Safety and Loss Prevention

Standard #22 for CT Operations

Module CT09
 Standard #22 Objectives
 The objective of this module is to prevent the following
during Coiled Tubing operations:
– accidents
– injuries
– damage to equipment
– loss of process or environmental damage
 The objective also focuses on:
– guidelines for executing CT operations
– responsibilities of lay Dowell team members
 Responsibility
 Location Manager
– Equipped and Maintained Units
– Necessary and Adequate Personnel (see 5.1)
– Personnel Training
 Sales/Technical Engineers/Managers
– Know/Understand SLP#22
– Work with client to comply with Dowell SLP#22 Std.
 Job Supervisor (SS/FE) “In Charge”
– Comply with all Stds.
– Prohibit/Inhibit risk exposure to Dowell Personnel
 Training Requirements - Operations
 0-3500 psi -or- 0-24,150 Kpa (see 5.2.1)
– Job Supervisor must have completed at Dowell TC, all courses for
Service Execution (SEC) and the Service Supervisor STEP (SSS) for CT
operations -OR-
– Must have completed the Field Engineer STEP (FES) for CT operations
at the Dowell TC -AND-
– Must complete Dowell approved Well Control course
• initial certification only available at the TC
• refreshers may be attained at the district level thru WCS Inc.
 >3500 psi -or- >24,150 Kpa (see 5.2.3)
– All previous training (AND)
– Prior job experience to insure competence
 Training Requirements - Managers
 All FSMs for CT operations must have successfully
completed a Dowell approved Well Control Training Course
which must initially be conducted at RTC
 Refresher Courses may be conducted at the district level as
for all personnel by WCS Inc.
 Standard #22 Covers
 Job Review & Planning
 Job Categorization by Pressure Severity
 Equipment Limitation and Requirements
 Setup and Wellhead Connection
 Stabbing the CT into the Injector
 Function and Pressure Testing
 Minimum STEM for BOP Equipment
 Normal Operations
 Shutting Down Operations at Night
 Flowback
 Emergency Procedures/Contingency Plans
 Emergency Procedures/Contingencies
 Emergency BOP Closure
 Failure of CT String at Surface
– Impending Danger Severity
– Check Valve Failures
 Collapse of CT String
 Wellhead Connection Leak Below BOPs
 Leaking Stripper
 Uncontrollable Ascent/Descent of CT String
 Guide Arch Failure
 Leaking Treatment Lines
 Power Pack Failure
 Crane Unit Failure
 Why Have Such Standards ?
Normal Operating Procedures
A sequence of actions, checks and controls to
ensure correct execution of the intended
operation
SAFETY
Contingency Plans
OF:
GuidelinesPERSONNEL
in the event reasonably foreseeable
but unplanned conditions are encountered
CLIENTS
during the operation

WELL Emergency Procedures

Trained response to conditions which
EQUIPMENT
jeopardize the safety of personnel or security
of the wellbore
 Job Review and Planning
 Planning Meetings between Dowell and Client
– Live Well Intervention
– Milling or Drilling
– Retrieval and/or Fishing
– Logging/Perforating
– Well Killing or any Well Control Intervention
 Information recommended for job design
– Well Characteristics
– Reservoir Data
– Field Logistics
– Operational Logistics

Districts should prepare a standard job order document to aid in data gathering process
 Pressure Categorization

 “Maximum Operating Wellhead Pressure” - MOWP

– 0-3,500 psi. .......... 0-24,150 Kpa ........... sweet/sour .. oil/gas
– 3,500-7,000 psi. ... 24,150-48,300 Kpa .. sweet/sour .. oil/gas
– 7,000-10,000 psi. . 48,300-69,000 Kpa .. sweet/sour .. oil/gas
 “Normal” Operations are < 3,500 psi -or- 24,150 Kpa
 “HPCT” Operations are > 3,500 psi -or- 24,150 Kpa
 Always consider the maximum possible pressure
 “Normal Operations”
<3,500 psi - 24,150 KPa
“High Pressure Operations”
>3,500 psi - 24,150 KPa
<7,000 psi - 48,300 KPa
“High Pressure Operations”
>7,000 psi - 48,300 KPa
<10,000 psi - 69,000 KPa
 BOP Stack Schematic Posting
 Current stack configuration
 Must match the rig-up
 Controls must be labeled
– Function
– Open/Close
 Accumulator volume
 Emergency BOP Closure
 Control Labeling - Example

BLIND

close open SHEAR

close open

SLIP

PIPE

close open close open

 Accumulator System Requirements
 CLOSE - OPEN - CLOSE for ALL components
– CLOSE Slips
– CLOSE Pipes
– CLOSE Shears (with enough force to shear pipe)
– CLOSE All other rams on stack
– OPEN All rams on stack
– CLOSE All rams on stack (with enough force to shear pipe)
 Must function at MOWP
 Must be charged properly with Nitrogen only
 Must meet ASME standard Sec VIII Div 1
Connecting to Wellhead - Threaded

 MOWP no higher than 2,000 psi (13,800 Kpa)

 No flange available (“Braden-Head Style”)
 “Sweet” Service Only
 Thread Inspection (both connector and wellhead)
 Torque Requirements
 Maximum CT size = 1-3/4” OD CT
 Must use 4-steel legs (hydraulic stand is prefered)
 Level Injector mounting (axial loading)
 BOP directly to adapter (no lubricator below BOP)
 Connecting to Wellhead - Flanged
 API 6B and 6BX specifications
– No double drilled flanges (must be destroyed)
– One-piece design according to Treating Equip. Manual
 Inspection
– pressure rating  seal ring groove
– H2S rating  bolt hole
– matching type alignment
 Adapting  obvious damage
– close upper master  never re-use seal rings
– bleed pressure  do not grease or lubricate
– no leaks allowed thru master  use only API bolts/nuts
– Client to operate valves  tighten evenly, faces flat
 Pressure Testing
 PT1 is the minimum of :  PT2 is the minimum of :
– 1.5 x max expected WHP – PT1
– MAWP of BOP, Flanges or X- – MAWP of Coiled Tubing
overs
 Test to PT2
– MAWP of wellhead
– CT Pipe
 Test to PT1
– Pipe Rams
– Blind rams – Stripper
– BOP body and kill line  CoilLIMIT
– Wellhead
– Flange and X-overs
Shutting Down Operations for Night
 POH Completely
 Shut in all master valves
– there must be a Closed upper “Swab or Crown” valve above any side
arm (flowline/wing valve) outlets.
 Bleed-off all pressure above the Closed wellhead
 Injector supported by 4-Steel legs and fastened via guy lines
from 4-corners
 Close and lock blind rams
 Two Dowell employees must remain on site.
– Crane and CTU operators
– Communication on site Lighting package on site
Security must be reviewed

Must be followed if any of the above conditions cannot be met

 Emergency Procedures/Contingencies
 Emergency BOP Closure
 Failure of the CT at Surface
 Collapse of the CT
 Stripper Leakage
 Uncontrolled Descent/Ascent
 Guide Arch/Gooseneck Failure
 Leak in Treating or Flowback Lines
 Power Unit Failure
 Failure of the Crane Unit
 Emergency BOP Closure
 Stop pipe movement
 Close slip and pipe rams
– If time and circumstances permit, review options with client. In
cases where there is an immediate danger to personnel and/or
equipment, proceed immediately.
 Stop pumping
 Close shear rams and cut pipe
– If time permits apply tension to pipe before cutting
 Pull pipe above the blind rams
 Close blind rams
 Manually lock all rams
 Set up to pump kill fluid into the kill port
 BOP Emergency Operation
PIPE STRING

STRIPPER

MUD
OF
SALT
WATER

WING VALVE
RETURN

PIPE STOPPED PIPE CUT STUB BLIND RAMS

SLIP AND PIPE WITHDRAWN CLOSED, FLUID
RAMS CLOSED CIRCULATING
 Coiled Tubing Failure at Surface
 Stop the Injector movement
 Advise all personnel of the danger (sound alarm)
 Reduce the pump rate to idle in lowest gear
 Perform a risk assessment:
– Immediate Danger - Emergency BOP Closure
– No Immediate Danger - You have 3 choices:
• Run the CT into the well
• Continue to POH with the CT
• Stop and perform field repairs to the CT prior to POH
 Coiled Tubing Failure at Surface

 “Running the CT Into the Well”

 RIH and position failure between stripper and pipe rams
 Close the slip and pipe rams
 Pump kill fluid through the CT slowly until well is dead*
 POH with the CT and replace the CT string**

The decision to RIH with the CT may result in a separation of the string
once the weight of the pipe is placed upon the failure. (Below chains)
* Fluid pumped into the kill port will result in some leakage past the pipe
rams since they aren’t designed to seal from the top
** Care must be taken when POH since the CT will likely fail more severely
upon bending again over the guide arch (gooseneck) again and/or at the
reel upon passing through the RC head.
 Coiled Tubing Failure at Surface

 “ Continue to POH with CT”

 Keep the pump rate at the minimum attainable
 Flush the CT with water*
 POH with the CT**

* If no water or other inert liquid is available, this option may not be viable.
Consultation with the client is a must when fluids are leaking onto ground.
** Care must be taken when POH since the CT will likely fail more severely
upon bending again over the guide arch (gooseneck) again and/or at the
reel upon passing through the RC head.
 Coiled Tubing Failure at Surface
 “ Stop & Perform CT Repairs before POH ”
 Close the slips and pipe rams (Manually lock both)
 Bleed the CT pressure, insure that the check valves are holding back
any formation or differential pressure
 if not holding, perform Emergency BOP Closure
 Attach a clamp on both sides of the failure and connect the clamps with
a cable
 Unlock and open both slips and pipe rams
 POH with low reel tension until hole is between reel and injector
 Attach clamp on CT at the RC head
 POH until CT is on ground (slack in tubing is required)
 Close slips and pipe rams again. (Manually lock both)
 Cut the CT and reconnect with internal splice connector
 Unlock and open both slips and pipe rams, RIH until CT slack is out,
remove clamp on reel and POH carefully. Keep all personnel clear
 Collapse of the Coiled Tubing
 Lower the CT until round CT lies across the BOP ram stack.
 Maintain enough circulating pressure to avoid any further
collapse of the CT.
 Close slip and pipe rams. (Manually lock both)
 Test the sip rams by lowering the weight of the CT onto the
slips gently.
 Kill the well through the CT if possible. It may be necessary
to lubricate & bleed through the kill port.
 Shut in and prepare to retrieve the collapsed CT
 Leak Between Wellhead and BOP’s
Non-Flammable/Non-Hazardous Fluid Leaks
 Stop pumping and perform a flow check.
 If there is no flow, POH immediately at a slow rate of
extraction so as not to “swab” the well.
 If the well flows, begin to pump the heaviest non-flammable
fluid down the CT and the annulus at the same time.
– If conditions are safe, POH as quickly as possible making sure the hole
stays full of fluid
– Upon clearing the master valve, CLOSE IN THE WELL!
Leak Between Wellhead and BOP’s
Flammable/Hazardous or H2S Fluid Leaks
 If at any time flammables, hydrocarbons or H2S are released
from the leak and the CT is at least 1-1/2 times the stack
height off of bottom:
– Shear the CT and allow it to fall into the well
– Close the master valve on the wellhead
 If the CT is on or near bottom and flammables,
hydrocarbons or H2S are released from the leak:
– POH 1-1/2 times the height from stripper to master valve*
– Shear the CT and allow it to fall into the well
– Close the master valve on the wellhead
 Leak Between Wellhead and BOP’s
* If the CT is stuck and cannot be raised then the
maximum tension must be pulled to stretch the
CT prior to shearing. It may be possible to clear
the master valve in this fashion however there
may not be enough stretch available thus the CT
may still obstruct master valve.

EVACUATE IMMEDIATELY !
EVACUATE IMMEDIATELY !
EVACUATE IMMEDIATELY !
EVACUATE IMMEDIATELY !
 Stripper Leakage
 Stop pipe movement
 Increase pressure in stripper system or activate tandem stripper.
 It is important to assess the situation before continu-ation of the
job (type of job, well characteristics).
– It might be safer to change the stripper inserts at this time even though
extra stripper pressure stopped the leak.
 Close slip and pipe rams. Manually lock both rams
 Bleed off pressure above pipe rams
 Follow manufacturers procedure for replacement.
 Re-energize and equalize pressure across pipe rams
 Unlock and open all rams and resume operation
 Runaway CT “Into the Well”
Initial Descent - Normal Procedure
 Advise all personnel to evacuate to safe distance
 Increase traction system pressure

If Normal Procedure is Ineffective

 Apply “Emergency Traction” pressure
 Keep injector running In-the-Hole to match speed
 Increase stripper pressure to maximum
Emergency Actions “When all else fails”
 Evacuate cabin until the CT hits bottom of well
 Close pipe rams and slip rams
 Assess damage, possibly resume operations
 Runaway CT “Out of the Well”
Initial Ascent - Normal Procedure
 Advise all personnel to evacuate to safe distance
 Increase traction system pressure

If Normal Procedure is Ineffective

 Apply “Emergency Traction” pressure
 Keep injector running Out-of-Hole to match
speed
 Increase stripper pressure to maximum
Emergency Actions “When all else fails”
 Evacuate cabin until the CT reaches surface
 Close pipe rams and slip rams
 Attempt to secure by closing blinds or wellhead
Runaway Coiled Tubing WARNING !

Do not attempt to jam or push any

items into the spokes of the reel in
an attempt to stop ascent/descent.

This can cause serious injury and

damage to equipment.
 Crane Failure While Above Wellhead
 If the Wellhead is Damaged:
– Close shears and drop CT
– Close blind rams
– Evacuate location
 If Wellhead is NOT damaged (Leaks Present)
– See 18.4
 If Wellhead is NOT damaged (Leaks not Present)
– Close slip and pipe rams. Manually lock both
– Prepare plan of action to retrieve CT