This article describes the following checklist for completion equipments:
1. Completion Equipment Preparation Checklist
2. Well Site Preparation Checklist
3. Make up/ Running Check Procedure
1. Completion Equipment Preparation Checklist
This procedure shall be followed in addition to the Contractors' own procedure. The Contractors shall at their base as a minimum perform the following:
- When new equipment arrives at the Contractor's Base, the Contractor shall perform an extensive series of mandatory inspections. These include initial visual inspection followed by full function and pressure testing of all relevant equipment.
- The relevant procedures, applicable standards and specifications for all pre-completion equipment supplied by Contractors involved in the pre-completion phase shall be detailed in their respective Quality Assurance Manuals.
- Equipment arriving at Companies Base shall be packed in designated boxes with appropriate description on the equipment. Prior to shipment offshore the equipment shall be flushed and when necessary, cleaned inside and outside with steam. The equipment will then be packed again in designated boxes for shipment offshore.
- All assembling and testing shall be performed by persons, who are qualified as Functional Test Operators.
- Two persons shall always be present during testing.
- Prior to shipment, an authorised Company representative shall approve the description of each sub assembly in writing. The workshop supervisor shall check equipment lists against the written approval with sub assembly description. This approval shall be retained by the contractor.
- Prior to assembly, the workshop personnel shall obtain approved equipment check list and test procedure from the workshop supervisor. Only properly approved equipment check list may be used.
- All pressure tests shall be recorded on a chart recorder which will then be attached to the equipment check list to be retained indefinitely by the Company
- All assemblies shall be tested to 5000 psi bar unless otherwise specified.
- After the pressure test, each assembly shall be drifted with the appropriate API spec. drift. All drift diameters shall be recorded on the equipment check lists. All drifts shall be inserted from both above and below the assembly to ensure that no deformation has taken place during make up.
- All assemblies shall be made up using the Jam system or equivalent. All make up torque-turn and pressure test charts shall be attached to the equipment check lists.
- The actual functioning of equipment and tools shall be tested before equipment leaves the contractors site.
2. Well Site Preparation Checklist
All inspection and testing shall be performed by contractor's personnel and witnessed by the Drilling Supervisor or his representative. This procedure shall be followed in addition to the Contractors' own procedure.
- Ensure that all equipment is clearly marked as it arrives on board.
- The gravel pack liner/ prepacked screens liner and downhole service tools required shall be laid out on deck and the Contractor's pre-completion supervisor (under the supervision of the Rig DE) will number and measure all items.
- The gravel pack liner/ prepacked screens liner and downhole service tools shall be flushed with water or steam cleaned.
- Ensure that all equipment is clean and free from scale and paint. Equipment which is painted or is scaled shall be rejected.
- Check the threads for damage and scale.
- Drift all gravel pack/ prepacked screen liner and downhole service tools.
- Apply correct Thread Compound and then replace the pin and box protectors.
- Inspect interior and exterior of each component. Ensure that all threads are clean and free from damage.
- Ensure that any/ all part numbers, dimensions, etc. correspond to the equipment check list.
- Complete the equipment check list.
- In addition the following specific tool inspections shall be performed:
Prepacked Screens
a) Screens shall be inspected for damage, correct wire spacing, and presence of holes in basepipe. Screen should be steam cleaned (or cleaned with high pressure water) if necessary.
b) Ensure that the collar is correctly made-up to the base pipe.
Gravel Pack Packers
a) Ensure that there are no obstructions in the ball seat.
b) Ensure that the correct ball is available.
c) Inspect the packer slips and element for damage.
Shear Out Safety Joint
a) Before picking up assembly, ensure that shear pins are inserted all the way into the ring groove.
Knock-out Isolation Valve
a) Ensure that the flapper valve is operating as specified.
Work String
a) If operationally possible steam clean every joint.
b) The work string shall be drifted.
3. Make up/ Running Check Procedure
This procedure shall be followed in addition to the Contractors' own procedure.
- In the case of gravel packing ensure, that the well clean-up programme is performed and the required cleanliness is achieved.
- Ensure that stripping table, elevators, slips and power tongs are in proper working order, and that the correct dies are fitted.
- Do not use pipe wrenches for manual make up.
- Inspect interior and exterior of each component. Ensure that all threads are clean and free from damage.
- Ensure that any/ all part numbers, dimensions, etc. correspond to the equipment check list.
- Complete the equipment check list
- Using a small clean paintbrush or pipe dope applicator, apply pipe thread lubricant sparingly to both pin and box thread, and sealing shoulders.
- Ensure that the power tongs are set to cut out at the recommended torque. If available a unit to control the initial make-up speed is recommended.
- Record all torque values when making up the gravel pack/ prepacked screen liner assembly.
- Drift each joint as it is picked up to the drill floor. Connections shall be equipped with protectors when transported to the rig floor.
- Screens shall be inspected on rig floor for damage, correct wire spacing, and presence of holes in base pipe. Screen should be steam cleaned (or cleaned with high pressure water) if necessary prior to running in hole.
- Ensure that the shear pins in the shear out safety joint are inserted all the way into the ring groove before picking up the assembly.
- After the gravel pack packer is made up to the string, the slips and packing elements should be inspected.
- Ensure that there are no obstructions in the gravel pack packer ball seat.
- The Rig Drilling Engineer and Contractor's Pre-completion Supervisor shall record the serial number of each item as it is made up to the gravel pack/ prepacked screen liner.
- Supervisors keeping a tubing tally should cross check with each other regularly to ensure that the prepacked screen/ gravel pack liner is made up according to the programme.
- It is critical throughout the running of the gravel pack liner assembly to ensure that no shock or jarring loads are created in the string. Always ensure that string movement is fully stopped before setting slips. Failure to observe this could result in the safety joint shearing and the gravel pack screen assembly falling.