SAUDI ARAMCO WORKOVER MANUAL

Drilling Technical Department September 2013

CHAPTER 2 WORKOVER PRACTICES

SECTION J SURFACE AND DOWNHOLE PLUGS

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SURFACE AND DOWNHOLE PLUGS

1.0 TYPES OF PLUGS

Back
2.0 SURFACE PLUGS

2.1 Back Pressure Valves

2.2 Cement Plugs
2.3 BOP Test Plugs

3.0 DOWNHOLE PLUGS

3.1 Mechanical Downhole Plugs

3.1.1 Plugs for wells with landing nipples
3.1.2 Retrievable plugs for wells without landing nipples
3.1.2.1 Monolock Plug
3.1.2.2 ME plug (PI Intervention)
3.1.3 Permanent Plugs
3.1.3.1 PosiSet (Thru-Tubing Bridge Plug)
3.1.3.2 EZ Drill SVB Squeeze Packer
3.1.3.3 EZ Drill Bridge Plug
3.1.3.4 Fas Drill Bridge Plug
3.1.4 Retrievable Plug for wellbores
3.1.4.1 Model 3L Retrievable Bridge Plug (Halliburton)
3.1.4.2 MC-II retrievable Bridge Plug (Smith)
SAUDI ARAMCO WORKOVER MANUAL
Drilling Technical Department September 2013

CHAPTER 2 WORKOVER PRACTICES

SECTION J SURFACE AND DOWNHOLE PLUGS

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SURFACE AND DOWNHOLE PLUGS

1.0 TYPES OF PLUGS

Several types of plugs are used for many purposes in the Oil Industry. Saudi
Aramco Drilling and Workover commonly uses Back Pressure Valves and Two-way
Check Valves, Balanced Cement Plugs, BOP Test Plugs and Mechanical Downhole
Plugs. These different plugs are used as safety barriers while installing, or
removing, well control and production equipment and as test plugs when pressure
testing equipment. When removing surface control equipment it must be replaced
with downhole isolation barriers. Plugs are the most commonly used isolation
barrier. Please refer to GI 1853.002, Isolation Barriers for Wells during Drilling and
Workover Operations (With and Without Rig) for the required number and type of
plug to be used.

2.0 SURFACE PLUGS

2.1 Back Pressure Valves

Back Pressure Valves are set in a special profile in the tubing hanger. They
are normally used while installing or removing production trees and BOP
equipment. Two way check valves can be installed in the same profile and
are used to test the equipment. A two way check valve shall only be used to
test equipment after it is installed, not during installation or removal
operations. This is because it is possible to pump kill weight fluids through a
back pressure valve but not through the two way check valve. More details
on these plugs and installation and removal procedures may be found in
Chapter 2, Section E-4.0.

2.2 Cement Plugs

Cement plugs may be spotted in casing or, in some cases tubing, and used
as an additional barrier during unusual well servicing operations. More
details on these plugs may be found in Chapter 2, Section F-5.0

2.3 BOP Test Plugs

BOP Test plugs are designed to be installed in a casing head, casing spool
or tubing spool to provide a bottom seal while testing BOPE. They are
designed and built to fit one size head or spool made by one Manufacturer.
For example, if you have a Cameron 13-5/8” 3M casing head you must use
a Cameron 13-5/8” BOP test plug. If you have a Gray 13-5/8” 3M casing
head you must use a Gray 13-5/8” BOP test plug. These plugs may not be

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interchanged. The preferred running procedure is to make up at least one

stand of drill pipe below the plug, preferably heavy-weight. The elastomer
seal on the O.D. of the plug should be visually inspected and a coat of
grease or pipe dope applied prior to running.

3.0 DOWNHOLE PLUGS

3.1 Mechanical Downhole Plugs

Downhole or “wireline” plugs are used on a daily basis in Saudi Aramco

operations. These types of plugs, along with the back pressure valve, are
used as isolation barriers after the completion string has been run. The
wireline plugs can be separated into two categories, the Wells with landing
nipples (X locking mandrel and the R locking mandrel) and the wells without
landing nipples (Monolock, ME Plugs, DW, EZSV, Fas Drill).

3.1.1 Plugs for wells with landing nipples

In order to use these plugs there must be a mating X or R landing

nipple installed in the completion string. Typically the X nipple is
installed in normal weight tubing strings and the R nipple in heavy
weight tubing strings.

Figure 1 shows the R and X models of landing nipples and lock

mandrels. The nipples are selective nipples as they will allow a plug to
pass through them and it can be set in a nipple below, or in the
selected nipple.

Figure 1 also shows XN and RN no-go landing nipples and lock

mandrels. These nipples are termed no-go because they have an
internal profile that will not allow the plug to pass below the nipple, and
thus it can only be set in that specific nipple.

The XR model of lock mandrel or pump-through plug are designed to

hold pressure differential only from below. They allow fluid to be
pumped through by applying tubing pressure above the plug until it
overcomes the well pressure, to equalize around the plug or kill the
well.

Saudi Aramco uses the PX, PXR and PXN plugs almost exclusively.
These plugs come equipped with a pressure equalization valve and
matching prong. They are set in X, selective, and XN, no-go, nipples.

These plugs are installed in three trips. On the first trip, the lock
mandrel is run and set in the profile. The second run is a check set tool

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run to determine if the lock mandrel is correctly set in the profile. The
prong is then inserted on the third trip, sealing the equalization ports
and preventing sand or fill from falling into the interior of the plug.

The plugs are retrieved in two trips. The prong is pulled out on the first.
This provides an equalization path and prevents the plug from being
blown uphole. Then the lock mandrel is retrieved.

All of these plugs may be run and retrieved on coiled tubing. This
method would be desirable in a horizontal or highly deviated well.

Table 1 and 2 list the common sizes of landing nipples and lock
mandrels available. It is always necessary to check the size and
weight of tubing and plug before attempting to run a plug.

Figure 1

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Figure 2

X and XN Landing Nipples and Lock Mandrels

For Standard Tubing Weights

Tubing X® Profile XN® Profile
Lock Mandrel ID
Size Weight ID Drift Packing Bore Packing Bore No-Go ID
in. lb/ft in. in. in. in. in. in.
2.3
1.660 1.380 1.286 1.250 1.250 1.135 0.62
2.4
2.4 1.660
1.900 2.76 1.516 1.500 1.500 1.448 0.75
1.610
2.9
2.063 3.25 1.751 1.657 1.625 1.625 1.536 0.75
4.6
2 3/8 1.995 1.901 1.875 1.875 1.791 1.00
4.7
6.4
2 7/8 2.441 2.347 2.313 2.313 2.205 1.38
6.5
9.3 2.992 2.867 2.813 2.813 2.666
3 1/2 1.75
10.2 2.922 2.797 2.750 2.750 2.635
4 11 3.476 3.351 3.313 3.313 3.135 2.12
4 1/2 12.75 3.958 3.833 3.813 3.813 3.725 2.62
5 13 4.494 4.369 4.313 4.313 3.987 2.62
5 1/2 17 4.892 4.767 4.562 4.562 4.455 3.12

Table 1

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Table-2 R and RN Landing Nipples and Lock Mandrels

For Heavy Tubing Weights
Tubing R® Profile RN® Profile
Bore Lock Mandrel ID
Size Weight ID Drift Packing Bore No-Go ID
in. lb/ft in. in. in. in. in. in.
1.900 3.64 1.500 1.406 1.375 1.375 1.250 0.62
5.3 1.939 1.845 1.781 1.781 1.640 0.88
5.95 1.867 1.773
2 3/8 1.710 1.710 1.560 0.75
6.2 1.853 1.759
7.7 1.703 1.609 1.500 1.500 1.345 0.62
7.9 2.323 2.229 2.188 2.188 2.010 1.12
8.7 2.259 2.165
2.125 2.125 1.937 0.88
8.9 2.243 2.149
2 7/8 9.5 2.195 2.101
2.000 2.000 1.881 0.88
10.4 2.151 2.057
11 2.065 1.971
1.875 1.875 1.716 0.88
11.65 1.995 1.901
12.95 2.750 2.625 2.562 2.562 2.329 1.38
15.8 2.548 2.423
3 1/2 2.313 2.313 2.131 1.12
16.7 2.480 2.355
17.05 2.440 2.315 2.188 2.188 2.010 1.12
11.6 3.428 3.303 3.250 3.250 3.088
4 1.94
13.4 3.340 3.215 3.125 3.125 2.907
12.8 3.958 3.833 3.813 3.813 3.725 2.12
13.5 3.920 3.795
3.688 3.688 3.456 2.38
4 1/2 15.5 3.826 3.701
16.9 3.754 3.629
3.437 3.437 3.260 1.94
19.2 3.640 3.515
15 4.408 4.283 4.125 4.125 3.912 2.75
5
18 4.276 4.151 4.000 4.000 3.748 2.38
17 4.892 4.767
4.562 4.562 4.445 2.85
5 1/2 20 4.778 4.653
23 4.670 4.545 4.313 4.313 3.987 2.62
15 5.524 5.399
6 5.250 5.250 5.018 3.50
18 5.424 5.299
24 5.921 5.795
6 5/8 5.625 5.625 5.500 3.50
28 5.791 5.666
17 6.538 6.431
20 6.456 6.331
23 6.366 6.241
5.963 5.963 5.770
7 26 6.276 6.151 3.75
29 6.184 6.059
32 6.094 5.969
35 6.004 5.879 5.875 5.875 5.750
7.050 7.050 6.925
8 5/8 36 7.825 7.700 7.250 7.250 7.125 3.75
7.450 7.450 7.325

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3.1.2 Retrievable Plugs for wells without landing nipples

3.1.2.1. Monolock Plug

This is a slip-type device which does not require a profile or

sealbore in the tubing string. It may be set hydraulically on
coiled tubing, on conductor line or on slickline (in
conjunction with an electric setting device). Once set, the
Monolock and associated plug assembly will hold pressure
from either direction and can be easily retrieved by slickline,
or coiled tubing. The Monolock Plug consists of the
following main components: slips, a sealing element,
Belleville springs, locking mechanisms, and an equalizing
valve. Retrieving the tools take two trips, first retrieving the
prong and then the Monolock itself.

Tool Tubing Tubing Minimum

Maximum
Size Size Weight Tubing
OD in.
in. in. lb/ft ID in.

3-1/2 3-1/2 9.3 2.992 2.78

13.5-
4-1/2 4-1/2 3.92 3.66
15.5
4-1/2 11.6-
4-1/2 4.000 3.78
13.5

5-1/2 5-1/2 17-23 4.892 4.532

7 7 23-26 6.366 5.97

7 7 26-32 6.276 5.92

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3.1.2.2. ME Plug (PI Intervention)

This is a high performance retrievable bridge plug/packer

that incorporates a high expansion solid rubber element

and powerful anchoring module. The tool has been

designed with a large bore that will serve as an internal junk
catcher when the tool is used as a bridge plug. Its slim
design allows passing restrictions found in most wells and
makes it a good candidate for wells with scale buildup.
Retrieving the tools is achieved by straight upward pull
using a GS style retrieving tool.

Tool Tubing Tubing Minimum

Maximum
Size Size Weight Tubing
OD in.
in. in. lb/ft ID in.

2-7/8 2-7/8 6.4 2.441 2.25

3-1/2 3-1/2 9.2-13.7 2.992 2.52

11.6-
4-1/2 4-1/2 3.826 3.27
15.1

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3.1.3 Permanent plugs

There are many suppliers for the permanent plugs. These plugs
cannot be retrieved and need to be drilled out.

3.1.3.1. PosiSet (Thru-Tubing Bridge Plug)

The PosiSet plugs are elastomeric-anchored plugs and are

run through tubing and set in casing to plug off non-
productive zones. Expansion ratios are typically 3:1. The
biggest advantage of the TTBP is its non-explosive
deployment feature. It can be set in deviated holes
including horizontal. It provides a minimum of 500 psi
differential pressure rating without cement. A small cement
plug can be spotted with dump bailer on top of them to
increase the differential pressure rating. The plugs are
drillable / pushable.

Note: This plug is not considered a well control barrier until

cement is placed on top of it followed by a
successful pressure test.

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3.1.3.2. EZ Drill SVB Squeeze Packer

The EZ Drill SVB Squeeze Packer is built from cast iron,

aluminum, rubber and has a brass mandrel to provide
unsurpassed drillability in general oilfield service
operations. Although primarily used for squeeze cementing,
the EZ Drill SVB Squeeze Packer can also be used as a
bridge plug or as a means of pressure-testing a workstring.
Regardless of its use, this tool can be run in quickly and
drilled out easily. It can achieve a positive set and seal,
regardless of pressure direction because the packer
elements, slips, and other components are specially
designed to set and seal at high pressures, yet offer little
resistance to drillout. The slips of the EZ Drill SVB Squeeze
Packer allow the packer to be set in all grades of casing up
to V150.

Tool Casing Casing Maximum Minimum

Maximum
Size Size Weight Casing Casing
OD in.
in. in. lb/ft ID in. ID in.

4-1/2 4-1/2 9.5-13.5 4.18 3.91 3.66

5 5 11.5-18 4.56 4.27 3.97

7 7 20-38 6.46 5.90 5.5

29.30-
9-5/8 9-5/8 9.06 8.20 7.75
70.30

48.00-
13-3/8 13-3/8 12.71 12.28 11.68
76.60

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3.1.3.3. EZ Drill Bridge Plug

An EZ Drill Bridge Plug consists of an EZ DRILL SVB

Squeeze Packer in which the sliding valve has been
removed and a bridging plug has been added. This bridging
plug is not removable. This plug isolates the well from
either way, up or down providing a safe barrier to the well
pressures.

3.1.3.4. Fas Drill Bridge Plug

The Fas Drill Bridge Plug is used similarly to a conventional

permanent bridge plug. The difference from an EZ Drill
Bridge Plug is the materials of which it is made. This plug
consists of composites and a packer set, giving it minimal
ferrous metal content. This makes it even easier to drillout
than the EZ Drill Bridge Plug, saving rig time and reducing
casing damage caused by long drillout processes, in case
encountered.

Tool Casing Casing Maximum Minimum

Maximum
Size Size Weight Casing Casing
OD in.
in. in. lb/ft ID in. ID in.

3-1/2 3-1/2 9.2-10.3 2.99 2.92 2.69

4-1/2 4-1/2 9.5-13.5 4.09 3.92 3.66

5-1/2 5-1/2 15.5-23 4.95 4.67 4.37

7 7 29-38 6.18 5.92 5.5

7 7 20-29 6.46 6.18 5.8

29.3-
9-5/8 9-5/8 9.06 8.20 7.7
70.3

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3.1.4 Retrievable Plug for wellbores

3.1.4.1. Model 3L Retrievable Bridge Plug (Halliburton)

The tool is run in the hole, set, and released from the tubing
or packer. It remains in place until the tubing or packer is
relatched, the bypass valve is opened, and the slips are
released. This plug can be run alone on tubing or can be
run below the RTTS or CHAMP IV Packer. When set, the
Model 3L Bridge Plug does not move up or down the
casing, regardless of pressure reversals. It consists of
packer-type sealing elements, mechanical slips, and a
large-area bypass.

Tool Casing Casing Maximum Minimum

Maximum
Size Size Weight Casing Casing
OD in.
in. in. lb/ft ID in. ID in.

11.6-
4-1/2 4-1/2 3.920 4.000 3.75
13.5

5 5 13-15 4.408 4.494 4.25

7 7 17-38 5.920 6.538 5.75

9-5/8 9-5/8 32-53.5 8.535 9.001 8.15

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3.1.4.2. MC-II Retrievable Bridge Plug (Smith)

The plug is run on tubing or drill pipe with a “Jay” type

running/retrieving tool, and sets with a quarter right-hand
turn. The running tool incorporates a collet restraint to
prevent accidental release when running or retrieving. It
holds pressure from above and below and is ideal for use in
multiple zone treating and testing operations. The MC-II
plug is ideal for shallow and deep operation wells.

Tool Casing Casing Maximum Minimum

Maximum
Size Size Weight Casing Casing
OD in.
in. in. lb/ft ID in. ID in.

4-1/2 4-1/2 9.5-13.5 4.09 3.92 3.75

7 7 26-32 6.276 6.094 5.875

7 7 17-26 6.276 6.538 6.0

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