1workover Onshore

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
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
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 ma
and the breakout cathead on the opposite side
D.3 Hoisting Tackle 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
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 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
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
ism 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.
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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.
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
NEEDLE VALVE
OVERALL LENGTH

9 2 FLUID PRESSURE GAUGE (WITH FLANGE), 0-10000 PSI
WELDNECK H/U FEMALE
WELDNECK H/U MALE
WELDNECK H/U FEMALE
WELDNECK H/U MALE
14 - RING GASKETS, STUDS, NUTS- AS PER REQUIREMENT
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
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
ons, 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

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
In the absence of mast manufact
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
relieve pressure on telescoping cylinder.
c. Tighten load guys with equal tension.
d.
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) 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
il 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
ifications, 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
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.

1) nks with liquid inside e.g.
workover fluid, diesel etc.
2) isted 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) 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)

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
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
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
enter the swivel bail on pushing the block and hook system
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
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
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
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
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
3.8.1
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
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. 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
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
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. 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,
should always be handled with thread protectors in place.
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
prevent undue bending.
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
metallurgical study be made. Every attempt should be made to
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
1.
checked.
2.
3. Never use pipe spinner to give torque while making up pie
connections.
4.
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....................
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 cl
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.
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.
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.
Sodium Chloride (NaCl)
The most commonly used brine.
Maximum density possible is 10 ppg.
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.
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.
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.
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.
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.
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.
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
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:
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.
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.
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.
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 semiso
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.
ed 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;
Fluid density
Wellbore temperature.
Crystallization temperature.
Formation compatibility
Corrosion control.
Health, Safety and Environmental (HSE) characteristics.
Economics.
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
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

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.
l/synthetic preflush.

chemical wash.

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 th
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
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.

4.10
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 0 F ( 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

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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

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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

G.2 BOP Control Unit

Fig 1.6: BOP Control / Accumulator Unit

10 |ONGC - SOP Workover Operations - Onshore

Bill of Material for Choke and Kill Manifold

ITEM QTY DESCRIPTION

ONGC - SOP Workover Operations - Onshore | 11

WELDNECK H/U FEMALE

WELDNECK H/U MALE

WELDNECK H/U FEMALE

WELDNECK H/U MALE

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

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

In the absence of mast manufact

of obstructions at the well site location (such as roads, pits,

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

ONGC - SOP Workover Operations - Onshore | 25

26 |ONGC - SOP Workover Operations - Onshore

ONGC - SOP Workover Operations - Onshore | 27

1) Obtain all statutory and regulatory clearances.

28 |ONGC - SOP Workover Operations - Onshore

ONGC - SOP Workover Operations - Onshore | 29

30 |ONGC - SOP Workover Operations - Onshore

49) Guy ropes should be anchored properly as per the

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