Pressure Control for Drilling Completion and Well Intervention Operations Oil Gas Industry PDF

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Author: Prakash Bahadur Thapa Centre for Risk, Integrity and Safety Engineering (C-RISE) Wells Standard Document Number Page 1 of 2 Faculty of Engineering & Applied Release Date Science Title of Manual Revision Number Memorial The University, controlled version St Control of this “Business John’...

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Pressure Control for Drilling Completion and Well Intervention Operations Oil Gas Industry Richard Ryerson

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SYST EM REQUIREMENT S WELL INT ERVENT ION EQUIPMENT kalyan chakravart hi

Author: Prakash Bahadur Thapa Centre for Risk, Integrity and Safety Engineering (C-RISE) Document Number Wells Standard Page 1 of 2 Faculty of Engineering & Applied Science Title of Manual Release Date Revision Number Memorial University, St Control John’s, NL, resides A1B online 3X5,in Canada The controlled version of this “Business Document” Livelink(register mark). Printed copies are UNCONTROLLED.

TABLE OF CONTENTS

TABLE OF CONTENTS 1

INTRODUCTION .................................................................................................................... 4 1.1 REQUIREMENT STATEMENTS .................................................................................. 4 1.2 DEFINITIONS ............................................................................................................... 5 1.3 ABBREVIATIONS ....................................................................................................... 10 1.4 CROSS-REFERENCES BETWEEN GLOBAL WELLS MANUALS ........................... 18 1.5 SUMMARY OF MAIN CHANGES .............................................................................. 18

2

STATEMENTS SUMMARY ................................................................................................. 20

3

ORGANIZATION OF WELL CONTROL OPERATIONS .................................................... 24 3.1 PERSONNEL RESPONSIBILITIES ........................................................................... 24 3.2 WELL CONTROL TRAINING AND ASSESSMENT................................................... 30 3.3 WELL CONTROL READINESS SELF-ASSESSMENT AND AUDITS ...................... 38 3.4 WELL PLANNING FOR WELL CONTROL ................................................................ 41

4

WELL CONTROL PRINCIPLES AND PROCEDURES ...................................................... 51 4.1 FORMATION PRESSURE ......................................................................................... 51 4.2 FORMATION STRENGTH ......................................................................................... 52 4.3 BARRIERS ................................................................................................................. 53 4.4 PRIMARY WELL CONTROL ...................................................................................... 59 4.5 SECONDARY WELL CONTROL ............................................................................... 66 4.6 TERTIARY CONTROL ............................................................................................... 77

5

GENERIC WELL CONTROL EQUIPMENT ........................................................................ 79 5.1 EQUIPMENT STANDARDS ....................................................................................... 79 5.2 INDUSTRY STANDARDS .......................................................................................... 79 5.3 MAINTENANCE, INSPECTION AND CERTIFICATION ............................................ 79 5.4 GENERAL REQUIREMENTS .................................................................................... 81 5.5 BLIND SHEAR RAM REQUIREMENTS ................................................................... 86 5.6 PIPE SHEARING AND SEALING .............................................................................. 87 5.7 DIVERTER EQUIPMENT ........................................................................................... 98 5.8 THE WELL KILL SYSTEM ....................................................................................... 104 5.9 MUD GAS SEPARATOR .......................................................................................... 113 5.10 PRESSURE TEST ACCEPTANCE CRITERIA ........................................................ 119 5.11 MAINTENANCE AND INSPECTION OF WELL CONTROL EQUIPMENT.............. 121

6

SURFACE WELL CONTROL EQUIPMENT ..................................................................... 124 6.1 CLASSIFICATION OF SURFACE BOP WELL CONTROL EQUIPMENT ............... 124 6.2 CHOKE MANIFOLD AND KILL LINE MANIFOLD ................................................... 139 6.3 CONTROL SYSTEM REQUIREMENTS FOR SURFACE BOP STACKS ............... 150 6.4 TESTS FOR SURFACE WELLHEADS AND BOP EQUIPMENT ............................ 155

7

SUBSEA WELL CONTROL EQUIPMENT ........................................................................ 160 7.1 BASIC COMPONENTS OF THE SUBSEA SYSTEM .............................................. 160 7.2 SUBSEA BOP STACK-UP ....................................................................................... 162 7.3 SUBSEA BOP SYSTEM COMPONENTS ................................................................ 163 7.4 INTEGRATED C&K MANIFOLD .............................................................................. 176 7.5 OPERATING AND CONTROL SYSTEMS FOR SUBSEA BOPS ........................... 177 7.6 TESTING SUBSEA WELLHEADS AND BOP EQUIPMENT ................................... 193 7.7 OPERATIONS RELATED TO SUBSEA BOP SYSTEMS ........................................ 202 7.8 SUBSEA WELL CONTROL...................................................................................... 215

8

COMPLETION WELL INTERVENTION OPERATIONS ................................................... 220 8.1 RUNNING A COMPLETION..................................................................................... 220 8.2 CEMENTED COMPLETIONS .................................................................................. 221 8.3 WIRELINE OPERATIONS........................................................................................ 222 8.4 SUBSEA AND WELL INTERVENTION SYSTEMS ................................................. 225 8.5 COILED TUBING INTERVENTION .......................................................................... 262 8.6 SNUBBING/HYDRAULIC WORKOVER UNITS....................................................... 268 8.7 MINIMUM CWI SURFACE STACK RIG-UP REQUIREMENTS .............................. 272 8.8 WELL TESTING ....................................................................................................... 273

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TABLE OF CONTENTS

8.9

CWI WELL CONTROL EQUIPMENT TEST REQUIREMENT OVERVIEW ............ 274

9

SPECIAL TOPICS ............................................................................................................. 277 9.1 HYDROGEN SULFIDE (H2S) ................................................................................... 277 9.2 ADVANCED WELL CONTROL ................................................................................ 279 9.3 HPHT WELL CONTROL .......................................................................................... 287 9.4 MANAGED PRESSURE DRILLING ......................................................................... 292 9.5 DYNAMIC ANNULAR PRESSURE CONTROL ....................................................... 296 9.6 CORING ................................................................................................................... 296 9.7 SEABED SHUT-IN DEVICE ..................................................................................... 298

10

WELL CONTROL CONTINGENCY PLAN ........................................................................ 300 10.1 INTRODUCTION ...................................................................................................... 300 10.2 CONTENT AND STRUCTURE ................................................................................ 300 10.3 WELL CONTROL CONTINGENCY PLANNING ...................................................... 303 10.4 WELL CONTROL CONTINGENCY PLAN RESPONSE .......................................... 307 10.5 CAP AND CONTAIN PLAN ...................................................................................... 309 10.6 WELL CONTROL CONTINGENCY PLAN ASSURANCE ....................................... 311

11

REFERENCES ................................................................................................................... 313

12

APPENDICES .................................................................................................................... 316

APPENDIX 1

WELL CONTROL PREPARATION CHECKLIST....................................... 316

APPENDIX 2

WELL CONTROL DRILL PROCEDURES ................................................. 321

APPENDIX 3

SHALLOW GAS .......................................................................................... 329

APPENDIX 4

FORMATION STRENGTH TESTING ......................................................... 333

APPENDIX 5

DRILL BARRIER EXAMPLES .................................................................... 343

APPENDIX 6

INFLOW TESTING PROCEDURES ........................................................... 345

APPENDIX 7

FLOW CHECK PROCEDURES .................................................................. 353

APPENDIX 8

MULTI-LATERAL WELL KILL DECISION TREE ...................................... 355

APPENDIX 9

SHUT-IN PROCEDURES............................................................................ 356

APPENDIX 10

KILL PROCEDURES .................................................................................. 364

APPENDIX 11

KILL PREPARATIONS AND CALCULATIONS......................................... 369

APPENDIX 12

KICK CONTROL WHILE TRIPPING .......................................................... 374

APPENDIX 13

DRILLERS METHOD .................................................................................. 376

APPENDIX 14

WAIT AND WEIGHT METHOD................................................................... 386

APPENDIX 15

KILL GRAPH CONSTRUCTION FOR DEVIATED WELLS ....................... 398

APPENDIX 16

KILL GRAPH CONSTRUCTION FOR TAPERED STRINGS .................... 401

APPENDIX 17

IWCF KILL SHEETS ................................................................................... 405

APPENDIX 18

VOLUMETRIC AND LUBRICATION METHODS ....................................... 406

APPENDIX 19

IDENTIFYING BALLOONING..................................................................... 413

APPENDIX 20

STRIPPING PROCEDURES ....................................................................... 415

APPENDIX 21

HYDRATE PREVENTION DURING WELL KILLING ................................. 421

APPENDIX 22

TESTS FOR SURFACE WELL CONTROL EQUIPMENT ......................... 423

APPENDIX 23

ACCUMULATOR TESTING........................................................................ 433

APPENDIX 24

TRAPPED GAS IN SUBSEA WELL CONTROL OPERATIONS ............... 437

APPENDIX 25

MEASUREMENTS FOR SUBSEA BOP AND WELLHEAD DATUM ........ 439

APPENDIX 26

CWI SURFACE WELL CONTROL EQUIPMENT REQUIREMENTS ........ 441

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TABLE OF CONTENTS

APPENDIX 27

WELL CONTROL CONTINGENCY PLAN TEMPLATE ............................ 462

APPENDIX 28

THE WELL CONTROL VIRTUAL EMERGENCY RESPONSE TEAM ...... 471

APPENDIX 29

WELL CAPPING ASSESSMENT ............................................................... 483

APPENDIX 30

MINIMUM CONTENT FOR RELIEF WELL PLANNING ASSESSMENTS 490

3

INTRODUCTION

1

INTRODUCTION

1.1

Requirement Statements

These statements designate a requirement intended to reduce or eliminate the occurrence of a process safety risk ranked as Risk Assessment Matrix (RAM) red or yellow 5A or 5B in Figure 1. To deviate, approval is required from the designated TA1 [per the Discipline Controls and Assurance Framework (DCAF)] and endorsement is required from the manual‟s Custodian [typically Principal Technical Expert (PTE)] of this manual. Deviations shall be risk-assessed and logged in the Facility Status Reporting (FSR) tool. A process safety risk is a hazard that can give rise to major accidents involving the release of potentially hazardous materials, release of energy, or both. The deviation approval is time-constrained per Table 1 and shall not exceed 12 months prior to additional approval requirements.

Figure 1 - Risk Assessment Matrix The word “shall” (lowercase) indicates a mandatory requirement that is ranked other than process safety risk RAM red or yellow 5A or 5B defined above. TA2 approval is required for deviation against a “shall” requirement. Custodian (PTE) endorsement can be requested at the discretion of the Technical Authority. The deviation shall be forwarded to the Custodian (PTE) for tracking through the online feedback tool. The

4

INTRODUCTION

deviation approval is time constrained per Table 1 and shall not exceed 12 months prior to additional approval requirements. Should: The word “should” indicates a preferred solution/option with no mandatory requirement. Table 1 – Time-Based Summary for Deviation and Derogation Requests Deviation

Derogation

Approver Approval of Original Extension Request Year 1 TA1 CEO TA1 TA2

TA0 CEO TA0 TA1

of Approval at of Extension at Year 2 TA0* CEO TA0* TA0

* Endorsement of Chief Wells Engineer required. 1.2

Definitions

Term

Definition

Certificate of Document in which a manufacturer, repairer, remanufacturer, or Compatibility

Recognized Technical Authority certifies that the part or system is compatible with the Original Product Definition, including design changes resulting from a malfunction or failure history of Well Control Equipment manufactured, remanufactured and/or repaired to the appropriate international standard / specification, and is fully compatible and/or can be integrated into other systems guaranteeing the operations envelope as defined by the Original Equipment Manufacturer.

Certificate of Document in which the OEM, or recognized technical authority Compliance

certifies that the equipment and/or system meets the required standards or rules as depicted in the relevant area of operations regulatory requirement.

Certificate of Document in which the OEM, OEM licensed facility certifies that Conformance

the assembly or part has been manufactured / remanufactured in

(COC)

conformance to the mentioned standard(s), specifications and

5

INTRODUCTION

Term

Definition guidelines in accordance with the Original Product Definition, including design changes resulting from a malfunction or failure history of well control equipment manufactured, remanufactured and / or repaired to the appropriate international standard / specification.

Certificate of Document in which the licensed facility, Recognized Technical Service

authority / owner or operator certifies that that the equipment has

(COS)

been inspected, properly maintained and tested in accordance with Original Equipment Manufacturer specifications.

Company

The Company is the party that initiates the project and ultimately pays for it. The Company may also include an agent or consultant authorized to act.

Contractor

The general term for an individual or firm that has entered into a legal contract to provide equipment, materials or services to the Company.

Deepwater

Wells and operations in greater than 1,000 ft (305 m) Water Depth (WD).

Derogation

.When not following requirements of documents or Process Safety Basic Requirements (PSBRs), the derogation procedure mandated in the applicable Control Framework manual shall be followed.

Deviation

Deviation is any non-compliance shall requirement statement. Not meeting either of these requirement statements requires the appropriate level of approval per DCAF. Approval of these statements is time-based and has an expiration period.

Exceptions to List of requirements and date that these specific requirements Go-Live Date

within the Wells Manual will become mandatory, where the go-

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INTRODUCTION

Term

Definition live date differs from the overall Wells Manual go-live date.

Go-Live Date

Date that the requirements of the Wells Manual will become mandatory and, if not followed, will require a deviation.

Manual

Global Wells Manual developed with input from the business lines, approved by the Discipline Leadership Team. The manual establishes requirements, guidelines, and good practices for Wells activities globally.

Safe Working The maximum Working Pressure at which Pressure Control Pressure

Equipment is allowed to operate as determined by the Original Equipment Manufacturer.

Next Review The next scheduled revision of the manual. The manual may be Date

revised prior to this date as conditions warrant. When using manuals, only the electronic copy is controlled while printed or saved copies are not.

Non-Primary

All pressure containing well control equipment that can be

Flow Wetted isolated from wellbore fluid / gas in case an influx. Equipment Original

The design owner or manufacturer of the traceable assembled

Equipment

equipment, single equipment unit, or component part.

Manufacturer

NOTE If any alterations to the original design and/or assembled equipment or component part are made by anyone other than the OEM, the assembly, part, or component is not considered an OEM product.

Recognized

The OEM, or registered professional engineer, or a technical

Technical

classification society, or engineering firm in which its employees

Authority

hold appropriate licenses to perform the verification in the appropriate jurisdiction, and evidence to demonstrate that the

7

INTRODUCTION

Term

Definition individual, society, or firm has the expertise and experience necessary to perform the required verifications.

Primary Flow Well control equipment directly exposed to wellbore fluids / gas Wetted

in case of an influx.

Equipment Statement of Document in which the OEM, OEM licensed facility, repairer, Fact

remanufacturer,

or

recognized

TA

certifies

that

the

maintenance/repair performed on a part or system is either not covered by a full service history and required traceability, or the maintenance/repair was made with limited scope defined by the Owner.

The

OEM,

OEM

licensed

facility,