ‘Vee’ to avoid accidentally slipping of persons.
g. Guardrails of minimum 3 ft. height should be installed on all
platforms / walkways which are more than 4 ft. above the ground
level. Toe board of 6” shall be provided in addition to handrail on
operation of floors / platforms / walkways.
h. A minimum of two (2) stair ways with hand rails shall be installed
on rigs to provide alternate exits from the rig floor to ground level
when rig floor height is six (6) feet or more.
i. A stairway with handrails should be installed beside the ramps
which should extend from the ground to the derrick floor.
j. Drill-pipe/ tubing kept for connection at inclined catwalk should
be properly secured to avoid slipping of the same.
14.3.2 DERRICK/ MAST
a. All equipment installed in derrick/ mast shall be secured with safety
line of appropriate strength to prevent them from falling.
b. Each derrick or mast should show name of manufacturer and safe
load capacity.
c. No derrick or mast should be subjected to a compression load
greater than the safe load limit shown on the manufacturer's
plate.
d. Derricks, mast guying and foundations should comply with the
standards for guylines, anchors and foundation bases for well
servicing units, as per manufacturer's recommendations.
e. Derricks and masts should be equipped with guards which should
prevent the hoisting lines from being displaced from the sheaves
during operations or when being raised or lowered from the
operating position.
f. A visual inspection of the service unit should be made by an
experienced person before the derrick or mast is raised or
lowered. An experienced person should be made in charge of
raising or lowering a derrick.
g. Before any derrick is raised or lowered, all tools and material not
secured to the derrick should be removed from the derrick.
h. The derrick should be level and plumb before guys are tightened

i. Before any load is put on the derrick, all crown guys should be
properly tightened.
j. No employee should be allowed on the carrier when it is being
raised or lowered.
k. Each derrick platform should be constructed, maintained, and
secured to the derrick to withstand the weight of employees or
other stresses, which may normally be placed upon it.
l. Finger boards should be attached to the derrick to keep them
from falling if jarred loose or broken.
m. Unattached tools or material of any kind should not be kept in the
derrick above the derrick floor unless there is occasion for their
immediate use.
n. No employee should be in the derrick or on the rig floor when the
initial pull is made on the rods or tubing or when working or
jarring stuck rods or tubing.
o. Derrick/ mast should be inspected once in a fortnight to check
whether the bolts are properly tightened and lock nuts or split
pins and spring washers are securely in place.
p. NDT inspection of the derrick / mast including cleaning and
examination of welded joints should be done for any defect
initially after five years / depending upon the condition of rig
ascertained after regular visual inspection and subsequently once
in every 3-5 years .
However in case any damage is suspected while carrying out
operation, NDT inspection may be undertaken early as situation
demands.
As any operational mishap/ untoward incident in the derrick
might affect its strength, NDT inspection may be undertaken
immediately prior to resumption of normal operation
q. All normal checks, as per the instructions of manufacturer, during
positioning, rigging and de-rigging should be made and recorded.
14.3.3 HOISTING LINES (CASING LINES)
a. Casing lie should be inspected in every shift to check;
1. Proper anchoring of dead end
2. General condition of strands/broken wire

3. Any twist or abnormality
4. Proper winding on drum.
b. All casing lines shall be visually examined by a competent person
once at least in seven days and the condition of the wire as to
wear, tear, corrosion, brittleness and fracture shall be noted. A
report of every such examination shall be recorded in a bound-
paged book kept for the purpose and shall be signed and dated by
the person who made the examination.
c. If on any examination made as aforesaid there is discovered any
weakness or defect by which the safety of persons may be
endangered, such weakness or defect shall be promptly reported
in writing to the DIC or manager and until such weakness or
defect is remedied the casing line shall not be used.
d. The wearing points of every casing line shall be moved by cutting
off at least thirty metres of the casing line after every 3000 tonne-
kilometres or at shorter intervals, where necessary so as to
prevent excessive wear of the casing line. Line cut off and shifting
should be planned as per the procedure laid down in API RP 9G/
OISD STD 178.
The operation shall be carried out under the supervision of the
driller or other competent person who shall record the date and
other particulars thereof in a bound paged book kept for the
purpose and shall sign and date the same.
e. Hoisting line or sand line should be removed from service when
any of the condition described in section 6.7 exist.
f. On any drum on which a hoisting line is wound, the end of the
hoisting line should be fastened securely to the drum and there
must be a reasonable number of wraps of the line on the drum to
eliminate any strain on the fastening to the drum.
14.3.4 HOISTING BLOCK
a. The crown block should be inspected and lubricated before rig
building. There should be protective standing board at crown
block position to enable inspection crew to stand.
b. Crown block assemblies should be securely bolted to prevent the
sheaves from jumping out of bearing. The sheaves should have
metal guards.

c. The clearance between the sheaves and the guards should not be
more than half the diameter of the rope so as to prevent the wire
rope from jumping out of the sheaves.
d. Hook should be equipped with locking device to prevent the load
from being accidently disconnected from the hook.
e. Any hook used for lifting should be equipped with a safety latch
or safety cable and pinned.
f. Elevators links should be securely latched with the hook by lock
nuts or suitable pins.
g. Travelling block sheaves should have suitable guards while in use
to prevent fingers of rig crew being drawn in to it during
operations.
h. When any load is attached to the travelling block, it should not be
left unattended.
i. When not in use, the travelling block should be kept as near as
possible to the rotary table and the brake lever of the draw-works
should be securely locked to prevent any inadvertent movement
of the block.
j. The travelling block should be inspected and lubricated at
prescribed intervals.
k. Travelling block, elevators, elevator links or similar equipment
should be reasonably free of projecting bolts, nuts, pins or other
parts upon which clothing of workmen may be caught.
l. Travelling block and similar equipment should be inspected and
maintained in good working condition and the applied load
should never exceed the manufacturer's listed rating.
m. Travelling block safety device crown-o-matic shall be installed in
order to prevent the block hitting the crown block accidentally.
14.3.5 WEIGHT INDICATORS
a. To indicate the suspended load, every well-servicing rig should
be equipped with a reliable weight indicator.
b. Weight indicators should be safety secured and should be easily
visible to the equipment operator.
c. The manufacturer's rated load capacity of the servicing unit
should not be exceeded.

d. Weight indicator must be calibrated from an approved agency
once in a year and its certificate must be maintained and available
at rig site.
14.3.6 DRAW-WORKS
a. The brakes, linkage and brake flanges of drawworks shall be
examined by a competent person once at least in every 24 hours.
If any defect is discovered during such examination, the draw-
works shall not be used until such defect is remedied. The results
of every such examination shall be recorded in a bound paged
book kept for the purpose and shall be signed and dated by the
competent person making the inspection.
b. The draw-works shall be fitted with a suitable device with its
control near the driller’s stand to stop the draw-works in case of
an emergency.
c. No draw-works shall be operated unless all guards are in position
and maintained. If lubrication fittings are not accessible with
guards in place, machinery shall be stopped for oiling and
greasing.
d. The draw-works shall be provided with an automatic device (
Crown–o-matic and Floor-o-matic for safety against accidental
over running of travelling block) which shall effectively prevent
the travelling block from coming closer than two metres of the
crown block on the one end and crashing on the rotary table at the
other end. The device must be reset at the start of operation in
each shift.
e. Provided that where special conditions exist which make the
compliance with provisions of this sub-regulation not reasonably
practicable, the Chief Inspector may by an order in writing and
subject to such conditions as he may specify therein, exempt or
relax from these provisions.
f. When it becomes necessary to remove a guard, the draw-works
should be completely stopped and engine shut off.
g. All air compressors should have at least one pressure control for
proper airflow. Use proper pins in relief valve.
h. The safety pressure relief valve on main air tank should be
checked periodically and kept in proper working order.

i. All valves kill switches and other working devices should be kept
in proper working order.
j. Safety pressure relief valves on hydrostatic lines should never be
set higher than the design rating of the hydraulic system or the
manufacturer's listed rating of the lines, whichever is less.
k. The equipment operator should not leave the brake without tying
the brake down or securing it with a catch lock.
l. The equipment operator should not leave the brake while hoisting
drum is in motion.
14.3.7 CATHEAD AND CATLINE
a. When a cathead is in use, a competent person shall be at the
controls and in the event of any emergency, he shall immediately
stop the rotation of the cathead.
b. When the cathead is in use there should be an authorised
employee at the draw-works control.
c. The operator of cathead shall keep his operating area clear and
shall keep the portion of catline not being used coiled or spooled.
d. When a rope or line is in use on a cathead, all other ropes or lines
should be placed at a safe distance, so as not to come in contact
with the cathead or with the rope or lines used on the cathead.
e. When the cathead is unattended, no rope or line should be left
wrapped on or in contact with the cathead.
f. The friction surface and flanges of a cathead on which a rope is
manually operated should be reasonably smooth.
g. Catheads, on which a rope is manually operated, should have a
rope guide to hold the on-running rope alignment with its normal
running position against the inner flange.
h. Cathead operated manually shall be equipped with a divider to
ensure separation of the first wrap of wire line or rope.
14.3.8 ROTARY TABLE
a. Rotary table gear, driving shaft/ chain and sprockets should be
securely guarded.
b. Operator should not engage the rotary clutch with out watching
the rotary table.

c. Operator must satisfy himself that persons are at a safe distance
from the moving parts.
d. The lock of the rotary table should not be used to arrest its
motion.
14.3.9 MUD TANKS
a. Hoses used for jetting operations should be manned and there
should be an employee stationed at the pump controls to shut
down the pressure in the event of emergency.
b. All discharge lines should be safely secured. All hoses under
pressure should be properly hobbled.
c. All fixed mud guns used for jetting should be pinned or hobbled
when unattended.
d. All portable tanks in excess of 2 meters in height used in testing
and treating should be equipped with a fixed metal ladder.
14.3.10 PUMPING UNITS AND PRESSURE LINES
a. Mud pump shall be equipped with a safety pressure relief valve
and an operating gauge in the system and maintained. The valve
shall be set to discharge at a pressure not in excess of the
established working pressure of the pump, pipes and fittings.
b. Calibration record of safety pressure relief valve and pressure
gauge must be available and maintained at rig site.
c. The discharge from a safety pressure relief valve shall be piped to
a place where it will not endanger persons. Relief valve and all
open ended pressure relief lines shall be securely clamped to fixed
support.
d. Bleed off valve shall be installed on discharged line of the pump,
to allow the residual pressure after isolation of the high pressure
circuit to be safely relieved.
e. Al chickson joints used for a pumping line should be pressure
tested and adequately anchored/ snubbed with adequate means
to prevent from swinging or kicking in case of sudden release of
pressure.
f. There shall be no valve between a pump and its safety pressure
relief valve.
g. All exposed moving parts shall have proper guard.

14.3.11 MATERIAL AND EQUIPMENT HANDLING
a. Rigging equipment including cranes for material handling shall
be checked prior to and during its use to ensure that it is safe.
b. Rigging equipment shall not be loaded in excess of its
recommended safe working load.
c. While operating cranes in the vicinity of overhead electric
transmission line adequate precaution shall be taken against
accidental contact with the electric transmission line during
movement of the same.
d. All rigging equipment and crane shall be examined by a
competent person and he shall record the results of his inspection
in a bound paged book kept for the purpose and shall be signed
and dated by the person making the inspection.
e. Size up the load that you are about to lift and get help if
necessary.
f. While lifting load, keep your back as nearly straight and vertical
as possible, bend the knees and do the lifting with the leg and
thigh muscles.
g. Be sure you have a secure grip on whatever you are going to lift
or carry and avoid jerking and awkward positions
h. Particular care must be exercised when doing group lifting or
carrying to avoid injury. One man in the group should give
signals so that everyone will work in unison.
i. Ensure that carne operator and other crew of logistic are working
with proper PPE.
14.3.12 HAND TOOLS
a. Tongs/ wrenches should be inspected frequently to eliminate
worn or sprung jaws, broken cages, springs, faces and bent
handles.
b. Inspect driving faces of hammers, chisels, drift pins, bars, and
similar tools frequently to eliminate mushroomed heads, broken
faces and other defects.
c. In applying force to a wrench/ tong, you should take a position
so that you will not lose your balance in case the nut or joint
suddenly loosens or the wrench slips.

d. Non-spark hammers (brass) shall be used when in an explosive or
flammable environment.
e. The wooden handles of hand tools shall be kept free of splinters
and cracks and shall be kept securely attached to the tools.
f. Hands tools shall never be left on ladders or elevated places.
g. Employees shall not use hand tools, which have become dull.
h. Hand tools shall not be used after being subjected to intense heat.
i. Electrical cords shall be checked and replaced if worn.
j. Before rolling up or coiling pneumatic hoses, electrical cords or
hydraulic hoses, disconnect from the power source.
k. Disconnect air and electrical tools from the power source before
changing bits, sockets and blades.
14.3.13 LADDER , STAIRWAYS, FLOORS & PLATFORMS
a. Every scaffold, stage, walkway, working platform, stairway and
ladder, whether temporary or permanent, should be constructed
and maintained in safe condition and should not be altered or
moved while in use.
b. Work areas should be clean and free of debris.
c. Walkways, stairways and exits should be kept clear to provide
unimpeded ingress and egress except during rig up, rig down
and moving.
d. Every stairway, ladder, ramp, runway, floor and platform should
be kept reasonably free of objects and substances which may
create a slipping or tripping hazard, or prevent or hinder the
escape of workmen in an emergency.
e. With the exception of exit and entrance openings, and loading
and unloading areas, a standard guardrail with mid-rail and a
four inch toe board should be installed at the outer edge of any
floor, platform, walkway, ramp or runway which is four feet
above the ground, or another floor or working level. Where
guardrails are not feasible, chains, or wire rope may be used.
f. A guardrail used and/or needed for the purpose of actual or
potential containment of equipment or material should be of such
construction and strength as to effectively contain the full load or
stress which may be anticipated to be applied upon it.

g. Any temporary stabbing board, or other temporary boards,
placed in derrick should be securely fastened.
h. A minimum of two (2) stair ways with hand rails shall be installed
on rigs to provide alternate exits from the rig floor to ground level
when rig floor height is six (6) feet or more.
i. A stairway with handrails should be installed beside the ramps
which should extend from the ground to the derrick floor.
j. Every opening in a derrick floor should be removed or guarded
when not being used.
k. A derrick floor, derrick walk or engine room floor should not be
used as a storage platform for equipment or material that is not
required for immediate use unless the material or equipment is
properly racked or stored, and does not cause congestion of work
areas or walkways
14.3.14 CONSTRUCTION AND LOADING OF PIPE-RACKS
a. Construction of pipe racks shall be designed to support any load
placed thereon.
b. Adequate provision shall be made to prevent pipe-tubular
material or other round material from rolling off pipe-racks.
c. No person shall go or be allowed to go between pipe-rack and a
load of pipe during loading, un-loading and transferring
operations of pipes unless effective protection device or system is
provided to protect such person from being hit by any load of
pipe in motion.
14.3.15 ANCHORING AND WIND GUY LINES
a. Every rig should be equipped with the number and size of guy
lines as recommended by the manufacturer.
b. Every guy line recommended by the manufacturer should be
utilized according to the manufacturer's specifications.
c. Guy lines should not be any closer than 3 meters from lower lines,
and in no case should a guy line be extended above or below a
power line and/or power be turned off and locked out.
d. All chains clamps and tensioning devices that will remain in the
working guy line must have as much strength as the guy line.
Those chains, boomers, clamps and tensioning devices not of

sufficient strength should be bypassed by continuing the guy line
through or around the anchor, then back to the guy line again.
The guy line should be properly secured with at least 3 U –bolt as
per OISD STD 185: WIRE LINE OPERATIONS.
e. A thorough inspection of all guy lines in use should be made
prior to each installation and no guy lines should be spliced.
f. Where the number, size and utilization of guy lines are
recommended by the derrick manufacture, anchors should be
used to secure the guy lines, except when other means or methods
of anchoring the guy lines are recommended by the manufacturer
which are at least as effective as these standards.
Expanding anchors, pipe anchors, concrete anchors, or other
approved techniques should be used as recommended by the rig
manufacturer/ API.
14.3.16 FENCINGS
a. The protected area surrounding every workover installation shall
be provided with fence of not less than 1.8 metres in height.
b. Every fence shall once at least in every seven days be examined
c. Precautions shall be taken to prevent any unauthorised person
from having access to any place which has been duly fenced.
14.4 WELL CONTROL EQUIPMENT

Well Control Equipment and Well Control are covered in detail in
Chapter -7 and 8 respectively of this manual. Safety guidelines/
Recommended Practices along with other details as covered in Chapter 7
ad 8 should be followed in addition to the requirements covered
hereunder in this section.
14.4.1 BOP STACK
For the purpose of servicing of wells, the blow out preventer shall be of
proper stack, specification and rating to ensure that:
a. Well is always kept under control in all situations,
b. Blow out preventer is installed & maintained to enable the shut
off of any flow from the well regardless of the type or diameter of
the tools or equipment in the well,
c. The well head pressure rating should be more than the maximum
anticipated surface pressure.

d. All the equipment should be selected to withstand the maximum
anticipated surface pressures.
14.4.2 CONTROL SYSTEM FOR BOP STACK
a. Well control fluids, equipment and operations shall be designed,
utilized, maintained and/or tested as necessary to control the well
in foreseeable conditions and circumstances.
b. All manual controls for mechanically operated blowout
preventers shall be located at least 0.60 meters outside the derrick
substructure. Instructions for operating the controls shall be
posted prominently near the control wheel.
c. Blow out preventers shall be connected to an accumulator system
which shall be capable of providing fluid of sufficient volume
and pressure to open hydraulically operated valve on bleed off
line to effect full closure of annular preventer all the time. It shall
be capable of closing any ram type blow out preventer and
annular within 30 seconds.
d. Hydraulically operated accumulator unit/ remote control panel
for the blowout preventers at ground floor level shall be installed
at a safe distance from the derrick floor and shall be easily
accessible to DIC.
e. All controls of power operated blowout preventers shall be
located within easy reach of the driller on the derrick floor.
f. Shift in-charge should ensure that BOP accumulator unit is
charged and sufficient oil is filled in oil sump.
g. All controls for blowout preventers shall be clearly identified
with suitable markers.
h. Provided that where special conditions exist which make the
compliance with this sub-regulation unnecessary or not
reasonably practicable the competent authority may by an order
in writing and subject to such conditions as he may specify
therein, grant relaxation from the provision of the sub-
regulation..
14.4.3 TESTING OF BOP STACK
a. BOP assembly should be function & pressure tested regularly
and proper well control practice shall be complied with in
accordance to OISD std 174.

b. Blowout preventer assembly including its control valves,
connected pipes and spacers etc. shall be pressure tested to the
rated pressure of the assembly or the maximum anticipated
surface pressures, whichever is less, soon after its initial
installation, reinstallation, following repair.
c. Notwithstanding anything stated above, the annular blowout
preventers shall not be subjected to more than 70 percent of its
rated pressure.
d. Necessary pressure testing device shall be provided and made
available with each rig.
e. All operational components of the BOP equipment systems
should be function tested at least once a week to verify the
components’ intended operations.
f. Full particulars of all tests mentioned above shall be recorded in
the daily report and in the case of pressure test, the pressure
applied and duration of test shall also be recorded by the persons
making the test.
If during any test, a blowout preventer assembly or any part
thereof is found to be defective, such defects shall be rectified
before resumption of normal operation of workover.
14.5 BLOWOUT
14.5.1 PRECAUTIONS AGAINST BLOWOUT
1. The following control equipment for the workover fluid shall be
installed and kept in use during workover operations :
a. A trip tank
i. to accurately measure the volume of workover fluid
required to keep the well filled at all times.
ii. to ensure filling of well with mud/ workover fluid
when the string is being pulled out.
b. A gas detector or explosimeter to measure the gas ppm in
the return fluid from the well.
2. If their is indication that formation fluids are entering the well,
immediate steps shall be taken to control the well.
a. Standing orders shall be framed regarding action to be taken
when a well kicks and the duties of each person employed

on the rig and such other persons as may be necessary may
be specified.
b. A copy of the standing order shall be pasted prominently
near the rig.
3. Each person employed on a rig shall have an adequate
understanding of the warning signs of a kick, the blowout
preventer assembly and be able to operate the controls for
blowout preventers.
4. Suitable control valves shall be kept available near the well which
can be used in case of emergency to control the well.
5. When running in or pulling out tubing, a gate valve and tubing
hanger shall be preassembled and kept readily available at the
well.
14.5.2 PRECAUTIONS AFTER A BLOWOUT HAS OCCURRED
1. On the appearance of signs indicating that a well is blowing out,
all persons other than those whose presence is deemed necessary
for controlling blowout shall be immediately withdrawn from the
installation and suitable action shall be taken in accordance with
the procedures formulated in the emergency plan prepared under
the provisions of regulation 72 of OMR.
2. During the whole time that any work of controlling a blowout is
in progress, the following precautions shall be taken -
a) Competent person shall be present on the spot throughout;
b) An area not less than 500 meters measured from the outer
most point of the installation shall be considered as danger
zone.
i) All electrical installations within the danger zone shall
be de-energised;
ii) Approved safety lamps or torches shall only be used
within the danger zone;
iii) No naked lights or vehicular traffic shall be permitted
within the danger zone.
c) A competent person shall ascertain the condition of
ventilation and presence of gases with an approved
instrument;

d) There shall be available at or near the place, adequate
number of approved type of self-contained breathing
apparatus or any other apparatus of approved type for use
in emergency;
e) Adequate fire-fighting equipment shall be kept readily
available for immediate use.
f) Any other equipment as required or deemed necessary.
14.6 COMBINED / SIMULTANEOUS OPERATIONS

Examples of combined operations are workover operation at cluster well
site, movement of land rig in / around the producing oil well, workover
operations undertaken on one of the cluster wells simultaneously
producing other wells/ scrapping / bottom hole studies / activation on
the nearby wells etc. The hazards associated with workover operations
are fire due to spark and gas leakage, uncontrolled flow of oil / gas,
perforation hazards, heavy objects handling and accidental rupture of
flow lines, damage to wellhead, X-mas tree etc.
As per OISD STD 186, the following guidelines are suggested for safe
operation at cluster well location:
a. A steel structure, removable type, strong enough to withstand
impact load is to be erected around the production well head, up
to a height of at least one foot above the X-mas tree. The structure
should be reinforced on all sides except one for operating the
valves. The reinforcement should be either double layer sand
bagging or prefabricated portable wall of M.S. plate or non-
flammable light materials. Alternately the three sides should be
enclosed by brick wall (at least 10" Thick).
b. The roof should be safe guarded either with removable type
prefabricated M.S. plate or good quality 3" thick plank which can
be removed during well servicing/scrapping operation.
c. There must be minimum three 10 kg. DCP portable extinguishers
near the producing well all the time during combined operation.
d. The producing well should be checked for any leakage of gas/oil
before movement of rig equipment in/around the area. In charge
of the area/well should be informed in advance for the rig
movement through their area.

e. Flow line from the producing well should be welded and no
chickson joint be used.
f. Flow line and gas input line to the producing well should be at a
suitable distance away from load carrying activities / vehicular
movement.
g. Caution notice board mentioning "DANGER - High pressure Gas
Line" should be displayed at 2/3 appropriate places.
h. Caution board mentioning "DANGER - Well on production"
should be displayed at the producing well.
i. Ensure there is a provision for killing the other well in case of
emergency.
j. If one well is in workover and remaining wells under production,
continuous monitoring for the presence of the gas be undertaken
at the following sites and corrective actions be taken as necessary
and record should be maintained.
o Near the producing well
o At cellar pit of working over well
o At derrick floor
k. If one well is under workover and the adjacent well is under
mechanical scrapping/ bottom hole study job, following
precautions should be taken
i. If any non FLP motor / other electric driven appliance is
within 15 m radius from the well to be scrapped by
mechanical means, then these motors have to be shut down
during the period of scrapping.
ii. Proper planning for scrapping be ensured along with close
co-ordination between production engineer and DIC for
cluster wells.
iii. Scrapping winch should be placed at least 18 m away from
the producing well as well as well being worked over and
the winch-engine should have a spark arrestor.
iv. No welding, cutting or other hot work be undertaken
during the period of scrapping.
v. No vehicular movement is to be allowed at site within 18M
radius during scrapping.

vi. DCP portable extinguishers (minimum three 10 kg.
capacity) must be placed near the well under scrapping.
vii. Any leakage of gas through stuffing box gland require
immediate attention. No gas should be allowed to vent from
the well into the atmosphere.
viii. Ensure that the wire line truck is placed in such a way that
the cable does not touch the well head / X-mas tree.
14.6.1 MOVEMENT OF LAND RIG IN OIL FIELD
The movement of rig takes place when any workover operation is
required to be undertaken on a well located inside or near the on land
production installation or passing near or through the production
installation where the rig movement requires crossing over or moving
parallel to the flow lines etc. Risk involve are damage to flow lines, fire
and pollution. Following precautions should be taken;
a. Check surface and underground pipelines prior to the movement
of the rig / heavy load.
b. During transportation over the pipeline, the vehicle should
pass/cross over with utmost care.
c. All vehicles including heavy earth moving equipment and the
cranes should be fitted with spark arrestor.
d. Flow line and gas input line to the producing well should be at a
suitable distance away from load carrying activities / vehicular
movement.
e. The producing well should be checked for any leakage of gas/oil
before movement of rig equipment in/around the area.
f. In charge of the area/ well should be informed in advance for the
rig movement through their area.
14.7 DRILLS AND TRAINING

14.7.1 BOP DRILLS
a. BOP drills should be conducted once a week with each crew.
b. Drill should be initiated at unscheduled times when operations
and hole condition permits and also at odd hours.
c. To conduct drill, a kick should be simulated.

d. The reaction time from the moment kick is simulated to the
designated crew member's readiness to start the closing
procedure should be recorded and response time should not be
more than 60 seconds.
e. Total time taken to complete the drill should be recorded and it
should not be more than 2 minutes.
f. Following drills should be performed:
o ON BOTTOM DRILL
o TRIP DRILL
o DRILL COLLAR IN BLOWOUT PREVENTER DRILL
o STRING OUT OF THE HOLE DRILL
14.7.2 FIRE DRILL
a. A fire drill should be conducted at least once in a fortnight.
b. Drills should be conducted at odd hours also.
c. Drills should be so conducted as to ensure that crew who could
not participate in a fire drill on one date will participate in the
same drill held at the next date.
d. The observer of the fire should immediately report to driller to
sound alarm (continuous intermittent rings) and should make an
attempt to put out the fire by applying the nearest suitable
extinguishing agent.
e. Each rig should have designated fire fighting teams. The fire
fighting/ rescue team (consists of six persons) should muster at
the fire station closest to the fire. After checking type of fire, they
should use appropriate equipment to extinguish the fire.
However all personnel should be assigned specific duties to be
carried out in the event of a fire drill and should be trained in the
use of fire fighting equipment as per classifications of fire.
f. The DIC be responsible for clearly indicating what additional
action would be taken in the event of a real fire, such as the
posting of a fire watch to guard against rekindling, restoring of
fire fighting equipment and other necessary topics.
g. Report of each fire drill should be prepared by DIC and a copy of
the same should also be sent to the base office.

h. Fire fighting pumps and stations should be inspected at intervals
not exceeding seven days. A record of inspection should be
maintained both on the rig and at the base office.
14.7.3 TRAINING
a. For guidelines on training, refer OISD Standard-154 for safety
aspects of functional training to rig crew
b. Assistant DIC, Shift In-charge, DIC, Safety Officer, Area In-

charge should receive training on well control operations from
reputed institute at interval not more than 3 years.
14.8 CONTINGENCY PLAN ( AS PER OMR 1984)

1. The manager shall frame a contingency plan for fire and submit a
copy thereof to the Regional Inspector who may approve it either
in the form submitted to him or with such additions or alterations
as he may deem fit.
2. The contingency plan shall contain;
a. Organization plan clearly stating the line of command and the
responsibilities of each person involved in case of emergency
situations;
b. Equipment plan clearly stipulating the equipment’s make and
type, capacity, location, correct operation and field of
operation;
c. Action plan clearly stipulating –
i. Alarm and communication system,
ii. System of notifying the authorities,
iii. The duties and responsibilities of each key personnel
including measures to be adopted to avert or minimise
the consequences of the emergency,
iv. When and how the equipment shall be used and when
and how the action shall be carried out, and
v. Help or information that would be available from
associated and external agencies including government
agencies,
vi. Guidelines for terminating the action; and
d. Plan for training of personnel and for mock-drills.

14.9 INSTRUMENTATION / ELECTRICAL SYSTEM/
LIGHTING
a. Shift In-charge should ensure in every shift that all instruments
are in functional order.
b. Electrical Engineer of Rig should ensure that earthing is done on
rigs as per the recommendation of IS: 3043 code of Practice for
Electrical Earthing and the Indian Electricity Rules 1956 &
amendment thereon, if any.
Double earthing must be provided for all the equipment (Static
and rotating both) and bunk houses.
c. The lighting provided in a mine shall as far as possible be so
arranged as to prevent glare or eye strain. Adequate general
lighting arrangement shall be provided during working hours at
the following places, ensuring that flame proof lights are fitted on
the mast & within 15 metres of well.
• Where natural lighting is insufficient
• Derrick floor
• Driller’s stand
• Monkey board
• Every engine and pump house
• Derrick sub structure
• Near blowout preventer controls
• Every place where persons are to work
• Every means of escape, access or egress
d. Electric lighting
• Every electrical lighting apparatus shall be of a type
approved by the Chief Inspector.
• The lighting system installed in the mine shall comply with
the provisions of the Indian Electricity Rules, 1956.
• Every electrical lighting apparatus shall be so fitted as to
protect it from accidental damage.

• The Chief Inspector may from time to time by notification
in the Official Gazette specify the standards of lighting to
be provided in any specified area or places in a mine.
e. Emergency lighting
Adequate number of self contained portable hand lamps of
approved type shall be made and kept available for immediate
use in emergency.
14.10 COMMUNICATION
a. Efficient means of communication shall be provided and
maintained in good working order between manned
installations/ rig and the office of the manager and other places of
work. Wherever possible this shall be by radio telephone and an
alternative means of signalling shall also be provided.
b. The communication and signalling system installed in the mine
shall comply with the provisions of the Indian Electricity Rules,
1956.
14.11 ENVIRONMENT PROTECTION AND WASTE

MANAGEMENT
a. The size and capacity of waste / effluent pit should be designed
as per the type of the rig, depth of the well, climatic condition of
the area and quantity of waste discharged during the operation of
the rig.
b. Any oil discharged from a well during its completion, testing and
repairs shall be collected in suitably constructed and adequately
fenced disposal pits/ tanks.
c. Oil pit should be made at a suitable distance to collect oil/
condensate during activation of well. Adequate care shall also be
taken so that in no case the accumulated waste / effluent from the
pit shall overflow or seep outside. In such case the excess amount
of waste from the pit shall be pumped out or be transferred to any
other central pit. There should be some provision for mechanical
/ manual lifting of oil from the waste pit, in case such a situation
occurs.
d. No disposal pits shall be constructed within 45 metres of any
railway, public road or of any public works or of other permanent
structure not belonging to the owner.

e. Formation water, oil, drilling fluid, waste, chemical substances or
refuse from a well, tank or other production installation shall not
be permitted, -
1. to create hazard to public health and safety;
2. to run into or contaminate any fresh water structure or body
of water or to remain in a place from which it might
contaminate any fresh water or body of water; and
3. to run over or damage any land, highway or public road;
f. Gas produced at any installation shall not be discharged to the
atmosphere unless burnt in accordance with clause (b) of OMR
Regulation 96 or in the manner otherwise approved by the Chief
Inspector through a general or special order.
Gas to be burned, shall be discharged from a flare line in the
following manner.
1. the flare-line shall terminate with the vertical rise of at least
9 metres or such greater height as may be required by the
Regional Inspector by an order in writing;
2. The flare-line shall be adequate anchored and provided with
suitable means to prevent extinction of the flame;
14.12 WORK PERMIT SYSTEM (OISD-STANDARD-105)

The Work Permit System is an important tool for safety. Success of the
system depends upon the training, motivation and participation of all
individuals concerned with its implementation. Since several
maintenance/ construction jobs are often carried out with assistance from
contractors, it is essential to provide sufficient exposure to contractor and
his employees as well about the work permit system.
If the work has to be performed at rig site by any person other than the
operating personnel of that area, a duly authorized written permit shall
be obtained by the person/ agency executing the work before
commencement of the work. However, even for operating personnel,
when work has to be performed outside their normal routine, an
exclusive permit to that effect by the authorized person shall be obtained.
14.12.1 TYPE OF WORK PERMITS
Based on the nature, the work shall be undertaken either under Hot Work
Permit or Cold Work Permit, for which formats are prescribed in OISD

STD. 105. Format for electrical lockout/ energizing is given in OISD-STD-
137 on "Inspection of Electrical Equipment".
14.12.2 PROCEDURE FOR WORK PERMIT SYSTEM
a) The Work Permit System shall always operate on "Owner - In-
charge" concept. The concerned management shall issue the
appropriate authority limits for various installations and type of
permits based on this concept.
b) The permit shall be in printed form. Separate forms shall be used
for Hot Work and Cold Work. A system of color coding is
recommended to identify two types of permits. The recommended
colors are pink for Hot Work Permit and yellow for Cold Work
Permit. All permits shall be serially numbered.
c) Hot Work Permit shall be in four copies. The original shall be in
pink color and other copies shall have the word "COPY" printed in
large pink letters.
Cold Work Permit shall be in two copies. The Original shall be in
yellow color and the copy shall have the word "COPY" printed in
large yellow letters.
d) It is recommended that both Hot Work Permit as well as Cold
Work Permit be made in the form of books with tear-off facility. In
the case of Hot Work Permit, the authorized original copy shall be
given to the receiver, the duplicate to the Fire Section, triplicate to
Safety Section and quadruplicate retained in the book. In case of
Cold Work Permit, the authorized original shall be issued to the
receiver, retaining the duplicate in the book.
It is recommended that plot plans of the installation and the
operating blocks should be displayed in the Fire and concerned
Unit Control Rooms respectively and site of hot jobs under
progress should be indicated on these plot plans with red pins.
This helps the incoming supervisors (both in Fire and Operating
Departments) to get a quick idea of the hot jobs being undertaken
and help in identifying the areas which require inspection/
attention, depending upon the criticality of the area and the job.
The Safety Officer/ Fire Officer/ Officer authorized will make
periodic check of the Hot Work Sites and see that the work is being
carried out as per conditions laid down in the Hot Work Permit. At
any point of time, if he considers that the conditions are not safe

enough for the work, he may suspend the work and inform the
Work Permit Issuing authority to restore the safe conditions so that
work can be restarted.
e) For simplification of procedure, Hot Work Permit also covers
permission for vessel entry, vessel boxing-up and excavation. All
activities outside the scope of Hot Work Permit shall be covered
by Cold Work Permit.
f) No hot/cold work shall be undertaken without a work permit
except in the areas pre-determined and designated by the owner-
in-charge. All work permits shall be issued by the person who is
designated as responsible person for the operation of the area
where work is to be carried out. In respect of work permits for
handling highly critical types of work and also for long duration
work such as in construction jobs in a running installation, the
authorizing level should be elevated.
g) The work may be planned to be done either departmentally or
through a contractor. In either case, the work permit should be
received and signed by the maintenance/ project /construction
supervisor of the company as he is responsible for the work of the
contractor also. Where no such independent supervisor exists, for
example in small installations, the owner-in-charge can issue the
permit to the contractor's supervisor directly and obtain his
signature.
h) Permit should be issued only for a single shift and its validity
should expire at the termination of the shift. However, where the
work has to be continued, the same permit may be revalidated in
the succeeding shift, by authorized person after satisfying the
normal checks.
In instances like plant turn around or an activity where work is of
continuous nature involving round the clock activity, blanket Hot
Work Permit could be given if the owner-in-charge is fully
satisfied that the conditions are totally safe for the multiple jobs to
be performed. But this should not be resorted to, especially in
highly integrated units.
Even when construction activity has to be undertaken in non-
operating areas in integrated units, it is recommended that
approval be obtained from designated senior management for
issuing blanket Hot Work Permit.

i) As a pre-requisite to issue permit, particularly in the case of hot
work/vessel entry permit, gas test for hydrocarbons / oxygen
deficiency / toxic gases shall be conducted as applicable.
j) Where gas-free conditions are not fully ensured for the duration of
hot work, a system of monitoring either by automatic or by
manual periodic verification shall be resorted to depending upon
the prevalent conditions of the operating area.
k) After completion or stoppage of the job, the person to whom the
permit was issued, should thoroughly check the area for clearing
of debris, removal of temporary electrical installations etc. and
then shall sign the work permit and return it to the issuer.
l) The issuer on receiving back the permit would satisfy himself
regarding completion of the job and that the area has been
cleaned. Then he shall also sign the permit and keep the records
for one month.
14.13 PRECAUTIONS DURING WELDING

a. No person other than a competent welder duly authorised in
writing by the manager or installation manager shall carry out
welding or cutting work requiring use of flame or electric welding
apparatus.
b. No welding or cutting work shall be undertaken by any welder in
any classified hazardous area unless a hot work permit is issued
to the welder by the Shift I/C or DIC. Copies of hot work permits
shall be entered in a register and stored.
c. No welding or cutting work shall be undertaken in hazardous
area unless the area is duly examined and found gas-free by a
competent person authorised for the purpose. A report of every
such examination shall be recorded in a bound-paged book kept
for the purpose and shall be signed and dated by the person
making the examination.
d. Welding/ cutting shall commence only after provisions of OMR
regulation 69(3) are complied with.
e. During the welding and cutting operation, the welder shall see
that:-
i. All flammable material, oil, grease, oil-soaked earth are
removed from the area;

ii. No matches, lighters or smoking apparatus or any other
source capable of igniting flammable gas is present at or
around his place of work;
iii. Adequate precautions are taken to prevent fires being
started by sparks, slag or hot metal;
iv. Adequate number of foam or dry chemical type fire-
extinguishers are readily available for immediate use;
v. When operations are carried out in confined space, adequate
ventilation by mechanical means is constantly provided to
prevent accumulation of flammable gas;
vi. When operations are carried out on pipeline which
contained flammable fluid, ensure that pipe is disconnected
or blinded / the line is isolated, drained and purged with
inert gas or water before hot work is undertaken. Adequate
precautions are taken against build-up of pressure in the line
while hot work is in progress;
vii. The installation manager shall ensure that hot work permits
are issued and welding and cutting operations are carried
out in accordance with the said permits.
viii. During the operation, tests for presence of hazardous
atmosphere shall be made with explosimeter at periodic
interval. If during any such test it is found that the area is
not gas-free, all welding/cutting work shall be stopped
forthwith and the operation shall not be resumed till the
area is made gas-free.
14.14 CLASSIFICATION OF AREAS FOR ELECTRICAL

INSTALLATIONS (OISD STD 105 and OISD STD 186)
Hazardous areas are those where during normal operations, a hazardous
atmosphere is likely to occur in sufficient quantity to constitute hazard. A
hazardous atmosphere is an atmosphere containing any flammable gas or
vapour in a concentration capable of ignition.
Hazardous areas are classified to assist selection of electrical equipment.

While classifying an area the probability of release of flammable liquids
or vapours in sufficient quantity to constitute an explosive or ignitable
mixture is considered. The question of whether such release is likely to

occur during normal operation, or only as a result of an unusual
occurrence or abnormal conditions, is also determined.
14.14.1 AREA CLASSIFICATION

To determine the type of electrical installation appropriate to a particular
situation, the hazardous areas have been classified into three zones
namely zone - 0, zone - 1 and zone - 2 according to the probability of the
presence of hazardous atmosphere.
Zone - 0
Zone-0 hazardous area means an area in which hazardous atmosphere is

continuously present or is likely to be present for long periods and any
arc or spark resulting from failure of electrical apparatus in such an area
would almost certainly lead to fire or explosion.
Zone-1
Zone-1 hazardous area means an area in which a hazardous atmosphere
is likely to occur under normal operating conditions. Such conditions are
likely to occur at any time at oil and gas wells and production
installations.
Zone-2
Zone-2 hazardous area means an area in which a hazardous atmosphere

is likely to occur only under abnormal operating conditions and if it
occurs it will exist only for a short time.
14.14.2 CLASSIFICATION OF HAZARDOUS AREA IN WORKOVER WELLS
Areas surrounding a well in the process of drilling or being serviced by
workover rig should be classified as follows:
Well head area
• When the derrick is not enclosed and the sub-structure is open to
ventilated area above the ground level extending vertically 8 m
above the well and horizontally 16m in all directions from the
well, the area should be classified as Zone-2 area.
• When the derrick floor and sub structure are enclosed, the entire
enclosed sub structure including cellar-pits, and sumps below the
ground level should be classified as Zone-1 area but the area
enclosed above the derrick floor should be classified as Zone-2
area.

• Cellars, trenches and pits below ground level and located in a
Zone-2 area, should be classified as Zone-1 area.
Producing oil and gas wells
• Area around a flowing well without any cellar and located in open
air is classified as Zone 2.
• Area around a flowing well located in open area with a cellar,
extending vertically up to 60 cm above the ground level should be
classified as Zone-2. The cellar should be classified as Zone-1.
• The area within a radius of not less then 16 m horizontally and
extending 8 m vertically above from an open discharge of
petroleum bearing fluid from a well under production test, should
be classified as Zone-1 area.
• The area within a radius of not less than 16 m. horizontally & 8 m
vertically from a well under production test in a closed system
should be classified as Zone-2.
Well servicing operation
• The area within a radius of not less than 16 m in all directions
from well servicing operations should be classified as Zone-1.
• If tests with explosimeter, made every two hours, show that
hazardous atmosphere does not exist then the area may be
classified as Zone-2.
14.14.3 USE OF ELECTRICAL EQUIPMENT IN HAZARDOUS AREA (OMR
1984)
a. No electrical appliance, equipment, or machinery including
lighting apparatus shall be used in zone ‘O’ hazardous area.
b. The Chief Inspector may from time to time by notification in the

official Gazette specify appliances, equipment and machinery that
are or may be used in zone 1 and zone 2 hazardous area which
will be of such type, standard and make as approved by the Chief
Inspector by a general or special order in writing. Where any such
appliances, equipment, or machinery has been specified by the
Chief Inspector, any appliances, equipment, or machinery other
than that approved by the Chief Inspector as aforesaid shall not be
used in such hazardous area.

14.15 CONTRCTACTUAL SAFETY METHODLOGY
Oil and Gas operations like Drilling, Workover, Production, etc are
inherently hazardous in nature. A large number of contractor workforce
is deployed to carry out for operation and maintenance of the rigs and to
undertake civil and other jobs. In order to improve the safety levels at
worksites, the contractor safety is of utmost importance. This section
covers broad guidelines which should form part of the management
system for enhancing the safety levels of the contractor workforce.
14.15.1 OWNER’S RESPONSIBLTIES
a) Management
The commitment to safety has to be emphasised by the owner by practice
by its own management and employees at all levels. The duties and
responsibilities of owner should include:
i) To provide specific information to contractors and make workers
aware on the hazards associated with job assigned.
ii) To provide information about Risk Mitigation measures available at
the place of work.
iii) To provide the contractor with information on Owners Safety Plan &
Regulations, Emergency Response Plan, lockout/ tag out procedure,
confined space entry, work permit system etc.
iv) To specify rules (e.g. for security including access arrangements) and
safety rules such as fire protection, first aid arrangements etc.
v) To provide comprehensive list of statutory regulations / standards
and specification, to be complied with during execution of contract,
in the tender document itself.
vi) To ensure training of the contractor workforce, medical examination,
and proper usage of safety equipment.
b) Representative/Engineer-in-charge
The duties & responsibilities of engineer-in-charge/ DIC should include:
i) To ensure that all contract requirements including Health, Safety,
Environment & Security are complied with.
ii) To ensure that contractor workforce deployed is adequately
qualified, trained and in state of health to commensurate with the
requirements of the job.

iii) To ensure that the Tools / Tackles and Machinery being used are
properly tested and are in sound working conditions and
necessary PPE are being used.
iv) To take the required necessary corrective action immediately
upon noticing or receipt of a report on non-compliance or any
such condition which poses a threat to health, safety or
environment. If during the course of execution of the contract, any
situation of non-compliance with the contractor's safety and
health plan are noticed / reported, the same shall be taken up
with the contractor for correction. In the event of repeated non
compliance, suitable action to be initiated as per the contract.
v) To ensure that the incidents are reported to all concerned within
stipulated timeframe.
vi) To ensure submission of a plan for safe working (Method
Statement/ Safety Philosophy) from contractor and approval of
the same by competent person / department.
vii) To ensure that Work Permit System in line with OISD-STD-105 is
adhered to.
viii) To ensure availability of all the documentation needed for the
execution of contract.
ix) To ensure that the contractor employ / designate a qualified &
trained Safety Engineer / Officer commensurate with
requirement of the job.
c) Safety Officer
The duties & responsibilities of the Owner's Safety Officer should
include:
i) To assess the hazards associated with jobs in consultation with all
concerned and establish safe working procedure including
identification of the escape routes.
ii) To undertake routine/surprise inspections of all work sites and
identify unsafe conditions & practices, if any. Check for
compliance of the safety practices being followed with approved
HSE Plan.
iii) To investigate promptly the incidents (including near-miss) in
order to advise corrective and/or preventive action.

iv) To maintain statistical information for use in analyzing all phases
of incidents and events involving contract personnel.
v) To provide the means for complying with the reporting
requirements for occupational injuries and illnesses.
vi) To review and monitor the contractor's adherence to approved
HSE plan and all applicable environmental, health, and safety
requirements.
vii) To ensure that Contractor’s Managers, Supervisors and workmen
at all levels (who will plan, monitor, oversee and carry out the
work) undergo Health, Safety and Environmental training as per
the contract in their respective responsibilities with respect to
conducting work safely and with due regard for the protection of
the environment.
viii) To document and to bring to the attention of the Owner's
Supervisor and Contractor any non-compliance/violation of the
safety norms against approved safety and health plan or safety
and health requirements and also raises these issues in the Safety
Committee Meetings.
ix) To take part in Tool Box Meetings at random and to ensure
maintenance of records.
14.15.2 CONTRACTOR RESPONSIBLTIES
a) Management
Duties & responsibilities of the contractor should include the following:
i) To implement safe methods and practices, deploy appropriate
machinery, tools & tackles, experienced supervisory personnel and
skilled work force etc. as required for execution.
ii) To prepare a comprehensive and documented plan for
implementation, monitoring and reporting of Health, Safety and
Environment (HSE) and implement the same after its approval.
iii) To nominate qualified & trained Safety Engineers / Officers
reporting to the Site in charge, for supervision, co-ordination and,
liaison for the implementation of the safety plan.
iv) To arrange suitable facilities in liaison with the owner for drinking
water, toilets, lighting, canteen etc as applicable as per Laws/
Legislation at site and also arrange for workmen compensation

insurance, third party liability insurance, registration under ESI / PF
act etc as applicable.
v) To arrange for fire protection equipment as per the advice of owner.
vi) To ensure that its employees have completed appropriate health and
safety training as required by the statute / regulation and also as per
requirements of the Owner. The documentation of such training
imparted to all its employees should be maintained and produced
for verification as required.
vii) To comply with all the security arrangements of owner.
viii) To ensure that the plant and equipment used on-site by him /
his employees is correctly registered, controlled and maintained in
sound working condition.
ix) To ensure availability of First Aid boxes and First Aid trained
attendant.
x) To ensure that all incidents including near misses are reported to all
concerned immediately.
xi) If any sub-contractor is engaged, the contractor should set out the
responsibilities, duties and safety measures that are expected of the
sub-contractor’s workforce. These measures should include the
provision and use of specific safety equipment, methods of carrying
out specific tasks on safety and the inspection and appropriate use of
tools.
The selection of sub contractors, if employed, should be approved by the
owner. Sub-contractor should comply fully with all safety rules and
conditions applicable to the main contractor.
b) Contractor’s Supervisor / Safety Officer
Duties & responsibilities of the Contractor’s supervisor/Safety Officer
should include the following:
i) To ensure strict compliance with work permit system by carrying
out work only with appropriate work permits and after ensuring
that all safety precautions / conditions in the permit are complied
with and closing the same after job completion.
ii) To ensure that required guards and protective equipment are
provided, used, and properly maintained.

iii) To ensure that tools and equipment are properly maintained and
tested.
iv) To plan the workload and assign workers to jobs in commensuration
with their qualification, experience and state of health.
v) To ensure that the workers understand the work to be done, the
hazards that may be encountered and the proper
precautions/procedure for carrying out the work safely.
vi) To take immediate action to correct any violation of safety rules
observed or reported.
vii) To ensure that the workers likely to be exposed to hazardous
chemicals/ materials have access to appropriate Material Safety
Data Sheets (MSDS), wherever applicable, and provide necessary
mitigation measures.
viii) To ensure inspection and certification of all tools (hand operated as
well as mechanically operated) being used. Defective tools shall be
immediately removed.
ix) To ensure that appropriate warning signboards or tags are
displayed.
x) To ensure that workers have proper training for their job
assignments, including use of appropriate PPE and first aid fire
fighting equipment.
xi) To comply with all applicable safety and health standards, rules,
regulations and orders issued by competent authority pertaining to
the assigned activities.
xii) To ensure that sick and/or injured workers receive appropriate first
aid and/or medical attention.
xiii) To report each incident and/or injury in accordance with established
procedures and assist in investigation.
xiv) To take necessary action for correction of any unsafe act / condition
at the workplace. However, in case the same is outside the limits of
authority, it should be reported to Owner’s Engineer-in-charge/ DIC
immediately.
xv) To conduct daily inspections to ensure compliance with safety
standards, codes, regulations, rules and orders applicable to the
work concerned.

xvi) To ensure that workers under their supervision are aware of their
responsibilities.
xvii) To maintain awareness, update training and convey important
safety and health information, contractor supervisors should
conduct tool box meetings at least weekly and also prior to start of
any work and maintain records in the required formats. All the
contractor workers should attend this meeting. The owner’s
supervisor/Engineer-in-charge and safety officers should also attend
these meetings on random basis.
xviii) To develop methods and display banners/posters to inculcate safety
consciousness.
xix) To attend training and ensure participation of his workers for
training as per schedule arranged by the Owner and keeps himself
updated.
xx) To keep records of number of persons working at the site.
xxi) To keep a constant liaison with Engg-in-charge / owners’
representative on safety issues.
xxii) To maintain accident & near miss record in a register.
xxiii) To ensure that only PPE of the approved type by owner is used at
site.
c) Contract workers
The duties & responsibilities of the contractor worker should include the
following:
i) To perform work safely as per the job requirement and
instructions.
ii) To inform all concerned regarding unsafe conditions/acts.
iii) To wear PPE as stipulated and necessary for the job.
iv) To inform promptly to their supervisor regarding all work related
incidents resulting in personal injury, illness and/or property
damage.
v) To take all necessary and appropriate safety precautions to
protect themselves, other personnel and the environment.

OISD CHECKLIST FOR WORKOVER RIGS
EXTERNAL SAFETY AUDIT CHECKLIST/QUESTIONNAIRE
ORGANISATION ________________________________
RIG ______________________________
BUSINESS GROUP ________________________________
PROJECT ________________________________
PERIOD _______________________________
AUDIT ROUND ___________________________________
SAFETY AUDIT TEAM --------------------- ----------------------
CHAPTE CONTENT PAGE
1 GENERAL 2
2 SAFETY MANAGEMENT SYSTEM 2
3 TRAINING 3
4 ACCIDENT/INCIDENT REPORTING &INVESTIGATION 4
5 PLANNED INSPECTION AND MAINTENANCE 4
6 EMERGENCY PREPAREDNESS 10
7 WORK PERMIT SYSTEM 12
8 PERSONAL PROTECTIVE EQUIPMENT 12
9 HEALTH & HYGIENE CONTROL 13
10 COMMUNICATION 13
11 MODIFICATIONS 14
12 ENVIRONMENT 14
13 WORKOVER OPERATIONS 15
14 HOUSEKEEPING 15
15 SAFETY SIGNBOARDS AND MARKINGS 15
16 DOCUMENTATTION 16
ABBREVIATION FOR ANSWERS
Yes (Y); No (N); Not Applicable (NA); NOT COMMENTED (NC); COMMENTS IF ANY (
C) (Details attached); Satisfactory ( ); Not Satisfactory (x)

CHAPTER 1: GENERAL
Brief Details of the Workover Rig
1.0 Brief specification of the rig
1. 1 Date of commissioning
1.2 Hook load capacity
1.3 Number of wells worked over
1.4 Brief details of major events, complications etc.
1.5 Brief details of major modifications/ replacements/

capital repairs undertaken.
1.6 Major achievements / Awards during last three years
1.7 Down time during last three years
CHAPTER 2: SAFETY MANAGEMENT SYSTEM:
2.1 Name of the safety officer designated for the

rig?(Regulation-14,OMR)
2.2 Name of the Fire officer designated for the

rig?(Regulation-15,OMR)
2.3 Do all levels understand their responsibilities?
2.4 Are copies of SOP (Standard Operating

Procedures) available and displayed?
2.5 Are following discussed in safety meetings held

with crew ?(Clause 4.1.2 – OISD-GDN.-206)
a)Recommended practices and Safe operating

procedures
b) Learning from past accidents/near misses.
2.6 Whether pre-operation conference held? (Clause

4.0(8) – OISD-GDN.-206)

a) Are safety measures and emergency
preparedness specific to operations being
undertaken discussed?
b) No. of observations raised in last pre-

operation conference?
c) No. of un-implemented observations?
2.8 Whether internal audits by following are carried

out?(OISD-STD.145)
a)Concerned Section
b) Project HSE/ Regional HSE
2.9 Whether system exists for monitoring

recommendations given by above audit teams?
2.10 How frequently are schedules reviewed by

Area Manager/ General Manager/Project
Manager?
2.11 Are due precautions taken for safe operation till
implementation of pending observations?
2.12 Do you have a schedule for inspection of all

equipment and systems available at the rig?
2.13 Are checklists used for these inspections?
2.14 Is it ensured that after repair of the equipment, it

would perform safely to its capacity?
2.15 Are views of safety department taken to ascertain

safety requirements are fulfilled at tendering
stage?

CHAPTER 3: TRAINING
3.1 Staff (Mines Vocational Training Rules-1966)
Total No. Of Staff
TRAINING COURSE TRAINED REFRESHER COURSE
i) MVT
ii) Fire Fighting.
iii) First-Aid
3.2 Officers(OISD Std-174 and others)
TRAINING COURSE TRAINED REFRESHER COURSE

Total No. of Officers :
iv) Well Control
v) Fire Fighting.
vi) First-Aid
3.3 Are First Aid / fire fighting Trained Personnel available in

each shift? Give numbers.
CHAPTER 4: ACCIDENT / INCIDENT REPORTING & INVESTIGATION

(OISD Std.-107and Clause 4.12 of Std.-206)
4.1 Is a record maintained of all injuries and dangerous

occurrences?
4.2 Is there any system for periodic review of accidents/fire for

analysing trend and prevent accidents/Fire?
4.3 Is there a procedure for informing the employees about an

accident and remedial measures to prevent recurrence of
similar accidents?
4.4 Are “Near Miss" cases reported and analysed?
4.5 Who constitutes enquiry into major incidents? What is the level
of enquiry officer?

4.6 How many near miss incidents have been reported in last two
years?
- From project
- From other projects
4.7 Recommendations of how many incidents from project/other

projects have been circulated among rig crew to enhance safety
awareness?
CHAPTER 5 : PLANNED INSPECTION AND MAINTENANCE
a) Non Destructive Testing
(Topic 9 of OISD-Std.190)
Is NDT of Mast and sub-structure done?
Is NDT of tubular and handling tools viz. slips, tongs elevators,

links etc. done?
b) Equipment Inspection
Blowout Control Equipment
(Clause 44 of OMR-84 and Topic 6.1 of OISD-Std.-174)
5.1.1 Pressure Testing Test Pressure Last Tested on
i) BOP :
a)Pipe Ram
b) Blind Ram
ii) Choke / Kill Manifold:
iii) X-mas Tree(All valves)
iv) H P Lines:
v) FOSV :
vi) Shut in valve :

5.1.2 Are Pressure Testing Schedule / Procedures
5.1.3 Is Function Testing Schedule / Procedures
5.1.4 BOP Control Unit
i) Location of Unit (16 Mtrs. away from well center)
ii) Condition of the Unit:
• Pressure Gauges
• Pressure steel lines / Fire resistant hoses
• Level of Hydraulic Oil
• Charging of Unit(1000 Psi +/- 100 Psi)
• Availability of sufficient number of charged bottles
iii) Remote control unit at derrick floor
iv) Availability of BOP locking wheels with suitable

extension rods protruding min. of 0.6m out of sub-
structure
5.2 Derrick Floor
i) Condition of Derrick floor area viz. Chequered

plates etc.
ii) Are all openings properly covered?
iii) Are railings with toe board provided to cover

Derrick Floor area?
iv) Condition of pipe hooks and fingers
v) Condition of pipe stand(raft)
vi) Availability of safety belt
5.3 Tongs
i) Condition of snubbing lines
ii) Condition of jerk line
iii) Clamps used on jerk line/snub lines/guy ropes/
cat line as per safety rules
iv) Condition of tong safety line

v) Condition of tong dies
vi) Condition of body and jaws of tongs
vii) Condition of elevators
viii) Condition of rotary slips
5.3 Winch
i) Condition of Winch
ii) Condition of foundation and its fastening with bolts
iii) Condition of Wire line
iv) Winding of wire line
v) Condition of its brake
vi) Its Guard
5.5 Draw works
i) Condition of casing line
ii) Condition of kick-back roller
iii) Is casing line properly lubricated?
iv) Condition of Draw works brake bands
v) Condition of Air valves and hoses for any leakage
vi) Condition of Auxiliary Brake(Eddy current/

Hydromatic)
vii) Condition of brake cooling system
Available Operational(Yes/No
5.6 Condition of twin safety device
a) Crown -o- matic
b) Floor – o-matic
5.7 Driller’s Console

i) Condition of Brake lever along-with locking
chain
ii) Stand pipe pressure gauge
iii) Drillometer
iv) Emergency shutdown switch( Should operate

on air shutoff of engines)
v) Portable Gas Detector
vi) Is calibration of gas detector done regularly?
5.8 Mud Pump
i) Is approach to mud pump proper?
ii) Condition of safety valve with proper setting of

relief pressure & the date when checked last ?
iii) The bleed line anchored or not?
iv) H.P. Mud manifold lines secured?
v) Condition of discharge pressure gauges?
vi) Condition of pump engine and transmission?
vii) Does pump gets positive suction fron

mud/brine tank?
viii) Does pump engine have spark arrestor fitted?
5.9 Air System and chassis
i) Whether Air drier/moisture trap provided in

the system?
ii) Has hydraulic testing of Air tanks been done?
iii) Pressure relief valves of air tank serviced and set
iv) Condition of tyres?
v) Power transmission shifter lock in place?

5.9 Engines
i) Are all engines provided with discharge

muffler and spark arrestor?
ii) Condition of gauges and instruments?
iii) Condition of diesel tank and fuel injection

lines for leakages?
iv) Housekeeping in the engine house?
v) Are all moving parts properly guarded?
5.11 Electrical System,
i) Authorization letter possessed by rig

electrician(s)?
ii) Single line diagram displayed?
iii) Proper double earthing of all electrical

equipment / Mast done with appropriate GI
strip ?
iv) Maintenance of earthing pits and their

resistance measurement?
v) FLP features of Junction Boxes, lighting and

cable connection viz airgaps, glands etc
maintained in hazardous zones?
vi) Availability and use of flame proof

environment working tools?
vii) Insulation record?
viii) Proper mat near electrical panel?
ix) Lighting voltage phase to phase ( 215 V)?

(Indian Electricity Rules-1956)

x) Are all fuses/relays/circuit breakers are
installed at their respective place and no
system is bypassed?
xi) Are values of settings of fuses relays within

prescribed limits (Check records and few
samples)?
x) Condition of electrical connections and

cable?
xi) Laying of cables done properly?
xii) Is aviation light as per DGCA rules fitted at

top of the mast?
xiii) Is safety torch available and properly

maintained?
5.12 Mud /Brine System
i) Quantity and specific gravity of reserve

mud /brine as per plan available?
ii) Are mud/brine tanks graduated to monitor
loss/gain of well fluid in the well?
5.13 Emergency Escape Device
i. Escape device installed or not?
ii. Condition of escape device (working or not)?
iii. Is angle of rope within permissible limits?
iv. Periodical operation / inspection carried

out every week?
v. Condition of track rope?
vi. Condition of haulage rope?
vii. Condition of hand brake?
viii. Number of clamps on wire rope and their

condition,?

ix. Condition of landing pad and escape route?
x. Is it ensured that travel path is free from

any obstruction?
xi. Are all topmen confident of using the

device?
5.14 Stairs and ladders
i) Condition of stairs/steps?
ii) Whether stairs are leveled, well secured

and clear ?
iii) Whether side rails of stairs ,Rig floor and on

trailor in position ?
iv) Condition of Mast ladder?
v) Is ladder properly secured with the mast?
vi) Provision of fall prevention device and its

condition?
vii) Is fall prevention device used regularly by

topmen?
viii) Are sufficient numbers of safety belts

available?
5.15 Material Handling & Storage
i) Are adequate storage facilities available for

the material handled?
ii) Are all slings in good condition?
CHAPTER 6 : EMERGENCY PREPAREDNESS
6.1 Is there a contingency plan?
6.2 Does it cover all anticipated emergency scenarios?
6.3 Whether resource requirement and role of different

personnel and agencies properly identified?
6.4 Are key personnel familiar with their emergency duties?

6.5 Are copies of duties of individuals to be performed in
emergency distributed and pasted at prominent places?
6.6 Is contingency plan up-dated regularly keeping in view

transfers/re-deployment of crew?
6.7 Is an approved Disaster Management Plan available?
6.8 Whether contact numbers and distances of nearest

hospital, fire station and GGS to which well(s) connected
displayed ?
6.9 Are following available as per OISD std .–189?
a) Fire water and pump
b) Monitor/hydrants
c) Fire hoses
6.10 Are different type of portable fire extinguishers available

and kept at appropriate place (as per OISD std.-189)?
6.11 How frequently are fire drills held?
6.12 Is response time of crew activities carried out in mock fire

reported?
6.13 Any deficiency observed in fire drill recorded and corrective

measures taken?
6.14 Do safety officer/fire officer brief crew about combating

fire in different Scenarios?
6.15 How frequently are BOP drills held?
6.16 Are BOP drills held as per OISD STD. 174?
6.17 Any deficiency observed in BOP drill recorded and

corrective measures taken?
6.18 Is there a written procedure to check availability and

reliability of emergency equipment?
6.19 Is there an emergency vehicle available?
6.20 Is it in good working condition?
6.21 Is Round the Clock Communication system available?

H2S Hazard Control
6.22 Is H2S anticipated in the area?
6.23 If so,are H2S detectors available at the rig?
6.24 Do employees understand H 2S hazard and safety

procedures ?
6.25 Is wind sock available?
6.26 Is self contained breathing apparatus available in adequate

number?
6.27 Are these fully charged and crew trained to use these sets?
Plant Security
6.28 Whether Rig is enclosed with fence?
6.29 Whether gates are manned?
6.30 Whether identity badges/cards are issued and worn by

employees and visitors and contractor personnel for
admission to restricted areas?
CHAPTER 7: WORK PERMIT SYSTEM
7.1 Are cold /hot work permit in OISD proforma

available?
7.2 Are all potential hazards and safety measures

to be taken to prevent any incident before issue
7.3 Are all hazards explained by a responsible

officer to workmen assigned to execute the job?
7.4 Is execution of job supervised by competent
officers?
CHAPTER 8: PERSONAL PROTECTIVE EQUIPMENT
8.1 Are work places where use of proper clothes,

safety shoes, helmets, hand gloves, goggles,

safety belts, fall arrestors & ear muffs etc.
clearly demarcated?
8.2 Do persons use these equipment?
8.3 Is it ensured that contractual labourers use

PPE’s?
8.4 Are individuals violating these instructions

warned?
8.5 Is the quantity of PPE adequate?
CHAPTER 9 : HEALTH & HYGIENE CONTROL
9.1 Is there a contingency plan available for medical
emergency including evacuation?
9.2 Is there a medical check-up schedule for the

employees?
9.3 What percentage of employees of the rig have

been medically checked?
9.4 Is there noise problem?
9.5 Has the problem been evaluated at the rig?
9.6 Is drinking water available?
9.7 Is test report of drinking water available?
9.8 Whether toilet provided at wellsite with water

connection?
9.9 Are adequate first aid boxes available readily?
9.10 Do first aid boxes contain all prescribed items?
9.11 Are medicines replaced before their expiry

date?
9.12 Is stretcher available?
9.13 Is blanket available?

CHAPTER 10 : COMMUNICATION
10.1 Does round the clock communication facility

from/to the rig exist?
10.2 What communication systems are available at
the rig viz. MART, VHF set ,TELNETetc.?
10.3 Do these systems have battery back-up in case

of power failure?
10.4 Is there a schedule for maintenance of these

equipment?
CHAPTER 11 : MODIFICATIONS :
11.1 Has any major modifications/alterations on the

rig been done?
11.2 Is risk analysis done before

modifications/alterations?
11.3 Was approval obtained from competent authority

for modifications/alterations?
CHAPTER 12 : ENVIRONMENT :
12.1 Layout of Workover site
a) Peripherial trench exists
b) Ring bund
12.2 Waste pit
a) Waste pit exists
b) Distance of waste pit from well center?
12.4 Oil Pit
a) Oil pit constructed to receive oil discharges
b) Distance of oil pit from well center in

metres
c) Distance of oil pit from road in metres
12.6 Water

a) Oil content in disposable water
12.7 Noise
a) Is noise level within limit?
b) Do employees use ear muffs/plugs where

noise level is more ?
CHAPTER 13: WORKOVER OPERATION
13.1 Is there any producing well at the workover site?
13.2 Has this well been closed and guarded by sand

bag wall if permanent wall does not exist?
13.3 Is it ensured that the pipeline leading to GGS is

closed before starting workover operation?
13.4 Whether well is connected to GGS by permanent

pipeline?
13.4 Distance from the well to oil pit is safe and is oil
pit emptied?
13.5 Is flow line anchored properly?
13.6 Is flareline used during testing anchored

properly?
13.7 Is it ensured that cellar pit is clean , annulus

valves of wellheads open and any activity in
annuli is monitored regularly?
13.8 In case “Combined Operations” are undertaken,

safety requirements stipulated in OISD-Std.186
are fulfilled?
CHAPTER 14: HOUSE KEEPING
14.1 Are following operating area clean?
a) Engine Room
b) Mud Pump
c) Storm Water Channels
d) Diesel Oil Tank
e) Derrick Floor

f) Cellar Pit
14.2 Are their sufficient disposal bins with lid for rags
and oil waste
14.3 Are these regularly emptied?
14.4 Do operators deal with spillages as they occur?
14.5 Is their water logging inside site during rains?
CHAPTER 15: SAFETY SIGN BOARDS AND MARKINGS
15.1 Display of prohibitory signs like:
a) No Smoking
b) No naked Lights
c) Use of mobile phone prohibited in hazardous

area?
d) Un-authorised entry prohibited
e) Carrying Match Box, Lighters
f) Electrical Danger Signs
g) Areas where safety shoes/helmets to be worn
h) Are hazardous zones demarcated as per OMR?
15.3 Whether site plan has been properly displayed?
15.4 Whether contingency plan displayed to meet

Emergency / Fire?
15.5 Display of names of :
a) First aid trained employees
b) Fire fighting trained employees
CHAPTER 16: DOCUMENTATION
16.1 Following registers to be maintained at the

installation

1. Training
- First Aid
- MVT
- Fire fighting
- Well Control
2. Form 'J' - Return for minor accident
3. Form 'K' - Minor accident register
4. 'Near Miss" Incidents Register
5. Minutes of Pre-operation meeting
6. Safety Meetings
7. PME of employees record
8. Fire Drill
9. B.O.P Drill
10. B.O.P, HP lines ,Choke& Kill manifold Pressure test

record
11. B.O.P. Function test
12. Inspection record Topman escape device
13. Casing line work done, slip & cut record
14. Pressure Vessels hydraulic test
15. Earth Test Records Earth Test Records
16. Insulation test records
17. Status of fire fighting equipment Status of fire

fighting equipment
16.2 Following records to be kept in files
1. Safety circulars
2. Audit by OISD
3. Internal Audits
4. Hot/Cold work permits
5. Daily checklists
6. Copies of DPR(Daily Progress Report)
7. N.D.T. records

16.3 Equipment logbooks and maintenance record of all
equipment to be maintained.

REFERENCES:
1. ‘CODE OF SAFE PRACTICES’ VOL 1 & VOL 2, HSE, ONGC
2. ‘DRILLING OPERATION PRACTICES MANUAL’, INSTITUTE OF
DRILLING TECHNOLOGY, ONGC, DEHRADUN, INDIA (JANUARY
2007)
3. ‘DRILLING OPERATIONS MANUAL’, INSTITUTE OF DRILLING
TECHNOLOGY, ONGC, DEHRADUN, INDIA. (1994)
4. ‘TECHNICAL MANUAL OF WORKOVER OPERATIONS’,
INSTITUTE OF OIL AND GAS PRODUCTION TECHNOLOGY,
ONGC, PANVEL.
5. ‘TECHNICAL MANUAL FOR PRODUCTION OPERATIONS’,
INSTITUTE OF OIL AND GAS PRODUCTION TECHNOLOGY,
ONGC, PANVEL.
6. API SPEC 5CT: SPECIFICATION FOR CASING AND TUBING.
7. API RP 5C1: CARE AND USE OF CASING AND TUBING.
8. API BULLETIN 5C2: Bulletin on Performance Properties of Casing,
Tubing, and Drill Pipe
9. API RP 9B: CARE AND USE OF WIRE ROPES.
10. API RP 53: BLOWOUT PREVENTION EQUIPMENT SYSTEMS FOR
DRILLING OPERATIONS
11. API RP 54 OCCUPATIONAL SAFETY FOR OIL AND GAS WELL
DRILLING AND SERVICING OPERATION
12. OISD STD-105: WORK PERMIT SYSTEM.
13. OISD STD–113: CLASSIFICATION OF AREAS FOR ELECTRICAL
INSTALLATIONS AT HYDROCARBON PROCESSING AND
HANDLING FACILITIES
14. OISD-GDN-115: GUIDELINES ON FIRE FIGHTING, EQUIPMENT
AND APPLIANCES IN PETROLEUM INDUSTRY
15. OISD STD 142: INSPECTION OF FIRE FIGHTING EQUIPMENTS
AND SYSTEMS
16. OISD STD 154: SAFETY ASPECTS IN FUNCTIONAL TRAINING
17. OISD STD 155: PERSONAL PROTECTIVE EQUIPMENT ( Part-I :
Non-respiratory Equipment )

18. OISD STD 155: PERSONAL PROTECTIVE EQUIPMENT ((Part-II :
Respiratory Equipment)
19. OISD STD 174: WELL CONTROL
20. OISD STD 175: CEMENTING OPERATIONS
21. OISD-GD-182: RECOMMENDED SAFE PROCEDURES &
GUIDELINES FOR WORKOVER AND WELL STIMULATION
OPERATIONS
22. OISD STD 183: STANDARD ON LOGGING OPERATIONS
23. OISD-GD-184: STANDARD ON REPLACEMENT OF PERSONAL
PROTECTIVE EQUIPMENT AND LIFE SAVING APPLIANCES
24. OISD STD 185: WIRE LINE OPERATIONS
25. OISD STD 186: COMBINED OPERATIONS
26. OISD STD 187: CARE AND USE OF WIRE ROPE
27. OISD STD 189: STANDARD ON FIRE FIGHTING EQUIPMENT
FOR DRILLING RIGS, WORKOVER RIGS AND PRODUCTION
INSTALLATIONS
28. OISD STD 190: DERRICK FLOOR OPERATIONS (ONSHORE
DRILLING / WORKOVER RIGS)
29. OISD GDN 202: INSPECTION OF DRILLING AND WORK-OVER RIG
MAST & SUB- STRUCTURE.
30. OISD GDN 203: OPERATION, MAINTENANCE AND INSPECTION
OF HOISTING EQUIPMENT
31. OISD GDN 207: CONTRACTOR SAFETY
32. OISD GDN 218: GUIDELINES FOR SAFE RIG- UP AND RIG- DOWN
OF DRILLING AND WORK-OVER RIGS

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CHAPTER-1

Workover Rig And Equipment

ONGC - SOP Workover Operations - Onshore | 1

2 |ONGC - SOP Workover Operations - Onshore

ONGC - SOP Workover Operations - Onshore | 3

4 |ONGC - SOP Workover Operations - Onshore

ONGC - SOP Workover Operations - Onshore | 5

G.1.2 Ram Blow-out Preventer

6 |ONGC - SOP Workover Operations - Onshore

Fig 1.2: Shaffer LWS Double Ram BOP

G.1.2.1 Type of Ram Preventers

Fig 1.3: Pipe Rams

ONGC - SOP Workover Operations - Onshore | 7

Fig 1.4 Variable Bore Ram

iii) Blind/ Shear Blind Ram

Fig -1.5 Shear Blind Ram

8 |ONGC - SOP Workover Operations - Onshore

ONGC - SOP Workover Operations - Onshore | 9

Fig 1.6: BOP Control / Accumulator Unit

10 |ONGC - SOP Workover Operations - Onshore

Bill of Material for Choke and Kill Manifold

ITEM QTY DESCRIPTION

1 13 VALVE MANUAL GATE ALONG WITH HANDLE, 2-1/16”

2 1 CHOKE ADJUSTABLE ALONG WITH HANDLE, 3 -1/16” –

3 1 CHOKE POSITIVE, 2-1/16”-10K (1” ORIFICE) C/W ½”

4 2 STUD’D CROSS, 5 WAY, 2-1/16”-10K

5 3 STUD’D BLOCK, 3 WAY, 2-1/16”-10K

6 1 SPOOL CROSSOVER, 3-1/16”-10K X 2-1/16” -10K X 12.00”

7 1 3-1/16”, 10K FLANGE CROSSOVER X 2” LP NIPPLE WITH

8 1 2-1/16”, 10K FLANGE CROSSOVER X 2” LP NIPPLE WITH

ONGC - SOP Workover Operations - Onshore | 11

9 2 FLUID PRESSURE GAUGE (WITH FLANGE), 0-10000 PSI

10 3 FLANGE X OVER 2-1/16”X 10K WITH 2”, 1502

11 2 FLANGE X OVER 2-1/16”X 10K WITH 2”, 1502

12 3 2-1/16”, 10K FLANGE X 2” NIPPLE C/W 2”, 1502

13 2 2-1/16”, 10K FLANGE X 2” NIPPLE C/W 2”, 1502

14 - RING GASKETS, STUDS, NUTS- AS PER REQUIREMENT

15 1 2.1/16” 10 K CHECK VALVE with 2-1/16”, 10K FLANGE X

Fig. 1.7: Choke and Kill Manifold

12 |ONGC - SOP Workover Operations - Onshore

Fig.1.8: Tubing/ Drill Pipe Elevator

C. Sucker Rod Manual Wrench and Elevator

ONGC - SOP Workover Operations - Onshore | 13

Fig 1.9: Sucker Rod Wrench

D. Swivel and Rotary Hose

14 |ONGC - SOP Workover Operations - Onshore

E. Kelly & Kelly bushing

ONGC - SOP Workover Operations - Onshore | 15

F. Drill Pipe and Tool Joints

16 |ONGC - SOP Workover Operations - Onshore

F1.11: Pipe Spinner

ONGC - SOP Workover Operations - Onshore | 17

18 |ONGC - SOP Workover Operations - Onshore

2.1 SITE PREPARATION (BEFORE RIG RELEASE)

ONGC - SOP Workover Operations - Onshore | 19

20 |ONGC - SOP Workover Operations - Onshore

2.3 RIG RELEASE/ RIGGING DOWN

ONGC - SOP Workover Operations - Onshore | 21

2.4 LOAD HANDLING AND TRANSPORTATION OF RIG

22 |ONGC - SOP Workover Operations - Onshore

ONGC - SOP Workover Operations - Onshore | 23

24 |ONGC - SOP Workover Operations - Onshore