Chevron Pacific Indonesia

IBU Drilling & Completion

Barrier Guidelines SOP
IBU – DC D002

Issued June 2020

Version 3.1
©2020 by Chevron Corporation

This document contains proprietary information of Chevron Corporation. Any use of this
document without express, prior, written permission from Chevron Corporation and/or its
affiliates is prohibited.

1
Contents
1.0 Purpose, Objective, and Scope.........................................................................................4
1.1. Purpose and Objective......................................................................................................4
1.2. Scope................................................................................................................................ 4
2.0 Well Control Procedure for Single Barrier Operation......................................................4
2.1. General.............................................................................................................................. 4
2.1.1. Non-Shearables and/or Non-Sealables across the BOP................................................4
2.1.1.1. Shut in Procedure for Well Control Event during Drilling Operation............................5
2.1.1.2. Shut in Procedure for Well Control Event during Tripping Operation..........................5
2.1.1.3. Shut in Procedure for Well Control Event when ESP Motor is at the
Rotary Table/Working Platform.................................................................................6
2.1.1.4. Shut in Procedure for Well Control Event During Run Screen or
Perforated Liner........................................................................................................6
2.1.2. Wells Unable to Hold Full Column of Fluid......................................................................7
2.2. Drilling................................................................................................................................ 7
2.2.1. Installation of Casing Hanger or Casing Pack Off...........................................................7
2.3. Workover and Routine Service...........................................................................................9
2.3.1. BOP, Tree, and Wellhead Accessories Removal/Installation for Non-Flange
Type Tubing Hanger....................................................................................................9
2.3.1.1. Oil Producer with ESP (GOR < 1 MSCF/STB)............................................................9
2.3.1.2. Oil Producer with ESP (GOR > 1 MSCF/STB)...........................................................13
2.3.1.3. Water and Steam Injector Well..................................................................................17
2.3.1.4. Gas Producer Well....................................................................................................20
2.3.1.5. Rigless Operation.....................................................................................................23
2.3.2. Removing Tubing Hanger Following Failure(s) on BOP test..........................................24
2.3.3. Running/Pulling ESP (Non-Sealable due to ESP Cable)...............................................25
2.3.4. BOP, Tree, and Wellhead Accessories Installation/Removal for Sucker Rod
Pumps Including Running/Pulling Sucker Rods..........................................................26
2.3.5. Wireline and Perforations Operations............................................................................31
2.3.6. Underbalance Perforation.............................................................................................31
2.3.7. Non-Mandrel ESP Cable Penetrator Tubing Hanger.....................................................32
2.3.8. N/D X-Mas Tree with Flange Type Tubing Hanger........................................................33
2.3.8.1. For Wells without Production/Injection Packer...........................................................33
2.3.8.2. For Wells with Production/Injection Packer................................................................38
2.3.9. Wellhead Change......................................................................................................... 41
2.3.10. LPT Seal as Temporary Barrier....................................................................................43
2.3.11. Tree Installation for Non-Gas Wells...............................................................................44
3.0 Other Consideration..........................................................................................................46
3.1. Well Suspension.............................................................................................................. 46
4.0 Resources, Roles, and Responsibilities..........................................................................47

Version 3.1 June 2020 2

 5.0 Measurement and Verification.........................................................................................48
6.0 Continual Improvement....................................................................................................48

Version 3.1 June 2020 3

1.0 Purpose, Objective, and Scope
1.1. Purpose and Objective
The primary purpose of this Standard Operating Procedure (SOP) is to serve as a
contingency plan reference for all IBU D&C personnel on Single Barrier operation and
other consideration that need to be governed in Well Barrier Design GTS (DCM-BST-
102007C-IBU). Single Barrier operations are those operations in which it is not possible
or practicable to maintain two independent barriers. During Single Barrier operations,
proceeding for a finite duration with a single barrier is permissible, provided that an
approved SOP is used, supported by a risk assessment. If not documented in Well
Barrier Design and this SOP, an MOC shall be required. Other consideration are those
operations which govern in previous version of Well Barrier Standard but not mention in
current version and still required to be govern due to the operation is still perform in IBU
D&C operation.
1.2. Scope
This document applies to all D&C Operations in IBU-SMO.

2.0 Well Control Procedure for Single Barrier Operation

2.1. General
2.1.1. Non-Shearables and/or Non-Sealables across the BOP
Scope of this SOP is for tripping operation when Non-Shearables and/or Non-Sealables
components across the BOP. The components are:
1. Drill Collar
2. Stabilizers
3. Directional equipment’s
4. Wash over pipe
5. ESP motor
6. Screen liner or perforated liner

Internal Barrier External Barrier

1. Hydrostatic Barrier 1. Hydrostatic Barrier

2. Kick control joint (to be installed 2. BOP
when well is flowing – well control
event)

 Ensure connection crossover is ready per connection type and size being used
(This will be called as kick control joint). Kick control joint is a preinstalled FOSV
 to 1 joint DP/pup on top and a crossover to a non-shearable/non-sealable
connection (size and type).
 For DSF (Steam Injected Area), in case of steam flow from inside string, asses
the possibility to make up the kick control joint connection safely on top of non-
shearable/non-sealable tubular while diverting the steam through choke lines.
The assessment shall cover gas detection surrounding the well (LEL <10%, H2S
<1 ppm).
 If uncontrollable flow occurred, drop the string and shut in the well with Blind Ram.
 If LEL and H2S detected, evacuate people to safe area and asses the possibility
to keep pumping the wellbore.

2.1.1.1. Shut in Procedure for Well Control Event during Drilling Operation
Follow 3S’s procedure for drilling:
Prior to perform 3S’s procedure, need to make sure the well is in full condition and
perform static test as per Table 1 of DCM-BST-102006-C-IBU-SMO.
1. Space out
 If practical, space out in order to locate the sealable area of tubular across
Annular, so that it will seal in properly.
 If not practical to locate the sealable area of tubular across Annular, assess the
possibility to install kick control joint safely and locate the kick control joint across
BOP stack. Otherwise, drop the string.
2. Shut down pump
3. Shut in well with Annular BOP or Blind/Shear Ram should we drop the string.
For any pipe light indication (string moving upward), open HCR valve to divert the
flow, drop the string and shut in with Blind Ram.

Follow well control event protocol prior to continuing operation.

2.1.1.2. Shut in Procedure for Well Control Event during Tripping Operation
Follow 3S’s procedure for tripping:
Prior to perform 3S’s procedure, need to make sure the well is in full condition and
perform static test as per Table 1 of DCM-BST-102006-C-IBU-SMO.
1. Stab-in Full Opening Safety Valves
2. Space Out
 If practical, space out in order to locate the sealable area of tubular across
Annular, so that it will seal in properly.
  If not practical to locate the sealable area of tubular across Annular, assess the
possibility to install kick control joint safely and locate the kick control joint across
BOP stack. Otherwise, drop the string.
3. Shut in well with Annular BOP or Blind/Shear Ram should we drop the string.
For any pipe light indication (string moving upward), open HCR valve to divert the
flow, drop the string and shut in with Blind Ram.

Follow well control event protocol prior to continuing operation.

2.1.1.3. Shut in Procedure for Well Control Event when ESP Motor is at the Rotary
Table/Working Platform
Stab in FOSV is not applicable:
1. If practical, assess the possibility to install kick control joint safely and
locate the kick control joint across BOP stack. Otherwise, drop the string.
2. Shut in well with Annular BOP or Blind/Shear Ram should we drop the
string.
For any pipe light indication (string moving upward), open HCR valve to divert the
flow, drop the string and shut in with Blind Ram.

Follow well control event protocol prior continuing operation.

2.1.1.4. Shut in Procedure for Well Control Event During Run Screen or Perforated
Liner
Prior to perform 3S’s procedure, need to make sure the well is in full condition
and perform static test as per Table 1 of DCM-BST-102006-C-IBU-SMO.
1. If practical, assess the possibility to install kick control joint safely and locate
the kick control joint across BOP stack. Otherwise, drop the string.
2. Shut in well with Annular or Blind/Shear Ram should we drop the string.
For any pipe light indication (string moving upward), open HCR valve to divert the
flow, drop the string and shut in with Blind Ram.

Follow well control event protocol prior continuing operation.

2.1.2. Wells Unable to Hold Full Column of Fluid
Detail procedure refer to SMO Loss Circulation SOP – Workover Operation.
1. In the case that a well is incapable of supporting full column of fluid, determine the
minimum pumping rate to control the well based on initial killing operations.
Determine the fluids source is sufficient to resume the operation with minimum
pumping rate; otherwise request for additional resources or SWA.
2. Continue to pump fluids at determined rates and monitor the well. The pumping
plan as follow:
a. Minimum pump rate required to control the well shall be based on the pump
rate applied during initial killing
b. Use formation water or completion fluids (KCL Water)
c. Monitor the well to ensure we have effective hydrostatic barrier. Acceptance
criteria:
 Flow check/pressure observation for minimum of 30 minutes.
 There is no pressure on surface & no flow appeared.
NOTE
Continuous Pumping shall be performed throughout the job at determine pumping
rate Minimum volume of water on hands to support operation during the jobs.
 Minimum 3 hours continuous pumping with 1 bpm pumping rate for the wells with
SFL data taken from Sonolog; OR
 Minimum 3 hours continuous pumping with 2 bpm for the wells without Sonolog
data
LCM Material only uses as contingency and must be communicated to asset team
before use it. Prior to use LCM material, all parties will discuss and conduct risk
assessment for any probability on plugging the formation

2.2. Drilling
2.2.1. Installation of Casing Hanger or Casing Pack Off
This procedure is applicable for following well designs:
 Casing Hanger Installations
 Casing Pack Off Installations

Internal Barrier External Barrier

1. Hydrostatic Barrier 1. Cement Annulus reached 50 psi

2. Shoe track Compressive Strength (CS, per lab
test)
Pre-requisite:
 Cement lab test results, specifically for the 50 Psi Compressive Strength Wait on
Cement (WOC) timing information
 50 Psi Compressive Strength (CS) measurement time begins after bumping the plug
or when all cement volume has been pumped into the well (for wells without float
collar). This timing refers to Cement in Place (CIP).
Note:
Refer to information stated in Drilling program and cementing contingency plan to
determine WOC timing. In the event of no cement return during primary cementing,
additional pumping cement on annulus will be required, thus WOC timing will begins
on the very last cement pumped into the well.
 After CIP:
– Flush Wellhead/Braeden head and BOP from excess cement by pumping from
the casing head/Braeden head side outlet. Use rig pump at high rate.
– Close Annular BOP and Cementing Head Valve while WOC to centralize casing
position and prevent from any debris fall into wellbore.
 Ensure multi gas detector and bug blower installed and functioning
 Prepare all Casing Hanger/Casing Pack Off, accessories, and running tools near the
well
NOTE
 Hang Up and N/D BOP ONLY performed when cement barriers already reached
at least 50 Psi Compressive Strength as per Lab Test Result.
 In a lost circulation condition (no cement return to surface) decision for Hang Up
and N/D BOP shall be discussed with Operation TL.

I. Casing Hanger Installation

Procedure:
1. After Cement reach 50 Psi CS during WOC, Check Annulus Pressure on the
Choke Manifold. Open the manifold valve and check for flow for 15 minutes (at
the mud tank returns). If flow continue, shut in the well and report to Operation
Leadership to discuss further plan.
2. Break out connection and Hung up BOP
3. Cut off and lay down excess casing
4. N/D BOP
5. Install Casing Hanger as per manufacturer installation procedure
6. Install Wellhead Section B (Tubing Spool).
7. Pressure Test Casing Hanger and Wellhead Connections
 NOTE
If flow occurred, assess the possibility to re-install the BOP safely. Otherwise,
evacuate people to safe area. The assessment shall cover gas detection surrounding
the well (LEL <10%, H2S <1 ppm, non-steam kick, and non-gas well).

II. Casing Pack Off/ Starter Head Installation

Procedure:
1. After Cement reach 50 Psi CS during WOC, Check Annulus Pressure on the
Choke Manifold. Open the manifold valve and check for flow for 15 minutes (at
the mud tank returns). If flow continue, shut in the well and report to Operation
Leadership to discuss further plan.
2. Lay down Casing Landing Joint and Cementing Head
3. N/D BOP
4. Install Casing Pack Off/ Starter Head
5. Perform Pressure Test (apply only for starter head)
6. N/U BOP and perform BOP pressure test.
NOTE
If flow occurred, assess the possibility re-install the BOP safely. Otherwise, evacuate
people to safe area. The assessment shall cover gas detection surrounding the well
(LEL <10%, H2S <1 ppm, non-steam kick, and non-gas well).

2.3. Workover and Routine Service

2.3.1. BOP, Tree, and Wellhead Accessories Removal/Installation for Non-Flange Type
Tubing Hanger
Scope of Work covered in this SOP:
 All activities from initial killing process, Tree removal and Nipple Up BOP
 All activities from N/D BOPE and Tree installation.
This SOP is not applicable to any jobs that involve pulling out tubing to facilitate BOPE
nipple up and testing.

2.3.1.1. Oil Producer with ESP (GOR < 1 MSCF/STB)

Internal Barrier External Barrier

1. Hydrostatic Barrier 1. Hydrostatic Barrier

2. Tubing Hanger (if practical)
 Picture: ESP Wellhead Configuration in IBU-SMO

Killing the well prior to removing Wellhead Tree accessories:

1. Prepare all connections and cross over needed to allow line up connection for
pressure checking, bleed-off pressure, and pumping through both sides of tubing
and annulus.
2. Install pressure gauge at tubing side (#1) and check tubing pressure.
3. Hook up annulus side outlet #1 to bleed line (manifold) and annulus side outlet #2
to mud pump.
  In case only one casing valve is functioning, line it up to manifold, thus the
manifold is functioning as bleed-off dan pump-in line.
Example of lineup arrangement (from available annulus valve, lineup might be
connected to the Pump Manifold):

Choke line arrangement:

a. One line to the mud tank
b. One line to pump discharge line
c. One line to the Swab tank/Bloey line
Stop operation, re-group, and discuss with TL Operation if no valves are
functioning.
4. Test hook up line to expected maximum pumping pressure +500 psi.
5. Open annulus valve to check the annulus pressure on manifold pressure gauge.
Report to TL Operation and Engineering for further analysis and advice.
Follow Bleed-Off 101 Rule.
If the pressure reading is zero psi in the tubing side and in the annulus side, open
annulus valve to check for flow for 30 minutes:
a. If confirm no flow, fill up the well with water:
 If well can hold full column of fluid, fill up well until well full and maintain
hydrostatic
 If well cannot hold full column of fluid, fill up the well with volume reference
to:
– IF Sonolog data available, calculate estimate volume of fluid required
from existing SFL depth to surface with additional 20% excess
– IF Sonolog data not exist, calculate estimate volume of fluid required
from the lowest open perforation zones to surface with additional 20%
excess
– Continuous pumping with Slow Pump Rate (SPR) throughout the job
Go to step #10 to nipple down Tree.
 b. If annulus pressure is not zero, prepare for bullheading:
 Bullhead from the annulus side, at least 2x hole volume for well that unable
to hold column of fluid.
 Bullhead from the annulus side, with 1.1x hole volume in case the well can
maintain full column of fluid.
WSR to report estimate fill up rate based on bullhead result to TL Operation. This
is critical information to determine required water or kill weight fluid volume on
hand prior to nipple down Tree.

Refer to Sonolog data of the individual well to verify SFL and to confirm the well
is subnormal. If losses observed, determine fill up rate and calculate required
volume of water or kill weight fluid on hands to support:
 Minimum 3 hours continuous pumping with 1 bpm pumping rate for the wells
with SFL data taken from Sonolog; OR
 Minimum 3 hours continuous pumping with 2 bpm for the wells without
Sonolog data

6. If continuous build up in tubing pressure, create communication between tubing and

annulus side with tubing puncher.
Discuss with DC Ops TL and DC Engineer to determine punching depth.
7. Hook up rig circulating line to tubing side (#4). Bullhead down through tubing with
minimum 1.5x tubing volume.
8. Observed annulus pressure for 30 minutes
a. If found pressure still exist or any flow indication, continue bullhead and
consider using kill weight fluid or LCM-polymer mud.
b. If no pressure, continue to next step while keep the hole full to maintain
hydrostatic barrier, continuous pumping from the annulus if the well unable to
hold full column of fluid.
9. Open side outlet casing valve (Bleed line).
Ensure bleed line are open to swab tank (if available), otherwise to mud
tank to monitor well condition and/or divert the flow when needed.
10. N/D Tree (Break out connection between Tubing Hanger and Tree).
Note:
If flow occurred, assess the possibility to stab in FOSV onto Tubing Hanger
safely, otherwise, evacuate people to safe area. The assessment shall cover gas
detection surrounding the well (LEL <10%, H2S <1 ppm, non-steam kick, and
non- gas well).
11. Stab in FOSV and close it.
12. N/U BOP and Test.
 Detail procedure of N/D BOP & N/U Tree:
1. Land Tubing Hanger complete with FOSV (in close position)
2. Locked Tubing Hanger in Wellhead
3. Observed annulus pressure for 30 minutes
a. If pressure exist or flow indication, bullhead and consider using kill weight fluid
b. If no pressure or no flow indication, continue to next step while keep the hole
full to maintain hydrostatic barrier, continuous pumping from the annulus if the
well unable to hold full column of fluid.
4. N/D BOP
5. Dismantle FOSV from Tubing Hanger to install Tree.
6. If well flowing when dismantling FOSV:
a. Assess the possibility to stab in FOSV onto Tubing Hanger safely, otherwise,
evacuate people to safe area. The assessment shall cover gas detection
surrounding the well (LEL <10%, H2S <1 ppm, non-steam kick, and non-gas
well).
b. If not possible, Driller to continue pump killing fluid and follow well control event
reporting protocol.

2.3.1.2. Oil Producer with ESP (GOR > 1 MSCF/STB)

Internal Barrier External Barrier

1. Hydrostatic Barrier 1. Hydrostatic Barrier

2. Tubing Hanger (if practical)

Picture: ESP Wellhead Configuration in IBU-SMO

Killing the well prior to remove Wellhead Tree accessories:
1. Prepare all connections and cross over needed to allow line up connection for
pressure checking, bleed-off pressure, and pumping through both sides of tubing
and annulus.
2. Install pressure gauge at tubing side (#1) and check tubing pressure.
3. Hook up annulus side outlet #1 to bleed line (manifold) and annulus side outlet #2
to mud pump.

 In case only one casing valve is functioning, line it up to choke manifold, thus
the choke manifold is functioning as bleed-off dan pump-in line.

Choke line arrangement:

a. One line to the mud tank
b. One line to pump discharge line
c. One line to the Mud Gas Separator (MGS)
Stop operation, re-group and discuss with TL Operation if no valves are
functioning
4. Test hook up line to expected maximum pumping pressure +500 psi.
5. Open annulus valve to check the annulus pressure on choke manifold pressure
gauge.
Report to TL Operation and Engineering for further analysis and advice.
Follow Bleed-Off 101 Rule.
If the pressure reading is zero psi in the tubing side and in the annulus side, open
annulus valve to check for flow for 30 minutes:
a. If confirm no flow, fill up the well with water:
 If well can hold full column of fluid, fill up well until well full and maintain
hydrostatic
 If well cannot hold full column of fluid, fill up the well with volume reference
to:
– IF Sonolog data available, calculate estimate volume of fluid required
from existing SFL depth to surface with additional 20% excess
– IF Sonolog data not exist, calculate estimate volume of fluid required
from the lowest open perforation zones to surface with additional 20%
excess
– Continuous pumping with Slow Pump Rate (SPR) throughout the job
Go to step #10 to nipple down Tree.
b. If annulus pressure is not zero, prepare for bullheading:
 Bullhead from the annulus side, at least 2x hole volume for well that unable
to hold column of fluid.
 Bullhead from the annulus side, with 1.1x hole volume in case the well can
maintain full column of fluid.
WSR to report estimate fill up rate based on bullhead result to TL Operation. This
is critical information to determine required water or kill weight fluid volume on
hand prior to nipple down Tree.

Refer to Sonolog data of the individual well to verify SFL and to confirm the well
is subnormal. If losses observed, determine fill up rate and calculate required
volume of water or kill weight fluid on hands to support:
 Minimum 3 hours continuous pumping with 1 bpm pumping rate for the wells
with SFL data taken from Sonolog; OR
 Minimum 3 hours continuous pumping with 2 bpm for the wells without
Sonolog data

6. If continuous build up in tubing pressure, create communication between tubing and

annulus side with tubing puncher.
7. Hook up rig circulating line to tubing side (#4). Bullhead down through tubing with
minimum 1.5x tubing volume.
8. Observed annulus pressure for 30 minutes
a. If found pressure still exist or any flow indication, continue bullhead and
consider using kill weight fluid or LCM-polymer mud.
b. If no pressure, continue to next step while keep the hole full to maintain
hydrostatic barrier, continuous pumping from the annulus if the well unable to
hold full column of fluid.
9. Open side outlet casing valve (Bleed line).
Ensure bleed line are open to swab tank (if available), otherwise to mud
tank to monitor well condition and/or divert the flow when needed.
10. N/D Tree (Break out connection between Tubing Hanger and Tree).
Note:
If flow occurred, assess the possibility to stab in FOSV onto Tubing Hanger
safely, otherwise, evacuate people to safe area. The assessment shall cover
gas detection surrounding the well (LEL <10%, H2S <1 ppm, non-steam kick,
and non-gas well).
11. Stab in FOSV and close it.
12. N/U BOP and test.

Detail procedure of N/D BOP & N/U Tree:

1. Land Tubing Hanger complete with FOSV (in close position)
2. Locked Tubing Hanger in Wellhead
3. Observed annulus pressure for 30 minutes
a. If pressure exist or flow indication, bullhead and consider using kill weight fluid
b. If no pressure or no flow indication, continue to next step while keep the hole
full to maintain hydrostatic barrier, continuous pumping from the annulus if the
well unable to hold full column of fluid.
4. N/D BOP
5. Dismantle FOSV from Tubing Hanger to install Tree.
6. If well flowing when dismantling FOSV:
a. Assess the possibility to stab in FOSV onto Tubing Hanger safely, otherwise,
evacuate people to safe area. The assessment shall cover gas detection
surrounding the well (LEL <10%, H2S <1 ppm, non-steam kick, and non-gas
well).
b. If not possible, Driller to continue pump killing fluid and follow well control event
reporting protocol.
2.3.1.3. Water and Steam Injector Well
Steam Injector Water Injector

Picture: Common Configuration IBU-SMO Wellhead for Steam and Water Injector Tree

Internal Barrier External Barrier

1. Hydrostatic Barrier 1. Hydrostatic Barrier

2. Tubing Hanger
3. Packer (if practical)

Killing the well prior to remove Wellhead Tree accessories:

1. Prepare all connections and cross over to allowed connection for pressure checking,
bleed-off pressure, and pumping through both sides of tubing and annulus.
2. Lineup all connections as per schematic below:
3. Hook up annulus side outlet #1 to bleed line (manifold) and annulus side outlet #2 to
mud pump.
 In case only one valve is functioning, then lineup to the choke manifold, thus the
choke manifold is functioning as bleed-off dan pump-in line.
 Choke line arrangement:
a. One line to the mud tank
b. One line to pump discharge line
d. One line to the swab tank or reserve tank if any
Stop operation, re-group, and discuss with TL Operation if no valves are
functioning.
4. Test hook up line to expected maximum pumping pressure + 500 psi.
5. Open tubing and annulus valve to read the pressure
Report to TL Operation and Engineering for further analysis and advice.
Follow Bleed-Off 101 Rule.
6. Perform pressure test to MASP (or maximum injection pressure whichever is higher)
against packer through annulus to check if the packer is still intact:
a. If the packer is leaking, then perform bullhead from both tubing (1.5x tubing
volume) and annulus side (1.5x annulus volume to bottom perforation).
b. If the packer is holding pressure, bullhead from the tubing side only, packer will
act as external mechanical barrier.
Beware of gas trapped below packer, detail procedure will be specified in the
well program
Note: some old injector wells not using injection packer, thus for wells without packer
will continue to next step.
7. After bullhead completed, observe pressure and flow indication from both tubing and
annulus for at least 30 minutes.
a. If found pressure still exist or any flow indication, continue bullhead and consider
using kill weight fluid.
b. If no pressure, continue to next step while keep the hole full to maintain
hydrostatic barrier, or continuous pumping from the annulus if the packer is
leaking.
8. Break-out Tree connection below tubing head adaptor.
9. Stab in FOSV and close it
10. N/U BOP and test.

Detail procedure of N/D BOP & N/U Tree:

1. Land Tubing Hanger complete with FOSV (in close position) as temporary barrier.
2. Locked Tubing Hanger in Wellhead
3. Observed annulus pressure for 30 minutes
a. If pressure exist or flow indication, bullhead and consider using kill weight fluid
b. If no pressure or no flow indication, continue to next step while keep the hole
full to maintain hydrostatic barrier, continuous pumping from the annulus if the
well unable to hold full column of fluid.
 4. N/D BOP
5. Dismantle FOSV from Tubing Hanger to install Tree.
6. If well flowing when dismantling FOSV:
a. Assess the possibility to stab in FOSV onto Tubing Hanger safely, otherwise,
evacuate people to safe area. The assessment shall cover gas detection
surrounding the well (LEL <10%, H2S <1 ppm, non-steam kick, and non-gas
well).
b. If not possible, Driller to continue pump killing fluid and follow well control event
reporting protocol.

2.3.1.4. Gas Producer Well

For gas well, it is mandatory to perform Wellhead Maintenance and Inspection prior
to rig move into the well location and use of Mud-Gas Separator.

Ensure DWSR have reviewed Wellhead Inspection report.

All gas wells shall have BPV installed inside Tubing Hanger prior to removing Tree.
In case the BPV cannot be installed, nipple down gas Tree operation shall follow
single barrier operation SOP as detailed below.

Picture: Common Configuration IBU-SMO Wellhead for Gas Producer Well Tree

Internal Barrier External Barrier

1. Hydrostatic Barrier 1. Hydrostatic Barrier

2. Tubing Hanger
3. Packer
Killing the well prior to remove Wellhead Tree accessories:
1. Prepare all connections and cross over to allowed connection for pressure
checking, bleed-off pressure, and pumping through both sides of tubing and
annulus.
2. Lineup all connections as per schematic below:

Swab Tank and MGS must be located at the farthest area from public facilities and any potenti

3. Hook up annulus side outlet #1 to bleed line (manifold) and annulus side outlet #2
to mud pump.
 In case only one valve is functioning, then lineup to the choke manifold, thus the
choke manifold is functioning as bleed-off dan pump-in line.
Choke line arrangement:

Swab Tank and MGS must be located at the farthest area from public facilities and any potenti

a. One line to the mud tank

b. One line to pump discharge line
c. One line to the Mud Gas Separator (MGS)
Stop operation, re-group, and discuss with TL Operation if no valves are
functioning.
4. Test hook up line to expected maximum pumping pressure + 500 psi.
5. Open tubing and annulus valve to read the pressure
Report to TL Operation and Engineering for further analysis and advice.
 Follow Bleed-Off 101 Rule.
6. Perform pressure test to MASP (or maximum injection pressure whichever is
higher) against packer through annulus to check if the packer is still intact:
a. If the packer is leaking, perform bullhead from both tubing (1.5x tubing volume)
and annulus side (1.5x annulus volume to bottom perforation).
b. If the packer is holding pressure, bullhead from the tubing side only, packer will
act as external mechanical barrier.
Beware of gas trapped below packer, detail procedure will be specified in the well
program
7. After bullheading completed, observe pressure and flow indication from both tubing
and annulus for at least 30 minutes.
a. If pressure still exist or any flow indication, continue bullhead and consider
using kill weight fluid.
b. If no pressure, continue to next step while keep the hole full to maintain
hydrostatic barrier, or continuous pumping from the annulus if the packer is
leaking.
8. Break-out Tree connection below tubing head adaptor.
9. Stab in FOSV and close it
10. N/U BOP and test.

Detail procedure of N/D BOP & N/U Tree:

1. Land Tubing Hanger complete with Back Pressure Valve.
If the Tubing Hanger do not have BPV profile, install FOSV (in close position) as
temporary barrier.
2. Locked Tubing Hanger in Wellhead
3. Observed annulus pressure for 30 minutes
a. If pressure exist or flow indication, bullhead and consider using kill weight fluid
b. If no pressure or no flow indication, continue to next step while keep the hole
full to maintain hydrostatic barrier
4. N/D BOP
5. Install Tree & test all Tree connections, remove BPV after installing Tree
completed. For well which do not have BPV profile, dismantle FOSV from Tubing
Hanger to install Tree.
6. If well flowing while dismantling FOSV:
a. Assess the possibility to stab in FOSV onto Tubing Hanger safely, otherwise,
evacuate people to safe area. The assessment shall cover gas detection
surrounding the well (LEL <10%, H2S <1 ppm, non-steam kick, and non-gas
well).
 b. If not possible, Driller to continue pump killing fluid and follow well control event
reporting protocol.

2.3.1.5. Rigless Operation

Detail procedure of remove / install Tree & BOP in Rigless operation:
For Steam Injector Well
1) If Tree valve is stuck close, execute the well by utilizing Hot Tap unit assist by
surface team and WCT (Well Cooling Team) Unit.
a. R/U Hot Tap unit and line up WCT or Injection Water Unit.
b. Drill master valve gate.
c. R/D Hot Tap unit.
d. Continue cooling down with WCT or Injection Water Unit.
e. Monitor pressure.
f. After confirming the well not flow for sufficient time, continue to N/D existing
Tree valve. If well flows during Tree removal:
i. Assess the possibility to re-install the Tree or FOSV safely and shut in the
well. The assessment shall cover gas detection surrounding the well (LEL
<10%, H2S <1 ppm, not steam kick, and not gas well).
ii. If not possible/unsafe, evacuate people to safe area and follow well control
event reporting protocol.
g. N/U Tree.
h. Function test all valve - might include grease swab and wing valve.
i. R/D WCT unit.
2) If Tree valve is partially stuck open, execute the well by utilizing surface team and
WCT (Well Cooling Team) Unit
a. R/U WCT or Injection Water Unit
b. Continue cooling down with WCT or Injection Water Unit
c. Monitor pressure.
d. After confirming the well not flow for sufficient time, continue to N/D existing
Tree. If well flows during Tree removal:
i. Assess the possibility to re-install the Tree or FOSV safely and shut in the
well. The assessment shall cover gas detection surrounding the well (LEL
<10%, H2S <1 ppm, not steam kick, and not gas well).
ii. If not possible/unsafe, evacuate people to safe area and follow well control
event reporting protocol.
e. N/U Tree valve.
f. Function test all valve - might include grease swab and wing valve.
g. R/D WCT unit.
 For Non-Steam Injector Well
1. Monitor pressure gauge at tubing and casing.
2. R/U WCT or Injection Water Unit
3. Bleed off pressure from annulus and string, continue to shut in the well.
4. Kill well / Cool down well using WCT or Injection Water Unit.
5. Monitor shut in pressure.
6. After confirming the well not flow for sufficient time, then continue to N/D existing
Tree. If well flows during Tree removal:
i. Assess the possibility to re-install the Tree or FOSV safely and shut in the
well. The assessment shall cover gas detection surrounding the well (LEL
<10%, H2S <1 ppm, not steam kick, and not gas well).
ii. If not possible/unsafe, evacuate people to safe area and follow well control
event reporting protocol.
7. N/U Tree Valve
8. Function test all valve - might include grease swab and wing valve
9. R/D WCT unit

2.3.2. Removing Tubing Hanger Following Failure(s) on BOP test

Observation shall be done prior to remove Tubing Hanger so there is no visual
sign of leaking on the surface.

Internal Barrier External Barrier

1. Hydrostatic Barrier 1. Hydrostatic Barrier

2. FOSV 2. BOPE (unverified connection)

Whenever BOP connection test failed against existing Tubing Hanger, please check:
1. If the well completed with packer or not?
2. If the well completed with packer, is the packer still intact or not?
Perform BOP Shell Test for wells with intact packer.
3. If the packer still intact and no leak, call TL and follow possible solution to close
side outlet annulus valve and test BOPE against packer. For high pressure test,
consider existing casing condition.

Pre-requirements:
 Keep the hole full to maintain hydrostatic barrier, continuous pumping
from the annulus if the well unable to hold a full column of fluid.
  Prepare blank Tubing Hanger or packer or cup-type BOP tester to test the
BOP, ensure rating and sizes are match with Wellhead / casing sizes.

Procedure:
1. Pick up landing joint and connect to FOSV installed on top of Tubing Hanger
2. Pull out of hole existing Tubing Hanger.
If flow occurred during pulling out Tubing Hanger, space out and shut in the well.
Prepare for bullhead operation to kill the well and proceed to next step.
3. Remove existing Tubing Hanger and replace with test plug component to test the BOP
(Test plug alternatives: blank Tubing Hanger, Cup type tester or Packer).
For wells with ESP, cut cable at one join below Tubing Hanger, and secure/clamped
cable to the tubing (using a cable clamp).
If flow occurred after removing existing Tubing Hanger, assess the possibility to
reinstall FOSV safely, space out and shut in the well. Prepare for bullhead
operation to kill the well and proceed to next step.
If uncontrollable flow occurred, drop the string and shut in the well with Blind
Ram.
4. Run test plug in hole and set as follow:
a. Tubing Hanger: land and set inside the Wellhead
Ensure annulus valve in open position prior to and during BOPE test.
b. Packer: follow the specific installation procedure
c. Cup type tester: follow the specific installation procedure
5. Perform BOP Connection Pressure Test

2.3.3. Running/Pulling ESP (Non-Sealable due to ESP Cable)

Internal Barrier External Barrier

1. Hydrostatic Barrier 1. Hydrostatic Barrier

2. FOSV

 Ensure FOSV is ready at the rig floor, has same connection type and size with the
production string.
 Ensure hacksaw to cut the cable is available in the rig floor during running/pulling
ESP.

Procedure:
1. Prepare all tools and equipment required for tripping ESP with cable
2. Trip ESP assembly as per approved program
3. Maintain hydrostatic barrier at all time:
  If the well can hold full column of fluid, fill up well until well full and maintain
hydrostatic barrier
 If well cannot hold full column of fluid, continuous pumping with Slow Pump
Rate (SPR) throughout the job.
4. If well is flowing during running/pulling, Driller shall sound alarm, and assess
possibility to shut in the well by following 3S’s procedure. The assessment shall
cover gas detection surrounding the well (LEL <10%, H2S <1 ppm, non-steam kick,
and non-gas well). The shut-in procedure (3S’s) as follow:
a) Stab FOSV and close the valve.
b) Rise up the last joint around 20 ft(*), open HCR to divert flow, close Annular
BOP to reduce flow rate coming out allowing rig crew to clamp and cut the
cable.
NOTE:
 (*) Each of rig may have different requirement based on their RSP.
 The intention is to reduce strong flow up to rig floor by diverting the flow to
blueline while the crew are cutting the cable.
 If uncontrollable flow occurred, drop the string and shut in the well with Blind Ram.
c) Open Annular BOP
d) Strip In – Lower the string to locate the sealable tubing area crossing BOP Stack.
e) Shut in well with Annular BOP.
For any pipe light indication (string moving upward) or uncontrolled flow, drop the
string and shut in with Blind Ram.

Follow well control event protocol prior continuing operation.

2.3.4. BOP, Tree, and Wellhead Accessories Installation/Removal for Sucker Rod Pumps
Including Running/Pulling Sucker Rods

Internal Barrier External Barrier

1. Hydrostatic Barrier 1. Hydrostatic Barrier

2. Tubing Hanger
 Picture: SRP Wellhead Configuration in IBU-SMO

Pre-requisite well condition:

For Duri A13 (or any non-steam breakthrough area), please refer to execution flow
process for Area-13 before proceeding to move in the rig.

Killing the well prior to remove Wellhead Tree accessories:

1. Prepare all connections and cross over to allowed connection for pressure checking,
bleed off, pumping through both side tubing and annulus.
2. Install Pressure gauge at tubing side (#4) to check tubing pressure.
3. Hook up annulus side outlet #1 to bleed line (manifold) and annulus side outlet #2 to
mud pump.

 In case only one valve is functioning, then lineup to the manifold, thus the
manifold is functioning as bleed-off dan pump-in line.
 Example of lineup arrangement (from available annulus valve, lineup might be
connected to the Pump Manifold):

Choke line arrangement:

a. One line to mud tank
b. One line to pump discharge line
c. One line to alternate tank or closed valve
Stop operation, re-group, and discuss with TL Operation if no valves are
functioning.
4. Test hook up line to expected maximum pumping pressure +500 psi.
5. Open tubing and annulus valve to read the pressure
Report to TL Operation and Engineering for further analysis and advice
If the pressure reading is zero psi in the tubing side and in the annulus side, open
annulus valve to check for flow for 30 minutes, confirm no flow, fill up the well with
water and go to step #9 to Pull Out Sucker Rod. Otherwise, prepare for bullhead.
6. If found pressure in annulus side:
 Bullhead from the annulus side, at least 2x hole volume for well that unable to
hold column of fluid.
 Bullhead from the annulus side, with 1.1x hole volume in case the well can
maintain full column of fluid.
WSR to report estimate fill up rate based on bullhead result to TL Operation. This
is critical information to determine required water or kill weight fluid volume on
hand prior to pulling/running sucker rods.
7. Bleed off trapped pressure on both tubing (#4) and annulus side (#8).
8. Observe annulus pressure for at least 30 minutes:
a. If pressure still exist or any flow indication, continue bullhead and consider using
kill weight fluid or LCM-polymer mud.
 b. If no pressure, continue to next step while keep the hole full to maintain
hydrostatic barrier, or continuous pumping from the annulus if the well unable to
hold a full column of fluid.
9. Proceed to pulling/running out sucker rod string. Keep the hole full to maintain
hydrostatic barrier throughout the job or continuous pumping from the annulus if the
well unable to hold full column of fluid.
NOTE:
If flow occurred, assess the possibility to stab in FOSV onto Rod BOP safely,
otherwise, evacuate people to safe area. The assessment shall cover gas
detection surrounding the well (LEL <10%, H2S <1 ppm, not steam kick and not
Mitigation plan if well flowing after risk assessment process involving Operations
gas well).
Leaders:
a. Stop pumping fluids from annulus side, divert the flow to mud tank from annulus
by opening side outlet casing valves to reduce flow rate coming out from tubing
side allowing rig crew to work around Wellhead.
b. Prepare FOSV.
i. Lower elevator close to Rod BOPE, open elevator and drop sucker rod string.
Note: if elevator cannot be opened, cut-off sucker rod and drop.
ii. Stab in the FOSV in open position onto Rod BOP.
iii. Close FOSV and shut-in well.
iv. Commence bullhead to kill the well through annulus.
WSR call TL Operation to report fill up rate observed and total water or kill weight
fluid on hand before proceed nipple down Tree.
1. If initial kill less than or equal to 100 bbls, required minimum water or kill weight
fluid on hand shall be 260 bbls.
2. If initial kill more than 100 bbls, required minimum water or kill weight fluid on
hand shall be 360 bbls.
10. N/D Tree (Break out connection between Tubing Hanger and Tree).
Note:
If flow occurred, assess the possibility to re-install the Tree or FOSV safely and shut
in the well. The assessment shall cover gas detection surrounding the well (LEL
<10%, H2S <1 ppm, not steam kick, and not gas well). Divert flow through casing
valve when attempting to stab in FOSV.
11. Remove cover plate.
12. Stab in FOSV and close it.
13. N/U BOP and test.
For Flush-by Operations (Change out Plunger)
WSR call TL Operation to report fill up rate observed and total water or kill weight
fluid on hand before proceed nipple down Tree.
1. If initial kill less than or equal to 100 bbls, required minimum water or kill
weight fluid on hand shall be 100 bbls.
2. If initial kill more than 100 bbls, required minimum water or kill weight fluid on
hand shall be 180 bbls.
1. Prepare and Install 2nd rod BOP on top of existing rod BOP. Ensure to have the ram
size match with the sucker rod size being pulled through 2nd rod BOP.
Note: Change rubber ram size for each sucker rod size on any tapper rod design.
2. After pulling/running out sucker rod string and continued with opening Rod BOP (to
change out plunger). Keep the hole full to maintain hydrostatic barrier throughout the
job or continuous pumping from the annulus if the well unable to hold full column of
fluid.
NOTE:
If flow occurred, assess the possibility to stab in FOSV onto Rod BOP safely,
otherwise, evacuate people to safe area. The assessment shall cover gas
detection surrounding the well (LEL <10%, H2S <1 ppm, non-steam kick and non-
Mitigation plan if well flowing after risk assessment process involving Operations
gas well).
Leaders:
a. Stop pumping fluids from annulus side, divert the flow to mud tank from annulus
by opening side outlet casing valves to reduce flow rate coming out from tubing
side allowing rig crew to work around Wellhead.
b. Close applicable rod BOP.
c. Prepare FOSV.
i. Lower elevator close to Rod BOPE, open elevator and drop sucker rod
string. Note: if elevator cannot be opened, cut-off sucker rod and drop.
ii. Stab in the FOSV in open position onto Rod BOP.
iii. Close FOSV and shut-in well.
iv. Commence bullhead to kill the well through annulus.
3. Continue with Well Program
2.3.5. Wireline and Perforations Operations
Scope: (If Pressure Control Equipment is not Deployed)

Internal Barrier External Barrier

Not applicable 1. Hydrostatic Barrier

2. Annular BOP (Unverified to seal on
Wireline Cable)

1. Ensure the well is in static Condition. If the well in loss condition, follow the
procedure of non-routine SOP “Well Unable to Hold Full Column of Fluid”.
2. R/U wireline Unit.
3. Continue job with wireline Operation.
Note: Wireline operators to prepare wireline cutter as contingency plan
4. If well flowing during wireline job:
a. If practical to POOH wireline tools immediately to surface clear from BOP stack
and shut the well in with Blind Ram. It is only applicable if the logging tool length
can be cleared off from BOP stack.
NOTE
Never shut in the well on logging tools or when Logging tool crossing the BOP
stack
b. If not practical to pull all wireline tools to surface, shut the well in with Annular
BOP on wireline cable. Kill the well with bullheading method. In case of Annular
BOP could not seal on wireline cable, cut wireline using wireline cutter. Drop
logging tools and shut in using Blind Ram.
NOTE
Driller, or designated person as identified in PJSM, shall report to DWSM and
Tool Pusher for well shut in verification and pressure monitoring

2.3.6. Underbalance Perforation

Underbalance perforation operation only allowed with Tubing Conveyed
Perforation. Procedure below covers Tubing Conveyed Perforation operation
which Christmas Tree already installed.

Internal Barrier External Barrier

1. X-Mas Tree (Master Valve) 1. Hydrostatic Barrier

2. Tubing Hanger
3. Packer
 Preliminary job: Christmas Tree must be installed and tested; annulus full of packer fluid.
1. Run TCP Perforation with Packer assembly. Fill in fluid inside tubing to create
underbalance allowing hydrocarbon flow to surface after perforation.
2. Set Production Packer. Do correlation log to ensure the expected perforation depth
3. Pressure test Production Packer
4. Land Tubing Hanger and test as per program
5. Install Christmas Tree and test all connections.
6. Drop detonating Bar for fire the TCP Gun
7. Close the Master valve immediately after drop bar.
NOTE
Ensure the annulus is full of proper density of Packer Fluid to overcome
formation pressure if packer leaks

2.3.7. Non-Mandrel ESP Cable Penetrator Tubing Hanger

Internal Barrier External Barrier

1. Hydrostatic Barrier 1. Hydrostatic Barrier

Refer to MOCP 18-001D, a non-mandrel ESP cable penetrator Tubing Hanger is still
acceptable for the following application:
 MASP = 0 psi
 Non-Gas producer wells or Oil Producer Wells with GOR < 400 SCF/BBL
 No LOC/HES issues with individual well and surrounding adjacent wells

Pre-requisites:
 Must change out Tubing Hanger seals
 Must use ESP Flat Power Cable #1

Installation Procedure:
1. RIH ESP and cable to desired depth based on well program
NOTE
Maintain hydrostatic pressure at all time:
 If well can hold full column of fluid, fill up the well until full and maintain the
hydrostatic barrier
 If well cannot hold full column of fluid, continuous pumping with Slow Pump
Rate (SPR) throughout the job.
2. Install Tubing Hanger complete FOSV on top of tubing string.
3. Check ESP Cable Reading. Ensure Cable Reading is still MET with requirement
 from ESP provider
4. Ensure to have ESP cable AWG-1 across Tubing Hanger. Cable hole sizes on
Tubing Hanger seal must be the same with the cable size.
5. Cut ESP Cable and Do Splicing (if needed).
6. Insert ESP Cable pass through the Tubing Hanger.

Picture: Example of Non-Mandrel ESP Tubing Hanger (Cable Feed Through)

7. Pick up landing joint to land the Tubing Hanger on Wellhead.

8. Tighten Lock Nut Screw.
9. Observed tubing and annulus for any flow for 30 minutes
 If flow occur, Shut In well and prepare for killing operation with bullhead from
annulus side and consider using kill weight fluid.
 If no flow, continue to next step while keep the hole full to maintain hydrostatic
barrier, continuous pumping from the annulus if the well unable to hold full
column of fluid.
10. N/D BOPE

2.3.8. N/D X-Mas Tree with Flange Type Tubing Hanger

2.3.8.1. For Wells without Production/Injection Packer
For Flange Type Tubing Hanger Wellhead, it is mandatory to perform Wellhead
Maintenance and Inspection prior to rig move into the well location.
Ensure DWSR have reviewed Wellhead Inspection report.

Internal Barrier External Barrier

1. Hydrostatic Barrier 1. Hydrostatic Barrier

 Picture: Flange Type Wellhead Configuration without packer in IBU-SMO

Pre-requisite well condition:

For Duri A13 (or any non-steam breakthrough area), please refer to execution flow
process for Area-13 before proceeding to move in the rig.

Killing the well prior to remove Wellhead Tree accessories:

1. Prepare all connections and cross over to allowed connection for pressure
checking, bleed-off pressure, and pumping through both sides of tubing and
annulus.
2. Install Pressure gauge at tubing side (#4) to check tubing pressure.
3. Hook up annulus side outlet #1 to bleed line (manifold) and annulus side outlet #2
to mud pump.
Choke manifold lineup schematic:

In case only one valve is functioning, then lineup to the choke manifold, thus the
choke manifold is functioning as bleed-off dan pump-in line.
  One line to mud tank
 One line to pump discharge line
 One line to the Mud Gas Separator (MGS)
Stop operation, re-group, and discuss with TL Operation if no valves are
functioning.
4. Test hook up line to expected maximum pumping pressure +500 psi.
5. Open tubing and annulus valve to read the pressure
Report to TL Operation and Engineering for further analysis and advice.
Follow Bleed-Off 101 Rule.
If the pressure reading is zero psi in the tubing side and in the annulus side, open
annulus valve to check for flow for 30 minutes, confirm no flow, fill up the well with
water and go to step to nipple down Tree. Otherwise, prepare for bullhead.
6. If found pressure in annulus side:
 Bullhead from the annulus side, at least 2x hole volume for well that unable to
hold column of fluid.
 Bullhead from the annulus side, with 1.1x hole volume in case the well can
maintain full column of fluid.
WSR to report estimate fill up rate based on bullhead result to TL Operation. This
is critical information to determine required water volume on hand prior to
pulling/running sucker rods.

7. Bleed off trapped pressure on both tubing (#4) and annulus side (#8).
8. Observe annulus pressure for at least 30 minutes:
 If found pressure still exist or flow indication, continue bullhead and consider
using kill weight fluid or LCM / polymer mud.
 If no pressure, continue to next step while keep the hole full to maintain
hydrostatic barrier, or continuous pumping from the annulus if the well unable to
hold full column of fluid.
9. Proceed to pulling/running out sucker rod string. Keep the hole full to maintain
hydrostatic barrier throughout the job or continuous pumping from the annulus if the
well unable to hold a full column of fluid.
NOTE:
If flow occurred, assess the possibility to stab in FOSV onto Tubing Hanger/Rod
BOP safely, otherwise, evacuate people to safe area. The assessment shall cover
gas detection surrounding the well (LEL <10%, H2S <1 ppm, non-steam kick, and
non-gas well).

Mitigation plan if well flowing after risk assessment process involving Operations
Leaders:
a. Stop pumping fluids from annulus side, divert the flow to mud tank from annulus
by opening side outlet casing valves to reduce flow rate coming out from tubing
side allowing rig crew to work around Wellhead.
b. Prepare for FOSV installation.
i. Lower elevator close to Rod BOP, open elevator and drop sucker rod string.
Note: if elevator cannot be opened, cut-off sucker rod and drop
ii. Stab in the FOSV in open position onto Rod BOP.
iii. Close FOSV and shut-in well.
iv. Commence bullhead to kill the well through annulus. Observe annulus pressure
for at least 30 minutes after bullhead process
WSR call TL Operation to report fill up rate observed and total water on hand
before proceed nipple down Tree.
1. If initial kill less than or equal to 100 bbls, required water on hand shall be
260 bbls.
2. If initial kill more than 100 bbls, required water on hand shall be 360 bbls.
10. Open side outlet casing valve (Bleed line).
Ensure bleed line are open to swab tank (if available), otherwise to mud tank to
monitor well condition and/or divert the flow when needed.
11. N/D Tree (Remove Rod BOP, pumping tee and production nipple).
Note:
If flow occurred, assess the possibility to stab in FOSV onto Tubing Hanger
safely, otherwise, evacuate people to safe area. The assessment shall cover gas
detection surrounding the well (LEL <10%, H2S <1 ppm, non-steam kick, and
non- gas well).
12. Stab in FOSV and close it.
13. Observe annulus pressure for at least 30 minutes:
  If found pressure still exist or flow indication, continue bullhead and consider
using kill weight fluid or LCM-polymer mud.
 If no pressure, continue to next step while keep the hole full to maintain
hydrostatic barrier, or continuous pumping from the annulus if the well unable to
hold a full column of fluid.
14. Pull out flange type Tubing Hanger. Slip the tubing on Wellhead
15. Disconnect and remove flange type Tubing Hanger from tubing
16. Install temporary blank Tubing Hanger with FOSV installed on it and land the
Tubing Hanger on Wellhead
Note:
If flow occurred, assess the possibility to re-install flange Tubing Hanger with
FOSV safely or install BOP safely, otherwise, evacuate people to safe area. The
assessment shall cover gas detection surrounding the well (LEL <10%, H 2S <1
ppm, not steam kick, and not gas well). Communicate with operation leader for
the resolution.
17. N/U BOP and Test.
2.3.8.2. For Wells with Production/Injection Packer
For gas well, it is mandatory to perform Wellhead Maintenance and Inspection prior
to rig move into the well location and use of Mud-Gas Separator.

Ensure DWSR have reviewed Wellhead Inspection report.

All gas wells shall have BPV installed inside Tubing Hanger prior to removing Tree.
In case the BPV cannot be installed, nipple down gas Tree operation shall follow
single barrier operation SOP as detailed below.

Picture: Configuration Wellhead and Tree with flange type hanger at gas well

Internal Barrier External Barrier

1. Hydrostatic Barrier 1. Hydrostatic Barrier

2. Production / Injection Packer

Killing the well prior to remove Wellhead Tree accessories:

1. Prepare all connections and cross over to allowed connection for pressure
checking, bleed-off pressure, and pumping through both sides of tubing and
annulus.
2. Install Pressure gauge above crown valve at tubing side to check tubing pressure.
3. Hook up bleed line to tubing side through production valve.
4. Hook up annulus side outlet #1 to bleed line (manifold) and annulus side outlet #2
to mud pump.
 Choke manifold lineup schematic:

In case only one valve is functioning, then lineup to the choke manifold, thus
the choke manifold is functioning as bleed-off dan pump-in line.

 One line to mud tank

 One line to pump discharge line
 One line to the Mud Gas Separator (MGS)
Stop operation, re-group, and discuss with TL Operation if no valves are
functioning.
5. Test hook up line to expected maximum pumping pressure +500 psi.
6. Open tubing and annulus valve to read the pressure
Report to TL Operation and Engineering for further analysis and advice.
Follow Bleed-Off 101 Rule.
7. Perform pressure test to MASP (or maximum injection pressure whichever is higher)
against packer through annulus to check if the packer is still intact:
 If the packer is leaking, perform bullhead from both tubing (1.5x tubing volume)
and annulus side (1.5x annulus volume to bottom perforation).
 If the packer is holding pressure, bullhead from the tubing side only, packer will
act as external mechanical barrier.
 Beware of gas trapped below packer, detail procedure will be specified in the well
program
Note: some old injector wells not using injection packer, thus for wells without packer
will continue to next step.
8. After bullhead completed, observe pressure and flow indication from both tubing
and annulus for at least 30 minutes.
9. If pressure still exist or flow indication, continue bullhead and consider using kill
weight fluid.
10. If no pressure, continue to next step while keep the hole full to maintain hydrostatic
barrier, or continuous pumping from the annulus if the packer is leaking.
11. Close lowermost master valve
12. Break-out Tree connection:
 For gas well: between lower and upper master valve.
 For steam and water injector: above master valve.
13. Observe pressure and flow indication from both tubing and annulus for at least 30
minutes.
 If pressure still exist or flow indication, continue bullhead and consider using kill
weight fluid.
 If no pressure, continue to next step while keep the hole full to maintain
hydrostatic barrier, or continuous pumping from the annulus if the packer is
leaking.
14. Open master valve to observe pressure at tubing side prior to break out flange
connection for 30 minutes.
15. Unbolt flange type Tubing Hanger and pull out ±4 feet to provide space for slip and
break out tong position. Slip the tubing on Wellhead.
16. Ensure master valve in open position and no flow indication. Break out and remove
flange type Tubing Hanger from tubing
17. Install temporary blank Tubing Hanger with FOSV installed on it and land the
Tubing Hanger on Wellhead
NOTE:
If flow occurred, assess the possibility to shut in the well by installing flange
Tubing Hanger with FOSV or install BOP safely, otherwise, evacuate people to
safe area. The assessment shall cover gas detection surrounding the well (LEL
<10%, H2S <1 ppm, not steam kick, and not gas well). Communicate with
operation leader for the resolution.
18. N/U BOP and test.
2.3.9. Wellhead Change

Internal Barrier External Barrier

1. Hydrostatic Barrier 1. Hydrostatic Barrier

In IBU-SMO, there are some cases related to missing Wellhead and require replacement
with incapability to maintain two barriers during operation.

Procedure to Install / Change Wellhead for wells with missing Wellhead and /or
accessories:
Scope for this procedure:
1) Install missing Wellhead
2) Install missing Wellhead accessories i.e. valve, etc.
3) Casing leak near surface or Wellhead leak

Rigless Operation
1. Observe well for any pressure or flow indication minimum for 2 hours
2. Observe and check gas content surrounding the well:
a. If found LEL and H2S, mobilize Injection Water Unit to fill up well.
b. If LEL and H2S continuously detected exceeding MSW requirement, suspend job.
3. Continue to the main job e.g., install casing sleeve, install valve, replace/install
Wellhead. Any test requirement will be detailed in the well program.
4. R/D Rigless unit.

Mitigation Plan:
NOTE
If flow occurred, assess the possibility to stab in FOSV onto Tubing Hanger safely,
otherwise, evacuate people to safe area. The assessment shall cover gas detection
surrounding the well (LEL <10%, H2S <1 ppm, non-steam kick, and non-gas well).

If flow occur during the operation, attempt to shut in the well if practical, otherwise
abandon the well.

Procedure to Change Taper Wellhead (Wellhead size smaller than the Production
casing)
Wells with ESP or OE Tubing Wells with Injection or Production Packer
1. N/U BOPE & test Option #1:
2. POOH ESP 1. N/U BOPE & test
3. Set cement barrier with 2. Unset Packer and raise up to ~300 ft above
minimum 100 ft cement column top perforation zone
length above uppermost 3. Dump sand to ~100 ft above top perforation
perforation zone for temporarily plug the open zones
4. Verify cement barrier with tag 4. Raise up packer to ~50 – 100 ft below
and pressure test Wellhead
5. Change Wellhead to the 5. Land Tubing Hanger
standard size 6. R/U CTU and test
7. Set cement barrier at with minimum 100 ft
cement column length at ~100 ft above
uppermost perforation
8. Verify cement barrier with tag and pressure
test
9. R/D CTU
10. Change with the standard Wellhead

Option #2:
1. N/U BOPE & test
2. Cut tubing above packer, estimated 30 ft
above packer
3. Dump sand to 30 ft above top fish (sand must
cover tubing cut).
4. Tag TOS
5. Set Cement Barrier with minimum 100 ft
cement column length above TOS
6. Verify cement barrier with tag and pressure
test
7. Change Wellhead to the standard size
2.3.10. LPT Seal as Temporary Barrier
This is applicable for following well designs, but not limited to:
 Prior completing well intervention (WS/WO) before well POP
 The well already on production mode but have a leak on the seal Tubing Hanger.

Internal Barrier External Barrier

1. Hydrostatic Barrier 1. Hydrostatic Barrier

Pre-requisite:
 Ensure Safe condition around Wellhead
NOTE:
If flow occurred, assess the possibility to install LPT seal safely. Otherwise,
evacuate people to safe area. The assessment shall cover gas detection
surrounding the well (LEL <10%, H2S <1 ppm, not steam kock and not gas well).

Installation Procedure:
1. Install Pressure gauge at casing side to check pressure.
NOTE:
Prepare WCT or Injection Water Unit to support killing / pumping activity
2. R/U WCT or Injection Water Unit
3. Kill well / Cool down well using WCT or Injection Water Unit.
4. Monitor shut in pressure.
5. Observed annulus for any flow / pressure build up for 30 minutes,
 If flow occur or pressure build up, continue killing operation with bullhead from
annulus side and consider using kill weight fluid.
 If no flow, continue to next step while keep the hole full to maintain hydrostatic
barrier, continuous pumping from the annulus if the well unable to hold full
column of fluid.
6. Install LPT seal:
 Unscrewed 4 bolts on the Wellhead an in alignment with LPT position,
 Install LPT rubber to wrap around the neck of the Tubing Hanger (above
Wellhead cover plate),
 Install LPT plate c/w seal and screwed tightly to the Wellhead.
 Picture: LPT Seal Component and Installation
7. Observe the condition of Tubing Hanger (after LPT installation), do flow check for 30
minutes to confirm no leaks from Tubing Hanger, the flow check also as barrier
verification of the hydrostatic Pressure.
NOTE
Longer flow check is recommended for repetitive leakage wells (1-2 hours)

2.3.11. Tree Installation for Non-Gas Wells

This SOP applies for the following well design:
A. For ESP with downhole check valve
B. For ESP wells without downhole check valve
C. For Sucker Rod Pump

Internal Barrier External Barrier

1. Hydrostatic Barrier 1. Hydrostatic Barrier

2. Tubing Hanger

Pre-requisite:
1. Perform offline pressure test of Production Tree, Valves and its accessories on the
first change after it is nipple down from the well.
NOTE
Immediately replace parts of production Tree which found leak/fail to hold
pressure during pressure test production Tree.
2. Ensure all connections are in good condition
3. Ensure whether downhole check valve is available in the well.

Installation Procedure:
1. Land Tubing Hanger with FOSV in close position on Wellhead
2. Test Tubing Hanger
 For Non-Mandrel Tubing Hanger, Tubing Hanger test will follow MOCP-18 001D
3. Check for flow for 30 minutes
  If flow occur or pressure build up, kill the well with bullhead from annulus side
and consider using kill weight fluid.
 If no flow, continue to next step while keep the hole full to maintain hydrostatic
barrier, continuous pumping from the annulus if the well unable to hold full
column of fluid.
4. N/D BOPE as per procedure
5. Installed production Tree above Tubing Hanger
6. Pressure test production Tree and all connection as per below procedure:
A. For ESP with downhole check valve
a. Fill up tubing and check for any leaks by visual observation on all production
Tree component and its connections.
b. Pressure test Tree and all connections against check valve. Ensure Master Valve
in open position during pressure test.

Picture: ESP Wellhead Configuration in IBU-SMO

NOTE
Immediately replace parts of production Tree which found leak/fail to hold
pressure during pressure test production Tree.
c. Close master valve when pressure test complete
d. Complete well & Move to next location

B. For ESP wells without downhole check valve

a. Conduct offline pressure test on existing master valve after N/D X-Mast Tree
to 500 psi + MASP for 15 minutes. If found leaking, contact Wellhead repair
service company to repair or change with prepared backup master valve.
b. Ensure connection between master valve and Tubing Hanger is tightened
properly.
c. Fill up tubing and check for any leaks by visual observation on all production
Tree component and its connections.
 d. Rig down Rig. Ensure to state in handover checklist if found any leaking
during POI and POP, call rig less team to conduct repair master valve
connection.
C. For Sucker Rod Pump
a. Install pressure gauge on sample cock connection
b. Perform test pumping by reciprocating the Sucker Rod to generate 300 psi
pressure for the testing against stuffing box.
c. Complete well & Move to next location

Picture: SRP Wellhead Configuration in IBU-SMO

NOTE
Immediately replace parts of production Tree which found leak/fail to hold
pressure during pressure test production Tree.

3.0 Other Consideration

3.1. Well Suspension
For well suspensions, it is foreseen that the suspension duration denoted by a
milestone or operational event. Well suspensions might constitute post drilling,
workover, completion, or securing the well operation (i.e. drilling rig moves off, WO rig
do well suspension until next P&A, Rigless intervention, or WO rig complete well).

Engineering shall define the type of barrier used, in consideration of barrier lifetime and
future intervention. Considering the lifetime of mechanical type barrier, its usage for
well suspension without predetermined future shall be avoided. Planned schedule (i.e.
Rig Schedule) may serve as strong foundation for engineers to use mechanical barrier
in well suspension. For undetermined future action after well suspension, cement cap
or full cement column shall be used as the barrier.

Barrier for well suspension still follow the barrier requirement, qualification, verification,
and type as guided on Global Technical Standard.
4.0 Resources, Roles, and Responsibilities
The following table outlines the roles and responsibilities associated with this procedure.
Table 1: Roles and Responsibilities
Role Responsibilities

DSR • Responsible for ensuring that IBU D&C Operations activities

adhere to the requirements in this SOP and all other
applicable standard
• Understand what is considered as single barrier operation
per Barrier Guideline SOP and its application in the field
• Understand when operation is not listed in this SOP, any
single barrier operations required MOC in place prior
execution
• Understand well control procedures, mitigations and
considerations for single barrier operations.
• Ensure all consideration prior executing single barrier
operation all are in place, verified and validated
• Understanding well control event reporting protocol based on
IBU Well Control Requirements

Drilling and • Responsible for ensuring that IBU D&C Design and planning
Completion Engineer activities adhere to the requirements in this SOP and all
other applicable standard
• Understand what is considered as single barrier operation
per Barrier Guideline SOP and its application in well program
• Ensure all mitigation based on this SOP and additional (as
required) are well informed in well program
• Understand when operation is not listed in this SOP, any
single barrier operations required MOC in place prior
execution

Operation Team • Understand what is considered as single barrier operation

leads and per Barrier Guideline SOP
Superintendent
• Understand when operation is not listed in this SOP, any
single barrier operations required MOC in place prior
execution
• Understanding well control event reporting protocol based on
IBU Well Control Requirements SOP
 D&C Operation • Review and approve this SOP
Manager
• Assist in any discussion of unusual conditions and how to
ensure compliance with this SOP

D&C Engineering • Review and approve this SOP

Manager
• Assist in any discussion of unusual conditions and how to
ensure compliance with this SOP

D&C Rig Hub • Review and approve this SOP

Manager
• Assist in any discussion of unusual conditions and how to
ensure compliance with this SOP

D&C General • Accountable for the approval and implementation of this

Manager SOP

5.0 Measurement and Verification

Number of deviations from the procedures from this SOP and Well Barrier Design
technical standard.

6.0 Continual Improvement

New regulations, documents, best practices and procedures are to be captured and
documented to ensure continuous improvement as well as addressing any gap identified.

Table 2: Signature Table

IBU Digital Approvals
Name of Endorser/Approver Digital Approval / Endorsement
Endorser Susilo Hadi Widodo 7/10/2020

IBU-SMO X Susilo Hw
Manager, D&C Engineering
Manager, D&C Engineering
Signed by: Susilo Hadi Widodo

Endorser Muhammad Andi Solihin 7/11/2020

IBU-SMO X MAS Approved

Manager, D&C Operations
Manager, D&C Operations
Signed by: Muhammad Andi Solihin

Endorser Candy Wijaya 7/10/2020

IBU-SMO X
Manager, SMO D&C Rig Hub
Manager, SMO D&C Rig Hub
Signed by: Candy Wijaya

Approver Joko Lelono 7/11/2020

IBU X J. Lelono
General Manager, Drilling &
General Manager, Drilling & Completion
Completion Signed by: Joko Lelono
Table 3: Document Control Information
Description

Review Date 14 June 2020

Next Review Due 14 June 2025

IBU D&C D002 Well Control Procedure for Single Barrier

Control Number
Operations

Table 4: Document History

Version Date Notes
Number
1.0 01 August 2015 First issuance

2.0 12 Nov 2017 2nd Revision

2.1 26 Feb 2018 Revised version from 2nd Revision

3.0 22 June 2019 New Barrier GTS

3.1 14 June 2020 Revised version from New Barrier GTS (3.0)