Fill Clean Outs

Recommended Practice: Wells: CTU Operations - Cleanout Procedures Page 1 of 47
Alaska Drilling and Wells

RP: Wells: CTU Operations – Cleanout Procedures
Formerly: PE Manual: Coil Tubing Operations
Section: CTU Fill, Ice, and Hydrate Cleanout Procedures
NSU ADW Wells NSU ADW Wells

Authority: Custodian:
Operations Supervisor Engineer
Wells: Coil Tubing Document Control Document Control
Scope:
Operations Administrator: Specialist
Alaska Wells Group
Issue Date: January 22, 2002 Issuing Dept:
(WELS)
Revision Date: October 30, 2008 Control Tier: Tier 4
Next Review Date: October 30, 2012
INTELLECTUAL PROPERTY AND CONFIDENTIALITY NOTICE

© 2009 BP America Inc. (for all US copyright notices) All rights reserved.
This document contains confidential information, which is the exclusive and proprietary property of BP America Inc. and affiliates.
In whole or part, this document or its attachments MAY NOT be reproduced by any means, disclosed or used for any purpose
without the express written permission of BP America Inc. or affiliates.
1.0 Purpose/Scope
This section provides guidelines for the Wells PE’s on how to plan and conduct fill cleanouts, ice
plug, and hydrate plug removal using coiled tubing on the North Slope.
Note: Section 7.0 contains Lessons Learned from the field.
2.0 Definitions
APE Anchorage Production Engineer
ASH Alaska Safety Handbook
BOP Blow Out Preventer
CTU Coiled Tubing Unit
DSO Drill Site Operator
EMS Environmental Management System
EOA Eastern Operating Area
EOC Eastern Offtake Center (EOA)
GPB Greater Prudhoe Bay
PCC Production Control Center (WOA)
SIBHP Shut-In Bottom Hole Pressure
SIWHP Shut-In Wellhead Pressure
SS Sub Sea Depth
SSSV Sub-Surface Safety Valve
SSV Surface Safety Valve
WOA Western Operating Area
WOE Wells Optimization Engineer
WSL Wellsite Leader
3.0 General Requirements

This section provides information on the planning, equipment and recommended procedures for
cleaning out wells using coiled tubing at GPB and other fields on the North Slope.
4.0 Key Responsibilities

BP Confidential and © 2009 BP America Inc.
Control Tier: 4 - ADW Revision Date: 10/30/2008
Document Number: UPS-US-AK-ADW-WLS-ADW-DOC-00049-4 Print Date: 3/24/2019
PAPER COPIES ARE UNCONTROLLED. THIS COPY VALID ONLY AT THE TIME OF PRINTING. THE CONTROLLED
VERSION OF THIS DOCUMENT CAN BE FOUND AT http://eportal.bpweb.bp.com/hse
Well Operations Supervisor is:

To designate the person to update manual as necessary to incorporate new policies or
procedures.
Wellsite Leaders are:

 Responsible for identifying and submitting changes to the procedures and methodology
based on new technology and new and better ways of performing work .
 Update the manual based on changes as a result of Root Cause Investigations.
5.0 Procedure
5.1 Fill Cleanouts
Fill cleanouts are performed to remove solid debris from the well which prevents optimal
production, perforating/stimulation opportunities or monitoring of the reservoir. Solid debris can
consist of frac sand, reservoir sand, cement cuttings, ice, hydrates, paraffins, asphaltines, rocks,
or even metal pieces from preceding well work. Two primary methods are used for cleanouts:
5.1.1 Normal Cleanout:

Circulation is down the coiled tubing and up the coiled tubing by tubing annulus. This is also
referred to as cleaning out the long way or a live well cleanout in the event the well is flowing
during the cleanout. This method is almost always used for cleaning out Ice and Hydrates and
will be discussed in detail in the Hydrate and Ice Plug Cleanout section of this document.
Live well cleanouts are used on wells flowing reservoir fluids into the wellbore. The advantage to
a live well cleanout is that addition of produced fluids adds to the total fluid rate available to
remove solids from the well and will aide in cleanout performance. Fluid returns are either taken
directly down the flowline or through a flowback separator before they are returned to the
flowline. At times, the cleanout may be through a flowback separator or choke manifold directly
to tanks (with the gas going to the system depending on solids content, allowable gel quantities,
and current facility constraints.
5.1.2 Reverse Cleanout:

Circulation is down the coiled tubing and production tubing annulus and up the coiled tubing.
Reverse cleanouts are only done on wells that are dead and where there is minimal circulation of
gas and oil. This type of cleanout is most frequently used after a frac stimulation where the well
is dead, dummied off, and a large amount of proppant has been left in the wellbore.
The bottom hole circulating pressure is higher when reverse circulating because the friction loss
due to the flow up the coiled tubing is added to the hydrostatic column of the fluid in the well.
Therefore a higher BHP is required to be able to reverse circulate a well than to clean out a well
in the normal direction (long way). Since the reservoir pressure of most producing wells at GPB
will no longer support a column of water, they cannot be reverse circulated with coiled tubing
when utilizing the normal liquids used by the Wells Group.
Recommended procedures for normal and reverse cleanout are presented below. Procedures
may require alteration to suit individual well circumstances.
Note on Injection Wells:

Water injectors and cycle MI wells frequently clog up with iron sulfide scale or biomass
(schmoo) across the perforations. In most cases these wells will not support a column of water
so a cleanout must be performed with the use of nitrogen. These wells are difficult to clean out
by jetting since the scale forms hard crusts which are difficult to break up. If the well is over
pressured, a reverse circulation cleanout can be attempted but the hard crusts make reversing
difficult also. Generally, these wells can be cleaned up with an HCL perforation wash or a
surfactant treatment down coiled tubing and then put immediately back on injection. In some
cases such as LPC or GNI injectors, water based fluids can be used to initiate the cleanout the
long way. Once returns are lost, the well can be put on injection to clear the production tubing
and the cleanout resumed by “fluff and stuff”, i.e. fluffing up the fill and pumping all debris into
the perfs.
Note on MMS wells at Northstar:

The revised MMS BOP requirements of 1-Apr-2006 stipulate that downhole checks must be run
on all coiled tubing operations. Discuss this with the Wells Operations Supervisor if reversing is
proposed or contemplated.
5.2 Job Preparation

a) Determine production tubing and casing size. Note any restrictions.
 Determine the proper size CT to be used. Typically 1-3/4” CT is suitable for most
cleanouts however in 2-3/8” liners, 1-1/2” CT is recommended due to annular clearance.
 The fluid rate through 1.75” coiled tubing is limited by the friction pressure to about 2.5 –
3.0 BPM. The restricted rate also limits the annular velocity. As tubing size increases,
circulation volumes increase and rates required to remove solids from the annulus also
increase.
 Determine the maximum annular velocity for the well configuration.
 Larger tubular sizes may increase the probability you will need nitrogen or lift gas to
increase the annular velocity. Nitrogen is highly recommended for 7” in which there are
normally no GLM. In all other cases, check on the availability of gas lift gas or a poor-
boy gas lift hookup. Nearly all wells in GPB will require either N 2 or gas lift assistance.
 More coiled tubing jobs are being done on wells that have been sidetracked by coiled
tubing drilling. These wells introduce different challenges – horizontal well bores with
minimal annular clearance (increased friction) and a tubing size increase (with
accompanying loss of velocity) as the solids enter the production tubing.
 Determine the maximum allowable pumping and annular pressure limits to be used
during the job.
b) Estimate amount and type of fill to be cleaned out.

 Be sure the fill has been identified as loose fill, perhaps with a wireline bailer run. Verify
that it does not have to be milled or under-reamed. Good down jetting nozzles can work
through sand bridges but are not effective in crusted sand laden with cement. Under-
reaming, prior to fill cleanout, has proven more effective in these cases.
c) Calculate the minimum annular velocity to remove the solids. Decide if the cleanout will be
normal (with or without N2 / gas lift) or reverse. (A rig up for reverse cleanout can also be
used for a normal cleanout so order a reverse rig up if there is any chance that a reverse out
may be done)
The following table provides guidelines for minimum rates based on particle size and type.
Minimum Rate to Remove Material (bbl/min)*
3-1/2” Tubing 4-1/2” Tubing 5-1/2” Tubing 7” Casing

Tubing Size (9.3 #/ft) (12.6 #/ft) (17 #/ft) (26 #/ft)
Particle Description
10 mesh Sand 0.7 1.5 2.5 4.3
20 mesh Carbolite 0.3 0.6 1.0 1.8
40 mesh Carbolite 0.1 0.3 0.5 0.8
0.1 inch steel 1.6 3.4 5.7 9.9
0.05 inc steel 1.1 2.4 4.0 7.0
0.1 inch aluminum 0.8 1.7 2.8 4.9
*Using Stokes Law and assuming 1.75” Coil and 2% KCL

Rate is 2 X settling velocity. For horizontal or high angle wells, the minimum rate required is
estimated to be 3-5 times the values above. Other sizes, particle density and fluid densities can
be calculated from Settling Velocity spreadsheet (based on Stokes Law).
d) Estimate the BHP. Determine if gas lift is available and hooked up or if nitrogen will be
required.
 Familiarize yourself with the current production characteristics of the well before the job.
Know the liquid production rate, oil cuts, formation gas rate, and gas lift rate. A slugging
well can be killed very easily during a cleanout.
 Unless the well has a very high GOR, gas lift and/or nitrogen will probably be necessary
to successfully lift the solids from the well. If gas lift is available, specify to Production
Control / drill site operator that at least 4 MMCFD* be supplied to the well. Remember
that loading the well during the cleanout will generally reduce the lift gas rate on the well
(higher hydrostatic head). The main purpose for requesting a high gas lift rate prior to
starting the job is so that the annulus pressures up and passes the maximum possible
gas to the tubing for any given tubing loading condition. (* in wells with extremely low
SIBHP, the A/L rate will need to be reduced, especially if N2 is also being used. It is
advisable to model the total fluid and gas rates expected during the cleanout to
determine the optimum starting point and then adjust A/L as conditions warrant.)
 Production Control (GPB – West Field) and Drill Site Operator (GPB – East Field)
monitor the lift gas rate by an automated orifice plate at the well pad skid. Some wells
have manual systems at an add-on skid or an orifice plate in the well house itself.
Depending upon the size of the orifice plate being used for the well, Production Control /
drill site operator may or may not be able to read the 4 MM rate. They can somewhat
exceed their maximum readable gas rate if you request it by overriding their gas choke.
 Know what mandrels currently contain gas lift valves and the respective orifice sizes. If
the bottom valve is too far from the tailpipe you may need the assist of nitrogen for
efficient cleanout. Check the last known BHP to determine if nitrogen will be required to
lighten the column from the perforations to the bottom gas lift valve. Likewise, if the
valve orifice sizes are too small to pass adequate lift gas, nitrogen will have to be used.
If you are unsure if the current gas lift valves can provide the gas needed to cleanout the
well, discuss your plans with the gas lift engineer (659-5893). It will be less expensive to
change out a gas lift valve than to use N2 to lift the well. DO NOT inject cold gas into a
well full of water – especially when there is coil in the well. Small neat methanol pills
should be pumped in the IA prior to bring on the A/L.
 If gas lift is unavailable for the well and it is not high GOR, injecting nitrogen into
cleanout fluids will assist in lifting the well. The bottom hole pressure at GPB, flowing or
shut in, can no longer support a full column of water. In order to remove the solids
without gas lift assistance, inject nitrogen at 600 to 1000 scf/bbl in both the circulation
water and Biozan or Flo Pro sweeps. Nitrified fluid rates through the coil will be
restricted to about 0.7 to 1.0 bpm because of the addition of nitrogen. The hydrostatic
head of the two phase mixture will also be reduced. The annular velocity, however, will
be greater due to the expansion of the nitrogen as it exits the nozzle. The lighter fluid
gradient will also reduce the possibility of fluid loss to the formation and reduce the risk
of solids bridging and sticking the coiled tubing. Once again, modeling the expected fluid
rates, A/L and N2 rates will provide the optimum starting point and can then be adjusted
as well conditions warrant.
 Some wells have extremely low bottom hole flowing pressures. In some of these cases,
even gas lift and nitrogen cannot effectively clean out the well. Shutting the well in 1 to
3 days prior to cleanout operations sometimes helps to build up near wellbore pressure
which can help the cleanout success.
e) Determine the fluid(s) to be used for cleanout operation.

 Hot clean water, either fresh water with 1% or 2% KCL (depending on reservoir) or
seawater, is available and is preferred for cleanout operations since it is non damaging
and readily available. Friction reducers should be added to the water to achieve the
highest circulating rate through the coil. A typical cleanout will require a minimum of 2 to
3 hole volumes, so have the necessary tanks on location (upright tanks are preferred).
Contact DSM and let them know that you will be performing a fill cleanout and may need
additional fluids or dirty trucks on a regular basis.
 In chrome wells or wells where TD may be difficult to reach, lubricants may be
necessary. Consistent success has been achieved with the use of the MI product Safe
Lube. This product is a water soluble, non-damaging, surfactant added to the cleanout
fluids in a concentration of 0.6% by volume. A typical 290 bbl vac truck will require 73
gallons. This product has been shown to be compatible with J-313 (friction reducer), and
Flo Pro. When using this product, keep in mind that it is not necessary to load ALL fluids
with safe lube as it is an expensive product. Good results have been realized by loading
the Flo Pro and using 30 to 50 bbl “pills” of XS KCL with safe lube. Each time a gel
sweep is pumped, good lubrication is seen. Periodically a 30 to 50 bbl pill of XS KCL will
keep the hole conditioned during the cleanout.
 Do not jet fill with water as very little carrying capacity is achieved. Use a high viscosity
fluid such as Biozan or Flo-Pro to lift the solids off bottom and out of the hole. You will
need to suspend the solids and maintain a fluid velocity up the wellbore greater than the
solids settling velocity.
 A typical cleanout requires 10 to 20 barrels of Biozan or Flo-Pro per 50 feet of fill when
working in 7”, plus an additional 10 to 20 barrels for a final sweep. This works out to a
approximate minimum 6:1 ratio up to a maximum of 12:1 ratio of gel to solids. Working
within this range is a relatively safe starting point. If well depths are greater than 8000’
and tubular/liner sizes are large, start at the higher ratios and order fluids accordingly. As
an understanding of the cleaning efficiency is gained through the first few “bites”, this
ratio can be changed as conditions warrant.
 Good cleanout technique includes jetting through fill with gel to the end of the planned
bite and then allowing ~1 bbl of gel out the nozzle while the coil is parked. Once the
clean gel is out the nozzle, the upward pass is started. This leaves a buffer at the tail of
the solids laden sweep to help offset the fallback while chasing up hole.
 Fluids and friction reducers are discussed in greater detail in the PE Manual Section
titled CTU Fluids.
f) Determine if the fill can be sent to the system or needs to go to a tank or separator.
 Decide if a flowback separator will be required. As a rule, a separator is suggested when
there is over 100 feet of fill in a 7” liner (3.7 bbls of solids) or when using over 40 barrels
of Biozan or Flo-Pro. Of course this is subject to many variables and should also be
discussed with the Well Operations Supervisor.
 Tanks can generally be used if the well can be cleaned out with a solid column fluid, can
be reasonably expected to have 70% or better returns, and does not have a lot of gas.
Gassy wells should be killed and then kept liquid packed during the cleanout so that the
well does not “turn around”, unload, and overwhelm the tanks with gas. Once again the
test separator may be a better option as gas lift or N2 can be used and the well flowed at
maximum rates during the cleanout.
 Determine if the plant can or is willing to take any gel back to the system. This should
always be discussed with the WOE (Wells Optimization Engineer) as more and more the
facilities are reluctant to take any quantity of gel due to the increased potential for a
system upset. Most likely all returns will have to go to a test separator or to tanks. If N2
or gas lift is going to be used, a test separator is recommended. In the past live
cleanouts have been done to tanks however the environmental risk is significantly
higher. The 500 bbl double walled tanks with gas buster and de-misters can be utilized
for fill cleanouts in some areas using gas lift and/or nitrogen. Consult with the Well
Operations Supervisor if a separator is not available and it is not an H2S well.
 When sending gel to the system through the test separator, arrange for anti-form to be
injected into the return fluid stream. This will aide in separation and in some cases has
allowed more gel to go to the facilities without problems.
 Determine if the well returns to tanks will be gas cut or not. If solid liquid returns are
expected, rig up the return micro motion. This will provide a better means to monitor
returns and spot losses more efficiently then regular tank straps.
g) Nozzle size and jet configuration.

 Select a medium size jet swirl nozzle, in relation to wellbore minimum ID. Most jetting
nozzles supplied by the coil companies are bored with 1/8 inch to 3/16 inch circulation
holes and come in sizes from 1.75 inch up to 3.5 inch. A swirl nozzle has down jets
along with angled jets to give the fluid a swirl pattern in the wellbore. Cleanout nozzles
should include upward pointing jets to help chase solids up hole. The size of the nozzle
and stingers should be weighted against the risk of getting stuck. Areas to consider are:
 With possible junk in the hole, it may be necessary to fish it, vacuum it using a venturi or
motor/venturi combination, push it to bottom, or use a slick assembly if absolutely
necessary that the cleanout will end up close to the junk. Thoroughly research the well
history to understand what is in the hole and the risks posed.
 Use smaller OD tools for 3-3/16” and 2-7/8” tubulars. When cleaning out 2-3/8” liners it is
strongly advisable to wait until 1-1/2” coil tubing is available.
 When running a slick assembly, always do the “swab shuffle” when getting close to
surface if the coil connector can not be used to tag up with. This involves checking the
swab, pulling up a certain amount, and rechecking until the tools are clear of the swab.
The distance which can be pulled is based on the distance from the swab to the stripper
and the length of the tool string.
 If the well has multiple zones with different pressures, the possibility exists for cross flow
to result in the loss of returns and subsequent plugging around the coil. If this potential
exists, consider running a small OD or slick assembly.
 When running large or over sized nozzles, consider making up an MHA with a
disconnect.
 If a nozzle smaller than 2-1/4 inch is chosen or required for clearance, use two rigid 4 to
5 foot extensions, sometimes referred as mandrel bypass bar or stinger, to help avoid
tagging up inside gas lift mandrels. In general, it is a good idea to run two stingers to
avoid any potential nozzle/gas lift mandrel interference. The use of stingers also has the
added benefit of slightly higher AV’s around the BHA when larger than the coil size.
 If cleaning out multi-lateral wells, special tools may be required to reach the desired bore
or lateral within the well. For cleanouts in the main bore, a long straight BHA is
recommended to bypass the lateral windows. This typically consists of four special 2-1/8”
stingers which when made up are approximately 20’ long. This BHA does not guarantee
that the coil will stay in the mainbore but increases the chances considerably. Other
methods exist for working in the mainbore or laterals such as diverters, isolation sleeves,
multi-lateral entry tools, or mainbore centralizers but these procedures are still being
tested.
 A nozzle size greater than 2-3/4 inch is usually not necessary on a cleanout nor
recommended since solids bridges above a nozzle can cause excessive over pull or
even result in stuck coil. The shoulder area caused by the nozzle and coiled tubing can
be a contributor to high over pulls. For the same reason, a nozzle with some up-jets has
an added advantage of being able to jet these solids bridges which may form above the
nozzle. The downside of using a jet swirl nozzle is if the fill is hard, by setting down on
the top, you may temporarily plug off the down jets. If this happens all jetting action is to

the side and up hole and little or no progress is made. Try to determine the fill type by
thoroughly reviewing files or requesting a wireline sample. Down Jet Nozzles (DJN) are
typically run for jetting hydrate or ice plugs or in cases where a Jet Swirl Nozzle (JSN)
has proven to be ineffective in jetting through the obstruction.
h) If the fill is to be reversed out, there are several differences that need to be considered and
included in the planning.
 Returns will need to be sent to a tank(s). The well should not be a ‘live’ well, i.e. gas
should be minimal for safety and to minimize spill potential. If the well has gas lift
valves, all valves should be dummied off.
 Determine the collapse pressure of the coiled tubing under the reverse out conditions.
Set maximum wellhead pressure based on collapse. Collapse will be based on the two
primary factors of differential pressure outside/inside the coiled tubing and the maximum
expected pickup weights while pulling out of the hole during the cleanout.
 The only fluid required will be water (2% KCL or seawater) with friction reducer (double
slick) and freeze protect fluids during winter operations. Do not use Biozan or Flo Pro
when reversing up the coil.
 No check valves will be used. (Ensure that the Well Operations Supervisor has been
notified and that well conditions have been reviewed with the service company) Discuss
in safety meeting). Review PE Manual Section – Operating Without Downhole Check
Valves in CT String.
 Nozzle size should be medium to large when compared to the tubing ID. Nozzle should
have a large center hole (~3/4 inch) and 4 other holes (3/16” to ¼ “diameter) around the
center hole.
i) Reverse Circulation Cleanouts

 Reverse circulation cleanouts are most often used on wells that have been frac’d with
large amounts of frac proppant left in the wellbore. Become familiar with the wireline
work that has been performed prior to the cleanout attempt. Note the depth where fill
was last tagged. Make an estimate of the reservoir pressure and determine if the
reservoir pressure will support a reverse cleanout once the perforations are uncovered.
If not, the cleanout may have to be finished “the long way”.
NOTE: In Milne Point, or where directional well profiles have long 55 to 75 degree “sail
sections”, reversing is the preferred cleanout method if possible. It is the required
method for post frac cleanouts.
 FIT Sleeve & Nozzle Size. If the cleanout is a post frac initial cleanout, note whether or
not the FIT (frac) sleeve used across the subsurface ball valve nipple during the frac
treatment has been removed. These sleeves have a reduced ID and will determine the
nozzle size that can be used for the cleanout. The ID of the sleeves will be determined
by the size of the ball valve seating nipple in the production string. Check the minimum
ID for FIT sleeves with the Wireline Supervisor.
 Select a medium to large reversing nozzle in reference to minimum ID. A 2-3/4 to 3-1/4
inch nozzle is normally used for reverse cleanouts on wells with tubing sizes of 4-1/2
inch or larger. In wells with 3-1/2 inch tubing, the FIT sleeve is too small and must be
removed before cleaning out below it. Make sure the nozzle has a large center hole in
addition to side jets. Typically a ball drop jet swirl nozzle used for cementing will work
well for reversing.
 Fluids used for cleanout operation. Water is the only necessary fluid for reverse
circulation cleanouts along with sufficient freeze protect fluid for the coil and wellbore.
Even though cleanout efficiency is high in a reverse cleanout, friction reducers are
important to reduce the friction losses up the coil and thus increase the cleanout rate

which can be achieved, while reducing the circulating pressures required. Thus it is
easier to stay below coil collapse pressure as well as minimize losses to the formation.
 Determine the expected depth at which the cleanout will be started. Use S/L tags in
vertical to slightly deviated wells. In wells with long 55 to 75 degree sections, plan on
starting the reverse out well above the start of these sections otherwise a “cascade” of
sand can overload the coil resulting in high reversing pressures, lost returns, and/or
plugged coil. It is generally a good idea to start reversing sufficiently high up in the tubing
and work your way down, closely monitoring WHP, to maintain a safe reversing pressure.
 Provide the wellbore parameters, well construction, SIBHP, and directional data to the
service company and request a modeling run be made to determine all of the tubing
forces and pressures to be expected during the job. Most importantly, the collapse
pressure limitations at the maximum expected pickup weights. Also review and
understand the maximum allowable losses before the reverse out will need to be
discontinued. Typically this is 40% to 50% of pump rate but is a function of fluid velocity
within the coil and thus will vary depending on coil size, length, and to a lesser extent,
well construction.
j) Low Pressure Skid (LPS)

 The low pressure skid performs a valuable function for coiled tubing work in GPB.
This skid, when used with the coil unit and other support equipment, allows well return
fluids to be filtered and returned to the coil unit and re-circulated. During large fill
cleanouts or other operations where large fluid volumes are expected, significant cost,
manpower, and trucking savings can be realized through the use of this equipment.
 The low pressure skid provides a means to make a complete re-circulation loop for
cleanout fluids and solids returned from the well.
 The system consists of a re-circulation tank with weir, centrifugal charge pump, filter
skid, chemical injection pump, generator, and all hoses from the tank farm back to the
coil unit.
 The low pressure skid is especially useful if large volumes of fill will be cleaned out
requiring significant fluid volumes. The low pressure skid can be used generally in
warmer weather conditions without much difficulty however the unit is best suited for
applications where there is little or no crude to be returned to the tank farm and no gas.
Live crude can not be re-injected into the coil and will need to be “skimmed” off with a
dedicated vac truck. In many cases this is not recommended therefore well conditions
during the cleanout and expected returned fluids must be carefully considered.
 Dead fluids returned from the well can be collected in the re-circulation open top
tank, run through the centrifugal charge pump to the low pressure skid, filtered, and
spiked with additional friction reducer as required. Gel sweeps are generally “caught”
when possible and directed to another open top tank.
5.3 Recommended Equipment

The following equipment is recommended for a fill cleanout using coiled tubing:
1. Normal cleanout with returns to the system:
 Pump-in sub with backside line.
 Reverse-out skid (so that you can pump down backside, coil or both)
 Upright(s) with enough fluid to circulate well 3 times. Fluid should be either 2% KCL
or seawater. Add 1 gallon of friction reducer per 1000 gallons of water (double slick)
 Additional upright for fluid if Safe Lube is to be used.
 Biozan or Flo Pro (plus vac truck or upright for storage). Do not put Flo-Pro or
heavy Biozan into an upright tank because these fluids cannot charge the coil pump
by gravity. Biozan up to 1.5#/bbl can be placed in an upright without problems.
Anything over 1.5#/bbl loading should be left in a vac truck.

 BHA – Dual checks and jet swirl nozzle. Optional – hydraulic disconnect, straight
bar or stingers.
2. Normal cleanout with returns to tanks:

 All the equipment for a normal cleanout to the system PLUS:
 Choke manifold
 Tiger tank (minimum of one)
 Open top tank (minimum of one)
 Secondary Containment for flowback tanks
 Test separator (if available)
 Flow cross (if using separator)
 Return micro motion if returns will not be gas cut.
3. Reverse cleanout.
 Reverse-out skid (so that you can pump down backside, coil or both)
 Upright(s) with enough fluid to circulate well 3 times. Fluid should be either 2% KCL
or seawater. Add one (1) gallon of friction reducer per 1000 gallons of water (double
slick)
 Choke manifold
 Tiger tank (minimum of one)
 Open top tank (minimum of one)
 Secondary Containment for flowback tanks
 BHA – Big center hole jet nozzle (no checks). Optional – hydraulic disconnect,
straight bar or stingers.
 Test separator (optional).
 Flow cross (if using separator)
4. Low Pressure Skid (LPS)

 Re-circulation tank with Weir
 Low Pressure Skid
a. Stocked with filters
b. Stocked with additional 5 gallon pails of J-313
c. Chemical injection pump
d. Sufficient hoses based on location layout
e. Generator for lighting
 Centrifugal charge pump
 One additional wells support hand for startup.
 Super sucker at end of job to clean out re-circ tank
5. Nitrogen – if needed (only if normal cleanout)

 N2 pumper
 N2 tanker (if large volume of N2 is required)
5.4 Execution - Normal (or Live Well) Cleanouts

1. Verify that gas lift is on and working (or N2 is on location) if lift is required. Prior to
opening up the A/L to the annulus, pump a three to five bbl spear of neat methanol using
the triplex pump down the IA immediately before bringing on the A/L. Once the A/L has
been opened up, inject small one to two bbl methanol pills every 10 to 15 minutes until
such time as the well is flowing and the A/L line has warmed up. Always keep pipe
moving if in the well while bringing on the A/L.

2. Ensure that a communication path exists into each annular space and that a functioning
gauge is installed. As significant fluid volumes will be pumped, the thermal conditions of
the well will change and may result in increasing annular pressures. Be prepared to
bleed IA and OA pressures if such conditions present themselves. Confirm maximum
pressures with the crews prior to the start of the job and ensure proper hoses are
available to safely bleed annular pressures should bleeding be required.
3. RIH with coiled tubing and dry tag the top of fill. Note depth as beginning fill cleanout
depth in report. Do not set down significant weight when tagging fill as the coil can
become stuck or the nozzle plugged. Once the fill has been tagged, pick up above fill
immediately and come on line with the pumps to ensure the coil is clear. In the event the
nozzle has become plugged and can not be cleared, a trip to the surface will have to be
made to clear the nozzle. The risks associated with a plugged nozzle are generally
accepted and consider far less than those associated with jetting into significant amounts
of fill and becoming stuck. As a result, “wet tags” or tags while pumping are discouraged.
4. As a rule of thumb, a 10 to 20 barrel slug of Flo Pro should be pumped for approximately
every 50 feet of fill to be removed. Jetting into the fill should not be done until the
Biozan or Flo Pro slug reaches the nozzle. Jet down at maximum pump rate through no
more than a 50 foot interval (sometimes called a bite). Plan to have enough high
viscosity fluid (Biozan or Flo Pro), about 5 barrels, to chase the solids laden Biozan or
Flo Pro to the tailpipe. Chase the solids up the hole at 80% (coil rate is 80% of the fluid
velocity in the casing/liner). It is important to have the clean high viscosity Biozan or Flo
Pro sweep behind since the solids will fall through the Biozan or Flo Pro while being
circulated out of the hole. If the solids fall completely out of the Biozan or Flo Pro back
into plain water before reaching surface, severe loss of cleaning efficiency results.
CAUTION: Special procedures must used when filling the upright tanks when using Safe
Lube as this product has a tendency to foam. Ensure the uprights are rigged up such that
fluids can easily be loaded from the bottom rather than the normal fill up lines going into
the top of the upright tanks. Filling from the top can result in a spill if excessive foaming
occurs.
5. Lifting more than a 50 foot bite from the liner at any one time is not recommended.
Keeping the bite to 50 feet or less will disperse the total fill up the hole over a greater
interval during the cleanout, thus reducing bottom hole pressures. Each section of fill
jetted out using the Biozan or Flo Pro should be circulated with water to the tailpipe, or
lowest operating gas lift valve, before attempting to jet additional solids. This usually
puts the Biozan or Flo Pro slug into the higher annular velocity area. You can develop a
cadence to a typical cleanout that imitates the following steps:

 Jet through bite with Biozan or Flo Pro while pumping water.
 Begin to chase to tailpipe while closely monitoring PU weights.
 Switch over to next Biozan or Flo Pro pill while jetting up.
 Once at the tailpipe, switch back to water and time it so that you reach top of fill
when next high viscosity gel pill reaches nozzle.
 Stop the jetting down and allow the last 1 bbl of clean gel to exit the nozzle.
 Repeat process.
NOTE: Based on the consistency of the fill, cleaning efficiency, directional survey (highly
deviated wells), and fluid velocities, it may be advisable to make periodic short trips up
to the first live GLV during live cleanouts or, in extreme cases to the point at which the
well becomes vertical. This will ensure solids are getting moved up hole and out of the
well. This will greatly reduce the possibility of fill settling out above the BHA and reduce
the amount of fill laying on the low side of the hole.
6. Monitor the coil weight when chasing bites to the tail pipe. “Pulling heavy” is a good
indicator of poor and insufficient cleaning. If over pull is encountered, more circulation
time before continuing the cleanout is necessary. Before resuming cleanout, a follow-up
sweep of Biozan or Flo Pro should be pumped. Additionally, larger slugs of Biozan or
Flo Pro should be used when the cleanout is continued or smaller bites with more
frequent sweeping to the tubing tail should be made. When taking returns to tanks,
closely monitor returns and adjust accordingly for losses to ensure each sweep makes it
to surface. Use a tracking sheet to keep tabs on where each sweep is in the hole and
when it will be at surface so that samples can be pulled if necessary.
7. Prior to pulling out of the hole, pump another slug of Biozan or Flo Pro as a final
sweep. A minimum of 10 barrels is recommended, more if well depths are deep or liners
are 7” or larger. While the Biozan or Flo Pro slug is exiting the nozzle, long upward and
downward movement within the Biozan or Flo Pro slug will help lift solids off the low side
of the casing and up into the tubing tailpipe. The nozzle must be at the base of the
Biozan or Flo Pro slug before the water reaches the nozzle so that the high viscosity pill
is not diluted. Chase the final Biozan or Flo Pro sweep to surface at 80% (coil rate is
80% of the fluid velocity). Ensure that no Biozan or Flo Pro is left downhole unless
specified in the well program. When chasing out of the hole, in large liners or long 55 to
75 degree sections, pump at maximum rate and reduce the OOH rate to between 50%
and 60%. This will result in higher annular velocities, critical for a good cleanout. In some
cases where poor hole cleaning is evident, additional gel sweeps may need to be
pumped while making a short trip and then continuing to chase OOH.
8. Chase the solids all the way to the surface. It has been observed many times that
an appreciable amount of solids are recovered during the trip out of the hole when the
nozzle is within 4000 feet of surface. This may be caused by the upward movement of
the coil itself or just due to excessive lag time of the solids within the fluids. For that
reason it is important to continue circulating until all the way out of the hole. Any solids
left in the hole after the cleanout can settle and form a bridge in the tubing if the well
must be shut in afterwards. To remove straggling solids in the tubing, it is recommended
that the well be allowed to flow at least two bottoms up volumes before shutting it in.
9. If you decide to use nitrogen to aid in the cleanout, inject N2 into both the water and
Biozan or Flo Pro at about 600 to 1000 scf/bbl. Then adjust your liquid pump rate to
maximum rate. You will need a Nitrogen handbook or a modeling run to determine the
total rate down the coil under the cleanout conditions.

10. When cleaning out a well through a flowback separator, monitor the gas and liquid
flow rates closely. If partial returns are indicated, reduce circulation rate and cleanout
rates accordingly. In most cases, a successful cleanout can be performed with as low as
1.5 bpm circulation rates, with gas lift assist, when Biozan or Flo Pro is used effectively.
Be sure the separator operators maintain a constant fluid level in the vessel so rate
measurements are as accurate as possible. Have frequent samples taken at the inlet of
the separator so that cleanout efficiency can be evaluated.
CAUTION: When coiled tubing and the portable flow-back test separator are rigged up
together, carefully follow pressure testing and bleed off procedures. Discuss these
procedures with both coil and separator crews prior to starting the job and, as always,
perform a thorough risk assessment. Always isolate the flowback unit from the coil unit
when testing and bleeding down the coil unit and before the coil rigs back their lubricator
from the well. Discuss how the surface lines, flowlines, jumpers, and offset well flowlines
will be freeze protected. Walk out all lines to ensure there are no dead legs which could
become frozen. Make sure good radio communications are established before
proceeding. Review procedures and assign roles and responsibilities for communicating
with the pad operator or DSO, strapping tanks, handling valves, managing trucks and
manifesting as well as sampling requirements.
11. If cleaning out down the flowline, monitor S-riser temperature and pressure to
determine if the well is being killed by the circulation rate being used. A decreasing gas
injection rate as measured by Production Control/drill site operator will also indicate how
severely the well is being overloaded. Expect some drop in gas injection rate and
surface flowing temperature during the job. Another good indicator is the amount of oil
in the S-riser samples. If the oil cut goes to zero, chances are the well has been killed
and partial losses are occurring. This situation warrants larger gel sweeps and/or smaller
bites and frequent short trips to check for cleaning efficiency. The circulation rate may
also have to be decreased to help the well catch up.
12. When cleaning out Carbolite, a dry tag, that is tagging bottom without pumping, is
often done at the end of the job and sometimes done at the beginning of the job to
establish or confirm a cleanout depth. Carbolite is forgiving and dry tags have been
made successfully with Carbolite fill in the hole.
5.5 Execution - Reverse Circulation

1. A wireline tag should have been made identifying the top of the fill. Use normal
circulation that is down the coil and up tubing by coiled tubing annulus, to remove the
cold viscous fluids from the wellbore down to the sand top. If no wireline tag is available,
run in hole slowly until a tag is seen. Do not set down significant weight otherwise the coil
can become stuck or the nozzle plugged. Once a tag is seen, pick up hole immediately
and come on line down the coil to clear the nozzle. If the sand top is up in the permafrost
area, it is better to jet out the fill down to at least 2500 feet using a normal circulation.
The cold, thick gels through the permafrost cause higher reverse circulating pressures.
Sometimes the well must be jetted even deeper if the gels are still too thick for reverse
circulation operations. If the well was fracted using a gel with a low temperature breaker,
this may not be a problem.
2. Set the maximum WHP to prevent coil collapse before starting the operation. Collapse
can occur at any point in the string but will generally happen just below the packoff,
where differential pressures are the greatest. Verify the strength of the coiled tubing
before starting the cleanout. Ensure a copy of the Hencky – Von Mises graph
(collapse/burst chart) is available for the coil during the job or the real-time Coil Limit plot
displayed by CTDS.

3. Begin reverse circulation immediately above the fill. Maximum rate is desired for the
reversing operation without exceeding coil collapse pressure. However, allowance must
be made for the density increase in the coil once the cleanout is in progress and solids
are being lifted up the coil. It is recommended that no more than 10% of the internal coil
volume consists of solids at any one time. For Carbolite, this represents an increase of
approximately 120 psi for every 1000 feet of vertical depth of the nozzle.
 In some cases a significant amount of fill can be present above the hard sand top.
This is common in wells with long sail angles of 65 to 75 Deg. When these types of
directional profiles are present, the recommended practice is to start the reverse out
from higher up hole. This process can greatly reduce or eliminate the possibility of
over loading the coil as sand is washed down or migrates from above in an
uncontrolled manner.
4. Use the Micro Motion readings (densitometer and rate meter at coil inlet), if available, to
monitor returns during the operation. As a rule of thumb, a safe reverse out is achieved
by keeping the density below 10.0 ppg. A bucket test at the tank should also be done
which helps estimate return rate and solids concentration. If using a flowback separator,
catch samples at the inlet to the separator. Returns must be monitored continually. If
circulation is lost, the fill in the coiled tubing will fall quickly and can bridge, plugging the
coil.
 The micro motion meter should be configured to ensure it reads flow in both
directions. The instrument tech can make a simple configuration change to allow the
micro motion meter to show flow in both directions. Most micro motion meters are
already configured for this purpose.
5. Once pressure and rate are stabilized, begin slowly washing down the hole to start the
cleanout operation. Adjust penetration rate and flow rate as needed to control well head
pressure. If well head pressure exceeds a desired level, stop the coil until enough solids
are removed from the coil to drop the circulating pressure. Proceed with the cleanout at
a reduced coil speed.
6. The coil speed will have to be reduced once the nozzle is below the tailpipe and into the
larger ID casing since the sand capacity per foot is greater.
7. As you approach the perforations, monitor returns with the Micro Motion meter and with
a bucket test at the tank. Watch for lost circulation. Sometimes, partial losses are
indicated by decreasing well head pressure since less circulation is going up the coil,
thus reducing the friction pressure. When partial returns are encountered, calculate the
fluid velocity in the coil and compare the velocity to settling velocities of the solids to
decide if reverse circulation should be continued. If insufficient rate up the coil cannot
be achieved at coil collapse pressure, end the reverse out.
a. A good practice for reversing is to stop reversing short of the perforated interval by
approximately 50’.
b. Circulate one to two coil volumes until returns are no longer solids laden.
c. Continue the reverse out closely monitoring returns and solids rates while
approaching the perforations.
d. End the reverse out when velocity inside the coil is insufficient to remove solids.
e. If returns fall off to ~ 70% of the pump rate, reduce the rate to lower the pressure
acting downhole and pick up hole and slow rate until returns are regained. Once
again, if insufficient rate up the coil can not be achieved, then consider going the
long way to finish the cleanout.
8. Once you have ended the reverse out, stop the coil and continue reversing, if possible,
circulating sand in the coil to the tank. If lost returns are too severe, switch circulation
down the coil while pulling out of the hole. Do not stop fluid circulation if sand is still in
the coil. Stopping circulation may allow a bridge to form in the coil which cannot be
removed.
9. Try to circulate a couple of coil volumes of clean fluid (the long way) before pulling into
the tailpipe to keep the tubing sand free. If losses are too great to circulate, pump at
least two coil volumes of clean fluid followed by a 5 bbl pill of Biozan or Flo Pro while
pulling out of the hole. Jet across gas lift mandrels while pulling to surface which helps
future wireline operations. (It is important to get all of the sand out of the coil before the
next job or operation. Sand remnants can cut out a motor or interfere with dropping balls
to function tools). If no gel was pumped after reversing then at the end of the job with the
coil at surface, pump a small gel pill down the coil, and chase out to the tanks at
maximum rate to clear the coil of any remaining debris.
10. If cleaning out an injector, the fill is often hard and it is difficult and at times slow and
inefficient to jet this fill because of the large ID casing (7” or 9-5/8”). It may be necessary
to jet the fill by pumping down the coil to ‘fluff up” the fill using Biozan or Flo Pro to
suspend the solids before it is reversed. Jet down the coil and fluff up 25 – 50 ft of fill
(depending on the size of the casing and coil volume). After fluffing the fill, pick up the
coil about 5 -10 ft and reverse the loosened fill up the coil. You need to circulate each
‘bite’ to surface before jetting and fluffing the next section of the well. The key to
cleaning out wells using this method is patience. You need to circulate a coil volume of
fluid for every 3 – 5 bbls of fill that you remove. If you get in too much of a hurry, you
can stick the coil with the fluffed up fill or get a bridge inside the coil because the solids
volume in the coil is too high. This methodology requires more fluid volume for
circulating as well requiring a “dirty” vac truck on hand after you have made 3-4 cycles.
5.6 Injector Cleanouts at Milne Point

Injector cleanouts at Milne Point have involved problems with removing biomass / mung to
allow slickline logging for reservoir monitoring. The majority of the injectors have 3-1/2”
tubing and 7” casing. A number of the wells are over pressured. The recommended
cleanout procedure for these wells is:
1. Rig up to take returns either down an adjacent well or take returns to an open top tank
which has been set inside secondary containment. The open top tank increases the
potential for spills but the Milne Point Field facilities are operating near capacity and the
ability to handle additional water – especially in slugs from a cleanout is limited. If you
plan to cleanout to the system, have flowback tanks on location as a contingency. As
with cleanouts involving gel and solids, discuss this with the Wells Operations Supervisor
before rigging up to be sure they can handle gel, slick water, and any other fluids you
may have to flow out of the well.
2. Use as large a nozzle size as possible for these cleanouts. A 2-1/2” jet swirl nozzle has
worked reasonably well for cleaning out the 3-1/2” tubing. Make sure that the nozzle has
good side jets to clean the ‘mung’ off the walls of the tubing.
3. If the well has a history of Schmoo problems And currently has some injectivity, consider
adding a SBG (Schmoo Be Gone) step to the program. In the event the well has
injectivity, SBG can be jetted down the coil with the well shut-in. Do not jet down to the
top of expected fill, stop jetting approximately 300 to 400’ above the top of fill, run in
hole and dry tag. Be sure to have an MSDS sheet for this product on location and review
all plans with MPU Wells Coordinator prior to pumping.
4. Run in the hole to the tubing tail while circulating down the coiled tubing and taking
returns up the tubing – coiled tubing annulus. Circulate at maximum rate. Monitor
return rate at the tanks or from the control room readings if going to the system.
5. Pump a 20 bbl sweep of Biozan or Flo Pro at the tubing tail and circulate to surface.
6. Continue to RIH while circulating at maximum rate. Circulate 10 bbl Biozan or Flo Pro
sweeps periodically while jetting the 7” casing. When at bottom, circulate a 20 bbl
Biozan or Flo Pro sweep. Chase the Biozan or Flo Pro sweep to the surface at 80%
(coiled tubing speed 80% of the fluid velocity). Chase OOH at 50% to 60% at maximum
rate through the long sail angles (55 to 75 degree sections) to ensure solids are moved
OOH. As annular velocities are critical for the removal of solids, maximum pump rate
and slower pulling speeds will result in higher velocities.
7. RIH and spot DAD acid or 15% HCL across the perfs. POOH.
8. Put well on injection as soon as the coil is out of the hole.
9. If a scale blaster is available, this might be considered instead of a jet swirl nozzle for
these cleanouts. The use of this tool should be balanced against the reduced circulation
rate down the coiled tubing due to additional pressure losses at the BHA. Run a Jet
Blaster (Jet Advisor) simulation to determine the limitations for your application.
5.7 Risk Analysis

The following table outlines the risk analysis for a typical coiled tubing fill cleanout job. The
hazards shown in the following tables are in addition to those shown in the tables in the PE
Manual Section, “Risk Analysis for Coiled Tubing Operations”, which address the hazards
common to all GPB coiled tubing jobs. The risk analysis should be reviewed prior to starting a
cleanout job with coiled tubing. If additional risks for a specific job are identified, the impact
should be assessed and remedies/mitigating measures should be discussed and documented.
Each hazard identifies the potential impact to personnel, the environment and economics. The
probability of an incident happening and the frequency of an incident happening is rated as very
low, low, medium, high or very high. For example, for the hazard of exposure to cold, the
potential for personnel contracting frostbite is low and the impact to an individual if they were
frostbitten is low.
5.8 Wellbore Fluid Tracking Sheet

Many methods exist for tracking where fluids are in the wellbore. Each PE will have his or her
own preferred method to manage this task. The important concept here is that it needs to be
managed. One method is to create a simple table or sheet, zero the MM at the start of pumping
down the coil and keep a running total. Before starting the cleanout, calculate the backside
volumes to the tubing tail from the approximate cleanout depth, backside volume from the tubing
tail to the first live GLV, and the backside volume from the GLV to surface. Keep these numbers
handy.
At the start of pumping write down the fluid type and starting MM reading, then add the coil
volume to it and this is the MM reading when the fluid will be at the nozzle. Note these numbers
in the WSR. With these data in the WSR, you can quickly determine where things are if you get
lost. Once the fluid is at the nozzle, add the backside volume from that depth to the tubing tail
and note this number. Add in the other incremental volumes and create a simple table such at
that shown below. Use the table to keep track of where fluids are in the well. This table works
well when returns are approximately 1:1. It can be adjusted for losses. When tracking sweeps in
this manner with A/L, the final point of interest is the active GLV. After this point the sweep
should make it to surface. When using N2 down the coil, this method will yield the most
conservative estimate of what is in the well. In reality, the sweeps will be out of the hole long
before the volumetric requirement is met. Once a fluid swap is made, write down the ending
number and calculate the volume. These incremental volumes will be handy to keep track of
final volumes used. An example of this is shown below:
5.9 Keeping Track of Trucks

Fill cleanouts can become fluid intensive, especially if a lot of fill needs to be cleaned out and
returns are going to tanks. A big job can require four or more transports round tripping. One
method to manage this is as follows. Name each truck for example, Clean #1, Clean #2, Dirty
#1, etc. Then make a column for each truck. When a truck arrives note the following under each
heading.
 Time arrived -- Name of driver
 Time Departed
 Fluid Volume
 Status – Sent for another round trip – or – released.
Using this method lets you quickly understand where trucks are
helps you to see bottle necks long before they affect your job.
Running out of fluid can be a serious problem during a cleanout
and will undoubtedly result in downtime and additional work to
get back to where you were. You can also see when to release
transports and in general be more efficient at managing fluids
and resources as your job progresses. Utilizing this method
also generates a summary sheet of all trucking and materials
so that at the end of the day, costing is a simple and efficient
task. All the loads are there along with volumes. On a final
note, another time saving technique is to complete any
manifesting (except time and volume) as soon as each
transport arrives on location. This will allow time for you to
accurately describe the load and the keep the driver from
waiting while you complete his paperwork or get involved in
another task. An example is shown to the right:

Recommended Practice: CTU Fill Cleanout Procedures Page 17 of 47
Fill Cleanout Risk Assessment
Potential for Injury / Probability of Risk Occurring

Description of Risk / Hazard Environmental Harm / / Impact of Hazard (Very Low Remedy / Mitigation
Economic Loss to Very High)
Potential for fire – use of direct fired N2 Personnel - injury Very low occurrence – Medium 1. Discuss in safety meeting
pump – in addition to other identified impact 2. Spot burners upwind and 25
flame/heat sources Environmental – potential of ft or more from any
spill; minor fire Very Low Occurrence – Low flammable or combustible
impact materials, e.g. methanol,
flow back tanks
3. Observe wind direction
4. Observe and react to any
temperature inversions
5. Identify ignition sources
6. Have fire extinguishers
within 50 ft
7. Leave fire lane
8. Current Emergency
Response plan
Potential for burns from N2 Personnel – Burns from Very low occurrence – Low 1. Hold safety meeting
extreme cold of N2 impact 2. Only trained operator to run
N2 pump
Economic Loss – Loss of N2 Very Low Occurrence – Very 1. Proper PPE to be used –
low impact insulated plastic or leather
gloves, face shield, long
sleeves
2. Use only aluminum or brass
connections and stainless
steel braided hose
3. Do not suspend braided
hoses above ground or
allow personnel under liquid
N2 lines

PAPER COPIES ARE UNCONTROLLED. THIS COPY VALID ONLY AT THE TIME OF PRINTING. THE CONTROLLED VERSION OF THIS DOCUMENT CAN BE FOUND
AT http://eportal.bpweb.bp.com/hse

Workover Fluids – risk potential exists Personnel – exposure Very Low Occurrence – Very 1. Discuss at safety meeting
when flowback is to tanks after a workover Low impact 2. Have MSDS on location
that left well loaded up 3. See transfer of fluids
Environment – spills Low Occurrence – Low impact above
4. Beneficial reuse is unlikely
Very Low Occurrence – Very unless there is a weighted
Economic – beneficial reuse low impact brine that can be recovered
to tanks. Not cost effective
to attempt to recover KCL
or seawater
5. Majority of jobs return fluids
to system which eliminates
disposal problem, exposure,
and limits spill potential


Use of liquid N2 – an inert gas that is Personnel – suffocation; Very Low Occurrence – 1. Hold safety meeting.
extremely cold. N2 can cause burns (from burns Medium impact Discuss danger of gas
cold). N2 may be used if cleaning out accumulation in
larger tubing or casing temperature inversion
Possible burns – from cold
2. Liquid N2 will be onsite in a
N2 pumper and possibly in
a transport as well
3. Use only trained and
qualified operators to pump
N2.
4. Use only equipment
certified for pumping N2
5. Use only aluminum or brass
connections and stainless
steel braided hose
6. All equipment to be rated
for max anticipated
pressure on job
7. Proper PPE to be used –
insulated plastic or leather
gloves, face shield, long
sleeves
8. Do not suspend braided
hoses above ground or
allow personnel under liquid
N2 lines
9. If flowback is to a tank, only
Tiger tank or a tank with a
gas buster will be used
10. For flowback to a tank –


tank volume will kept at less
than 60 %


Loss of well control – Stuck coil, coil part, Personnel – injury, potentially Very Low Occurrence – High 1. Discuss roles and
washout of line or choke or flowline failure fatal impact responsibility in safety
accompanied by BOP failure; if reversing meeting
out, increased potential for loss of well Environmental – major spill; Very Low Occurrence – High 2. Use proper BOP
control since no checks will be in BHA and release of toxic gas; impact 3. Test all lines and BOP
risk of collapsed or plugged coil – limits contamination of land and before starting job per BP
options if coil parts water standards.
Very Low Occurrence – High 4. Monitor WHP, CTP and coil
Economic – loss of impact life
production; loss of a well; 5. Flow to system whenever
damage to facilities Low possible
6. Current EMP
7. BOP drills
8. If reversing out, in the pre-
job safety meeting - discuss
the limited options that are
available when no checks
are in BHA.
9. Strictly follow collapse
pressure limitations while
reversing and review
contingency procedures for
collapsed coil and plugged
coil prior to well entry
Pressurized equipment – high pressure Personnel – Injury Low Occurrence – Medium 1. Utilize only equipment with
pumping equipment – for N2 – in addition to impact working pressure rating >
water and methanol max anticipated pressure
Environment – spill; fire Low Occurrence –Medium 2. Minimize length of surface
impact lines
3. Discuss at safety meetings
Economic – damage to Very Low Occurrence – Low 4. Minimize number of


equipment impact personnel near high
pressure lines and
equipment
5. Pressure test before
beginning job. Low / high
pressure test
6. Do not exceed working
pressure of equipment
High noise levels – N2 pump – in addition to Personnel – hearing damage Low Occurrence – Low impact 1. Use appropriate hearing
other identified high noise areas protection
2. N2 operator to have
headset to be able to
communicate with CTU
operator
Stuck Coil – may require cutting coil and Personnel – injury Low occurrence – High impact 1. Monitor returns
increased potential for parting pipe 2. Use frequent Biozan or Flo
Low occurrence – Medium Pro sweeps and short trips.
Environmental – spill, impact Energize fluid with N2 if
possibly major if loss of well necessary
control; 3. Be patient
Medium Occurrence – Low 4. If reversing out, discuss
Environmental - gas release impact limited options because no
if flowing to tanks checks in BHA
Economic – damage to Very low Occurrence – High

equipment and facilities; impact
additional workover cost; loss
of well; loss of production
Live fluid going to tanks Personnel – injury Very Low Occurrence – Low 1. Discuss in safety meeting
impact 2. Increases potential for fire
or explosion
Environmental – spill; Low Occurrence – Low impact 3. Consider using mobile


separator to monitor returns
Medium Occurrence – Low and minimize hydrocarbons
Environmental – gas release impact to flowback tanks.
4. All flowback tanks in
secondary containment
5. If fluid is energized, limit
flowback tank volumes to
60% of capacity
6. DO NOT take returns to
open top tank if high GOR
or using N2
7. DO NOT take returns to
tanks if H2S present in
returns
Fill recovery – solids in tanks Environmental – solids High occurrence – low impact 1. Solids will accumulate in
disposal tanks when flowing back to
Medium occurrence – low tanks.
Economic – cost to cleanout impact 2. In cold weather, try to keep
tanks liquid level low to prevent
tanks from freezing
3. If flowing to tanks, try to
send solids to open top tank
not Tiger. However, if high
GOR go to Tiger.
Fill recovery – iron sulfide; increases Personnel - injury Very Low Occurrence – 1. Discuss potential in safety
potential for fire from spontaneous medium impact meeting
combustion 2. Check solids to make sure
Environmental – solids Very Low Occurrence – low iron sulfide is not
disposal impact component – increased
potential for iron sulfide if
Economic – cost to cleanout Very Low Occurrence – low cleaning out scale
tanks impact 3. Iron sulfide can produce


toxic gas if mixed with acid
4. Keep iron sulfide wet
5. Notify Well Support of iron
sulfide so that it can be
handled and disposed of
safely
6. Follow SOP for handling
Iron Sulfide
Fluid contamination – Biozan or Flo Pro Environmental – Low Occurrence – Medium 1. Do not swap fluids ‘on the
and/or methanol; methanol and Flo-Pro contaminated fluid can impact fly’. Disconnect methanol
become a disposal problem hose before pumping
Biozan or Flo Pro – and
Economic – Tie up vac truck vice versa
or tank with contaminated Low Occurrence – Low impact 2. Do not allow Flo-pro and
fluid methanol to mix – forms
thick gel / emulsion which
cannot be pumped and is
difficult to break
3. Biozan or Flo Pro will
degrade
Fluids with lubricants, safe lube Environmental – Spills due to Low Occurrence – Low Impact 1. Rig up supply hoses on
foaming uprights to allow fluids to be
loaded from the bottom of
upright
2. Load all fluids with
lubricants from the bottom
of the source tank/upright.
Do not use the standard fill
up port.
Use of Hot Oil Unit 3. Follow separate
instructions as per
Schlumberger Exemption


4. Review Risk
Assessment in the PE
Manual Section for
Pumping Fluids
Fill Cleanout with the Portable Test Unit 1. Follow separate Risk
Assessment in the PE
manual section for flow
backs using the portable
well test unit.
IA Ice Plugs/Hydrate Plugs Environmental – Loss of 1. Prepare a separate risk
casing/tubing integrity assessment for the well of
interest.
Economic – Loss of well

6.0 Key Documents/Tools/References

 ADW Emergency Management Plan (March 2008)
 BP Getting HSE Right
 BP’s Eight Golden Rules of Safety
 BP Global Drilling and Well Operations Policy
 Alaska Safety Handbook
 North Slope Environmental Field Handbook
 BP Alaska PE Manual
7.0 Lessons Learned

Additional information can be found in TeamLink by referencing the tracking number.
1) TeamLink LL #10133, October 2007

 During milling and motor operations with small (1 11/16") motors, suggest we look into a
sequencing valve. This valve would allow us to pump beyond the recommended motor specs
for cleaning out larger tubulars while milling in small liners. This sequencing valve would
bypass the motor at a pre-determined rate and allow the higher rate with no damage to the
motor.
2) TeamLink LL #10215, June 2008

 A low value of LSRV should be specified if a significant volume of gel is to be circulated
around the backside of the coil to prevent excessively high circulation pressures while
pumping the gel down the coil tubing.
 A recipe of 3% by volume "Lube-776" (MI product) and 2% by volume "Lotorq" (MI product)
provides significant lubrication properties.
3) TeamLink LL# 10236, June 2008

 Laboratory investigation into the behavior of biopolymers (Biozan and Flo-Pro) indicated loss
of low shear rate viscosity and solid/liquid separation when exposed to set cement from CT
milling operations.
 If other problems were encountered during a cement milling operation, then this coupled with
loss of viscous pill quality, could result in stuck pipe.
 Further investigation revealed that Diutan gum (Geovis XT), when mixed in KCL, tolerates
cement well. Geovis XT also found to have superior low frictional pressure drop down the
coiled tubing.
4) TeamLink 10269, October 2008

 If well conditions require deployment of the toolstring past the depth at which it can be
conventionally recovered, the agitator may be used to agitate the toolstring back OOH by
holding maximum tension on the CT and circulating through the agitator at optimum rate. In
these scenarios, also consider use of a metal-metal friction reducing agent to reduce the
drag forces acting on the CT.
5) TeamLink 10456, March 2009

 Proper nozzle selection is critical for fill cleanouts of suspected hydrates with coiled tubing.
Not all down jet nozzles will be successful. Determination of the jet trajectory should be
evaluated for the tubular size to be cleaned out. A picture of a successful nozzle design in
attached to LL 10456.

Revision Log
Custodian/
Revision Date Approving Authority Revision Details
Author
Andrew Pfaff
January 22, 2002 Steve Rossberg Original Issue
Updates to Foam Cleanout
November 29, M. Aivano / T. Procedure as a result of spill on
Doug. Cismoski
2004 Norene V-106 ( Traction report 2004-IR-
1076265 )
Wells Revised Approving Authority and
March 14, 2006 Jerry L. Bixby Operations Custodian. Extended next review
Supervisor date and changed SOP to
General revisions. Addition of
hydrate, and ice cleanouts.
November 5,
Clark Olsen Kirk Forcade Addition of fluids management,
2007
tracking, and gelled diesel
cleanouts. PE peer review.
Added Sec. 7, ‘Lessons Learned’
January 29, 2008 Doug Cismoski M. Seward w/
LL # 10133
Added LL # 10215 & 10236;
Well Operations
June 4, 2008 M.Seward Revised header; Added reference
Supervisor
to ADW EMP
Well Operations C. Tzvetcoff /
October 30, 2008 Added LL # 10269 to section 7.
Supervisor M. Seward
Well Operations
March 31, 2009 C. Tzvetcoff Added LL # 10456 to section 7.
Supervisor
Chris
July 22, 2010 Andy Kirk Add BP Confidentiality Statement
Tzvetcoff
(or, see attached e-mail )

Approving Authority signature Date

Appendix 1 - Foam Cleanout Procedure

Introduction
Foam is an excellent cleanout medium due to its low density and excellent particle carrying
properties. It also tends to have low fluid loss, reducing potential formation damage. Formations
with low BHP that cannot sustain a column of liquid are candidates for foam cleanouts, as well as
casing and tubular configurations that reduce annular velocities.
Foam is a mixture of a base fluid in the continuous phase and gas. An appropriate surfactant is
added allowing a reduction in surface tension for foaming to occur. The gas exists as small,
interspersed bubbles. Foam has excellent solids carrying capabilities as compared to a fluid
system with the rheological properties of a two-phase fluid. Foaming with a gelled base fluid can
generate higher viscosity foams.
The foam properties are influenced primarily by the base fluid composition and the gas to base
fluid ratio. The properties are also highly dependent on pressure and temperature, as both affect
the gaseous volume.
Stable foam can only exist within a certain range. In order to define this range the concept of
foam quality is used. Foam quality is the volumetric measurement of the gas content of the
foam expressed in percentage. Below 52% the fluid is considered a Nitrified Fluid. Stable foam
exists between 52% and 96% foam quality. In this region, the bubbles of nitrogen form a self-
supporting system in which there is little migration of gas or liquid, hence the term stable foam.
The result is an increased fluid viscosity that generates the excellent particle carrying ability.
As the foam quality increases its carrying ability also increases, up to 96% foam quality. Above
96% foam quality, the foam tends to break down into a mist destroying the fluid viscosity
properties that allows successful carrying of solids.
Foam cleanouts utilize the “pseudo viscosity” of the two-phase foam, allowing superior particle
carrying properties, as the solids are bound to the interspersed gas bubbles. Foam can
effectively clean out solids at annular velocities as a low as 20 ft/min.
Foam is primarily suited to the two following scenarios:

 Low BHP
 Long deviated well bore sections
 Large Wellbore / Tubular Configurations (low annular velocities)
Foam Cleanout Design

Foam has the following limitations:
 Foam has a lower jetting capability than fluids, and is more suited to non-compacted fill
 Hydrocarbons tend to break down water based foam stability
 Annular clearance between BHA and tubing should not be less than ½ inch, as the
pressure drop in a small annulus can adversely affect foam quality
 Foam returns need to be broken at surface
To optimize the foam design, the appropriate gas and base fluid rates need to achieve the
following:
 The highest possible downhole foam quality to ensure optimal solids carrying properties
of the foam, without exceeding 96% foam quality at surface
 The adjustment of foam quality by varying well head pressure
 The base fluid properties with respect to sensitivity of the formation
 The method of displacing the well to foam to minimize ECD due to a low BHP

 The need to clean up past the “heel” of a deviated well periodically to avoid the
possibility of excessive bedding of fill
 The pumping of a gelled base foam slug at regular intervals to assist in hole cleaning.
The increase in ECD needs to be accounted for, due to the gel being more viscous.
Fluid Design
The design of the foam base fluid is critical to the success of the operation. The type of base
fluid whether water based or oil based is dependent on the job requirements.
In producing oil wells, a water-based foam can be used as long as well bore influx is avoided
since hydrocarbons reduce the surface tension of the foam thus degrading the foam. The
negative impact of hydrocarbons can be offset slightly by increasing surfactant concentration in
the base fluid. The addition of HEC gel also aids foam stability in the presence of hydrocarbons,
and this gelled base fluid can be used to create periodic foam slugs that assist in hole cleaning
(similar to gel sweeps in a conventional FCO). However, the use of gelled foam slugs or gelled
base fluid needs to be assessed since the increased viscosity also increases the Equivalent
Circulating Density (ECD), which may result in fluid losses in low BHP wells.
It is also possible to use an oil based foaming agent for diesel based foams if hydrocarbon
breakdown is considered to be a major concern. The only advantage of an oil based foaming
agent is the resistance to foam degradation from hydrocarbons. A job designed with an oil based
foam will not be any quicker, nor more efficient than a comparable water based foam. Use of the
simulator predictions with strict monitoring of returns should ensure that the well is never
intentionally under balanced. The oil based foaming agent option adds some additional foaming
agent cost to the job.
Essentially the base fluid will contain a foaming agent, friction reducer and some HEC gel for
stability if required. For freshwater and seawater based systems the current preferred foaming
agent is Dowell’s F104. Typical concentrations range from 6 - 12 gals/1000 gal (of base fluid).
Slightly higher concentrations are required in seawater base fluids.
Typical designs are:

 Freshwater: F104 @ 6gal/1000 gal + J313 @ 1gal/1000 gal
 Seawater: F104 @ 8-10gal/1000 gal + J313 @ 1gal/1000 gal
 Hydrocarbon base fluids: G9 foamer @ 8.5 – 11 gal/1000 gal
Wellbore Simulator
Dowell’s CoilCADE* wellbore simulator (WBS) models the flow of fluid in the wellbore
environment. With a given set of initial conditions, the WBS uses the equations for conservation
of mass and momentum to determine the distribution of the fluids, continuous and dispersed fluid
velocities, and pressures encountered when those conditions are met in the field.
The WBS also uses reservoir data or reservoir production history, which will indicate wellbore
influx or leak off. This allows tailoring of job designs that ensure design parameters are within
pore and fracture limits of the formation.
The WBS allows a realistic operational design schedule to be inputted that reflects taking “bites”
of fill, pulling up hole, circulating, pulling up/into the tubing tail, etc. From this a pumping
schedule can be developed prior to commencement of the job and should allow the job to occur
within important parameters that are required by the WBS:
 Rate of Penetration
 Pumping Rates
 Wellhead Pressure

 Well Configuration
From this, the WBS is able to calculate:

 Sand Loading Concentration
 Downhole Pressure
 Circulating Pressure
 Foam Quality Throughout Job
 Annular Velocity
 Formation Under/Overbalance History
The results from the WBS are the primary guide to adjusting foam rates and WHP on location
during the job. The results also cover estimated BHP and circulating pressures, allowing
selection of appropriate rates to prevent wellbore influx or excessive leak off into the formation.
Use of the WBS output with a strict monitoring of returns prevents intentional underbalancing of
the well. The model output needs to calibrated with the actual results observed during the job.
A 100 psi decrease in WHP can have dramatic affects on the foam quality. It is a good practice
to always run the WBS with 300-400 psi WHP when selecting appropriate design variables.
The following conclusions from WBS assist in the optimization of the foam cleanout:
 Increasing gas rate, increases foam quality, BHP and circulating pressure
 Increasing base fluid rate, decreases foam quality, reduces BHP and circulating pressure
 Increasing WHP, decreases foam quality, increases BHP and circulating pressure.
The circulating pressure is higher in the WBS as it assumes an in-line foam generator is used on
the surface. The WBS will allow selection of N2 and liquid rates, satisfying the upper and lower
foam quality limits at surface and bottom hole conditions. It is important to remember that the
calculated circulation pressure and BHP are based heavily on the rheology of the base fluid input
to the WBS.
Typically aim for foam quality towards the upper end of the scale as the particle carrying
properties of the foam increase with foam quality and are best at 96%, with a recommended
minimum downhole foam quality of 75-85%. Within the range of stable foam lie two distinct
regions describing foam quality:
 Wet Foam is the common term for foam quality between 52%-85%, it is typically less
rigid and has more fluid like appearance (i.e. soapy bubbles)
 Dry Foam is the common name for foam quality between 85%-96%. As it name suggests
it is a very rigid foam, often referred to as shaving cream quality.
Stable foam (Between 52% and 92% foam quality) displays power law rheological tendencies.
The viscosity increases with foam quality until 92%.
Job Preparation
1. Review the well files and well program. Discuss any issues that are not clear and concerns
with the Well Operations Supervisor and Anchorage Engineering.
2. Review the chapters on “Nitrogen Lifting” and “Fill Cleanouts” in the Coiled Tubing
Operations section of the PE manual.
3. Determine the base fluid to be used for the foam. Decide if foamed Biozan or Flo Pro
sweeps are to be part of the program.
4. Collect the information for a CoilCADE* simulation of the job and provide the data to Dowell
for input into CoilCADE*. Discuss the output with the Dowell Coiled Tubing Cell Leader and
CoilCADE* Engineer. Make additional runs as necessary to evaluate job and anticipated
conditions.

5. Have Dowell conduct laboratory testing prior to the job consisting of verification of fluid
design to ensure compatibility of additives and base fluid. Some friction reducing agents
such as J313, tend to decrease foam stability. The samples should be tested for foam
stability as per the Standard Foam Stability Test:
 Mix a 100ml sample of base fluid in a blender at high speed for 1 min. Let the sample
sit for 4 min. The minimal acceptable stability limit for a CT foam, is a maximum of 50
ml of base fluid breaking out of the foam in 4 min.
 Base fluid and foam viscosity can be qualitatively measured within the lab. It is essential
that this be as correct as possible. Typically base fluids consisting of water will have a
Newtonian viscosity of 0.9 cp and this is the value recommended for the simulations.
If cold weather, determine the impact of methanol on the foam and additives
6. Coordinate nitrogen and nitrogen pumper for the job. Nitrogen is supplied by Halliburton and
the pumper is provided by Dowell. Plan on at least 5000 gallons of nitrogen depending on
how much fill to be cleaned out
7. Ensure that MSDS for nitrogen and for all additives are on the CTU.
8. The best quality foam will come from a clean transport without blowing the fluid into an
upright tank – contamination may occur from the tank. Agitate the base fluid and surfactant
using the transport paddles for proper mixing. Coordinate with Well Services for at least two
clean vac trucks for the base fluid.
9. A foam cleanout is not a routine operation at GPB. Develop a detailed job procedure and a
risk analysis prior to beginning the job. Obtain approvals from the Well Operations
Supervisor.
Recommended Equipment
1. Pump-in sub with backside line.
2. Reverse-out skid (so that you can pump down backside, coil or both)
3. Vac truck (s) with base fluid.
4. Biozan or Flo-Pro (plus vac truck for storage).
5. Filter
6. BHA – Dual checks and jet swirl nozzle. Optional – hydraulic disconnect, straight bar
7. Choke manifold (to have data header or chemical injection sub)
8. Tiger tank (minimum of one)
9. Open top tank (minimum of two)
10. Gauge tank (inside containment)
11. Transfer pump (or plumbing) to allow fluid transfer from Tiger tank to open top tanks
12. Secondary Containment for flowback tanks
13. Nitrogen transport (Halliburton)
14. Nitrogen pumper (Dowell)
15. M45 Breaker (Dowell)
16. F104 Foamer (Dowell) – mixed with the base fluid
17. Portable pump trailer or chemical injection pump for injecting breaker
18. If cold weather
 Heaters
 Triplex
 Methanol tanker
19. Air compressor
20. Hudson sprayer with M45 breaker
21. Eye wash station
22. A minimum of six radios with backup batteries
23. Nitrogen tables on the CTU
24. Well support personnel – at least one additional to help with chemical injection pump and
fluid transfers.

Execution
1. Coordinate with the drill site/pad operator and Production Control to shut-in the well at least
48 hours prior to the job to allow the well and BHP to stabilize. Shut-in the gas lift and bleed
the IA pressure to 500 psi or less.
2. Rig up a flowback setup with the following addition – have a chemical injection sub (or use a
data header) for injecting M45 breaker upstream of the choke manifold. If using a chemical
injection sub, plumb the sub as far upstream of the choke manifold as possible, install
chemical injection at the Tee on the pump-in sub. Plumb in the chemical injection pump and
test the pump to be sure that it is operational. The breaker is necessary to break the foam.
Plan to take foam and/or energized returns to the Tiger tank. Plumb the tanks so that fluid
can be moved from the Tiger tank to the open top tanks. If necessary, install a transfer pump
between the tanks.
3. Only a maximum of half a tank volume will be flowed into each open top tank. Have
additional lighting staged at tanks so that volumes can be clearly seen and any misting
identified.
4. Move in and rig up the CTU using the standard procedures.
5. Hold a safety meeting with all personnel before pressure testing the equipment and lines.
Discuss the program and risks associated with the job. Explain the importance of injecting
breaker. Discuss fluid transfers and spill prevention. Make sure all personnel understand
their assigned duties and have a radio. Utilize all proper PPE including nitrile gloves, face
shields and eyewash stations while working with chemicals.
6. Make up the BHA. Pressure test the BOP and lubricator per standard procedures with a low
and high pressure test.
7. Verify that the wing valve and lateral valves are closed. Install the fusible cap Open the
swab and start RIH. Pump an initial 5 bbl slug of base fluid. Begin generating foam by
pumping water (with foamer) at 0.3 – 0.4 bpm and nitrogen at about 500 scf/min. Maintain a
WHP of about 200 – 300 psi by using the choke. Monitor the returns at surface for foam
quality and rate.
8. RIH to approximately 2000 ft and check the foam quality. Foam should look like shaving
cream or whipped cream – soapy bubbles is not good quality foam and sand will fall out of
solution.
 Raise nitrogen rates as necessary during the job to adjust foam quality
 As foam quality increases, smaller bubbles are formed – optimum foam quality should
be in the 80 to 92% range – if the bubble size is non uniform, liquid slugs can occur and
tend to break down foam prematurely
 Foam quality is highly dependant on pressure and temperature – choke pressure at
surface becomes critical
 One for one returns during the job is essential
9. Continue to RIH adjusting foam quality and pressures per the CoilCADE* output. At about
500 ft from the tubing tail, slow coil rate to about 20 ft/min. Be sure that the wellbore fluids
have been displaced. Check that foam quality is between 85 – 92%. Verify that the
chemical injection pump and defoamer are working. Check that the pressures are in
agreement with the CoilCADE* model output. Make adjustments as necessary.
Note: Restrictions in the return lines will reduce foam quality. Ensure a restriction free return
line to accurately gauge the quality of the foam from downhole.
10. The fill cleanout procedure should begin at the tubing tail and continue until PBTD (or fill
cleanout depth) is reached
 It is essential that circulating pressures and WHP be monitored, as this is the only
accurate way to identify sand load in the annulus. It may only take a 200 psi increase in
circulating pressure before returns are lost.
 Patience is a key and a rule of thumb is never to take more than a 20’ to 25’ bite of fill @
5’/min. This should be followed by PUH 20’ and circulating for 5-10 minutes above the

last fill depth. Regularly chase the fill to the tubing tail (after every 3 - 5 bites). Long
trips to above the horizontal section may be necessary throughout the job.
 Circulation times with foam are longer than with conventional fluids. It is recommended
that bottoms up times be adjusted to reflect this. Allow double the time required based
on the foam flowrates at the nozzle from WBS.
 If possible, dry tag fill and verify against wireline tag. Flag pipe and adjust depth counter.
Record depths in well report
 Perform regular weight checks.
 Monitor Circulating Pressure. If it increases more than 200 psi above baseline value,
PUH above fill and circulate
 Calculation of potential sand loading at various run-in speeds can be performed with
CoilCADE*. It is not recommended that 4% sand loading by weight be exceeded.
Theoretically, foam can handle up to 10% sand loading by weight. However this
significantly increases the potential of stuck pipe in the event of a loss of return or foam
generation equipment problems, especially in deviated wells.
 Monitor Circulating Press and WHP, adjust WHP as required for foam quality.
11. At TD, circulate bottoms up based on foam flowrates prior to POOH. Monitor returns for
sand. Sweep the well using a foamed gel pill from TD to the tubing tail while POOH at 15
ft/min. Run back to TD at 15 ft/min while pumping another foamed gel pill to ensure wellbore
is clean. Note pick up and RIH weights.
12. POOH at 50% (coil speed is 50% of annular velocity of fluid) while chasing returns to the
surface. Chase returns all the way to surface.
13. Freeze protect the well as necessary.

Appendix 2 – Hydrate and Ice Plug Cleanouts

Introduction
Hydrate and ice plug cleanouts differ from other types of cleanouts in that in virtually all cases,
trapped pressure can exist immediately below the plug or can be dispersed at random intervals
throughout the plug. This trapped pressure, if not handled correctly, can result in getting blown up
the hole, kinked or “crinkled” coil at surface, and in some cases serious well control problems.
Ice and hydrate plugs can form in an annulus, in tubing or both. It is important to understand if
any of the annular spaces are frozen or hydrated off in addition to the tubing when planning,
executing, and securing the well at the end of the job.
Ice plugs are formed by freezable fluids being left in the well either at surface or in the
permafrost zone, extending down to approximately 2000’ TVD in many areas within GPB. Over
the course of time, freezable fluids will ultimately form a plug in this region as typical
temperatures range from ambient to 20 Deg F within a 100’ of surface and then gradually climb
from 20 Deg F to 30 Deg F at approximately 1800’. Thaw bulbs resulting from production or
injection into the well can sometimes delay the freezing of these fluids down hole but surface
lines, tree and the near surface well bore including tubing and casing annuli, S-riser, and flow line
will freeze in the winter months resulting in an impermeable and immoveable ice plug.
Hydrate plugs are the result of the freezing of a mixture of hydrocarbon gasses and water. This is
commonly called a hydrate, gas hydrate or clathrate. A gas hydrate is an ice like crystalline solid,
usually formed by methane, surrounded in a lattice or cage of water molecules. Hydrates look
very similar to ice however they exhibit several different properties. Plugs formed by this
material can be significantly harder than pure ice and are also stable at temperatures
significantly higher than freezing, under the right conditions of pressure. As with ice plugs,
hydrate plugs are generally impermeable and immoveable after their formation and pose the
same risks as ice plugs during the process of removal.
Ice and hydrate plugs can generally be removed chemically by jetting mutual or universal
solvents such as methanol, methanol water mixtures, or hot water. These plugs can also be
removed by mechanical means by the jetting action of fluid, drilling or milling. In some cases, ice
and hydrate plugs can be removed by pumping hot fluids down the inner annulus to thaw out the
production tubing when communication exists to the tubing through ported sleeves, gas lift
valves or other down hole equipment. Ice and hydrate plugs have even been successfully
removed by pumping neat methanol slowly or intermittently down the production tubing. Do not
use KCL brines or fresh water for this operation.
As a result of the significant risks associated with the removal of an ice or hydrate plug with
trapped pressure below, the recommended method is to remove the plug by jetting primarily with
60/40 methanol water as the working fluid and neat methanol pills. This is performed while
choking the returns to hold WHP high enough to overcome the upward force acting on the plug.
Jetting with hot water, although significantly less expensive than 60/40 methanol water or neat
methanol, is discouraged as it can result in very serious consequences in the event the coil is
damaged at the instant the plug becomes free and/or large amounts of gas is allowed to flow up
the coiled tubing annulus. If wellbore conditions fall within the hydrate curve, water and gas could
rapidly form a hydrate and immediately freeze the coil in the well.
Ice and hydrate plugs, just like packers or bridge plugs, are very effective at trapping and holding
pressure from below. The danger of removal comes from the fact that these plugs are generally
encountered at shallow depths or at surface and therefore the hydrostatic column of fluid above
the plug at breakthrough is rarely enough to over come or reduce the total upward force acting
on the plug to within acceptable limits.

Unlike cleanouts of paraffin, sand, fill, mung, etc. where any differential pressure normally acts
only upon the cross sectional area of the coil, ice plugs, hydrate plugs as well as packers and
bridge plugs are exposed to the entire cross sectional area of the tubular in which they are
encountered. Simply put, the force exerted on the area of the plug is transmitted directly to the
coil once the plug becomes free. For example, if a plug is encountered in 5-1/2” tubing with 3800
psi differential across it, an upward force of over 72,000# will be exerted on the coil if the plug is
free to move up hole. With no reduction for safety factor applied, the absolute maximum force
which can be withstood by new 1.75” coil is roughly 12,000 lbs* before it buckles in the lubricator.
Based on the ratio of plug areas with respect to the coil area, it can be demonstrated that higher
differential pressures can be safely handled with smaller tubing sizes for the same coiled tubing
string and lubricator. This is because the total force for any given pressure acts on a smaller area
in smaller tubing ID’s. The point of buckling however will still be the same. This buckling or
kinking typically occurs in the biggest ID such as in the lubricator below the stripper. Picking up
on the coil once this has occurred may result in parted pipe, the coil pulling out of the stripper,
loss of containment at the stripper, and environmental damage in the form of an uncontrolled
release or spill.
As can be seen from the above example, when coiled tubing is subjected to sufficient upward
force, the tubing string will buckle, kink or “crinkle”. This will most likely result in a loss of coiled
tubing integrity, loss of well control at the stripper, and inability to safely pump fluid down the coil
or into the well without significant risk and expense.
The key elements to safely and properly executing an ice or hydrate cleanout include a thorough
understanding of the forces acting on the coil, coil limitations, well bore construction in the
vicinity of the plug, accurate expected bottom hole pressure, current location of the plug, an
understanding of how the plug was formed, and steps taken to remove the plug prior to
performing a coiled tubing cleanout.
* HS-80, 0.109” wall in 6.13” ID lubricator. Maximum allowable upward force is a function of coil size, weight, grade, and
maximum ID constraining it as well as running footage and ovality.
Job Preparation
1. Review the well files and well program. Discuss any issues and concerns that are not
clear with the Well Operations Supervisor and Anchorage Engineering. Specifically
confirm SIBHP and the depth to the datum at which this pressure references. A thorough
understanding of how these values were obtained and the range of accuracy will play a
key role in the subsequent calculation of required WHP or back pressure to be held
during the cleanout.
2. Review down hole equipment and any plugs, sub surface safety valves, etc. which may
be in the hole. Pay special attention to SSSV’s which are frozen in. It may be necessary
to make arrangements with S/L to pull the valve once the tubing has been cleared to this
depth if coil can not be run through the valve. In some cases, an extension sub can be
used to jet through the SSSV by a few feet to facilitate pulling the valve.
3. Determine if the tree has a choke in the well house. If not, or if the well is an injector, a
jumper line to an offset well to take returns will be required. Using a choke located in the
manifold building is difficult due to distance from the CT unit in the event a radio failure
or choke swings and, in some cases, may expose the flow line to unnecessarily high
pressures. Maintaining backpressure control through a choke located in the immediate
vicinity of the coil unit is preferred.
4. Thoroughly review the chapters on “Coiled Tubing Problem Procedures” and “Risk
Analysis for Coiled Tubing Operations” in the Coiled Tubing Operations section of the
PE manual.

5. Work through the Ice/Hydrate plug calculations in the Ice/Hydrate Plug Calculations
Section of this document.
6. Provide the well bore diagram, directional survey, and bottom hole pressure and datum
to the service contractor so that they may also perform the tubing force calculations to
confirm required backpressure and anticipated pressure under the plug.
7. Review the AWGRS to understand how the plug was formed, what the most likely
composition is, and where the expected top of the plug is. In some cases a slickline drift
has been made and the plug depth is therefore known. Plug depth can also be estimated
from the volume of non-freezable fluid left in the well from previous pumping attempts to
clear the plug. When trying to determine this volume, take into account the fact that
pumping may also be followed by bleeding therefore leaving less than the pumped
amount in the well. Based on this volume, the depth to the plug can be estimated.
8. Review AWGRS to understand if the IA is clear of if there is the possibility that it could
be frozen or hydrated off as well.
CAUTION: As the thermal profile is complex to model in the IA while pumping hot fluids,
inner annulus pressure buildup is difficult to predict but could pose significant danger if
no path exists for pressure release. Once the tubing is thawed, consider pulling a dummy
valve after thawing the tubing or ensuring that live GLV’s are present prior to bull
heading or circulating fluids down the tubing to prevent excessive trapped IA pressure.
Excessive trapped IA pressure could burst casing or collapse production tubing. Review
all IA thaw operations with Well Operations Supervisor prior to execution.
Specifically discuss the risks associated with thermal expansion in a trapped
annular space, fluid volumes and temperatures to be pumped, and develop the
exact, well specific procedure, to remove the IA ice plug. Prepare a risk
assessment specific to the well.
9. Whenever possible, make a S/L drift to determine the depth of the plug if the plug depth
is not known and can not be estimated.
10. Review the directional survey for the well to determine the final freeze protect volume of
fluid to be pumped to cover the permafrost zone down to a depth of 2500’ TVD. In
vertical wells, MD and TVD are often sufficiently close however in many of the newer
wells, the MD and TVD depth can differ significantly and need to be accounted for when
calculating volumes.
11. If at all possible, do not start an ice or hydrate plug cleanout with a new set of packoffs.
Plan to change packoffs at least one to two runs prior to an ice or hydrate cleanout. New
packoffs make snubbing even more difficult. After a couple of runs, the required stripper
force is greatly reduced as the packoffs are somewhat broken in. With less force
required to get through the stripper, a higher backpressure can be applied.
Recommended Equipment
 Jumper line to offset well flow line if the wellhead does not have a choke on the tree.
 Reverse-out skid with an IA line – if the IA will need to be thawed or if IA pressure
needs to be bled down. Be sure to specify an IA tie-in on the Wells Support Order
form.
 One transport of 60/40 methanol water for pressure testing, hydrate jetting, and final
freeze protect.
 One transport of 90 bbls of neat methanol. Wells support has two 90 bbl transports
which can be round tripped if more than 90 bbls will be required.
 Sufficient fluid to freeze protect IA at end of job if necessary. May be crude if
pumped with the hot oil unit. This is much less costly than diesel.

 BHA – Dual checks, two stingers and down jet nozzle (DJN). Reasonable nozzle
OD’s range from 1.75” - 2.25” OD with 2.0”-2.25” being the most commonly used
range. When selecting a nozzle, smaller holes are generally better than large holes
as they offer better jetting action. Make sure that there are at least three to four jets
of 1/8”. If all holes are smaller than this, plugging can occur. For jetting of ice or
hydrate plugs, use a down jet nozzle rather than a jet swirl nozzle to concentrate
hydraulic horse power and jetting action down on the plug. Paraffin or ashpaltine
plugs are more effectively cleaned out using a jet swirl nozzle due to the softness of
the plugs and tendency for wall adhesion as opposed to the hard plugs formed by ice
or hydrates.
 Rock screens – confirm installation in the suction manifold of the CT pump.
 Choke manifold with two choke lines
 Tiger tank (minimum of one) – Plan on taking returns to the facility, but a tiger tank
can be used in case there is a facility shut-down. Be sure to request a true Tiger Tank
with a demister screen for the hatch versus an open top with a gas buster..
 Air compressor
 If the IA needs to be thawed out
o Hot Oil Unit – It is a good idea to call out a hot oil unit if the IA has a suspected
ice or hydrate plug. The only method of melting an ice plug in the IA is through
heat conduction to the IA from warm fluids in the tubing. The hot oil unit will be
used to heat water only.
o Optional second upright of warm 80 Deg 1% KCL for kill or jetting depending on
final agreed procedure, ease of hauling fluids, equipment availability, etc.
If cold weather
Heaters
Triplex
Methanol pup
One upright of 290 bbls of 1% KCL in winter months
Execution
1. Move in and rig up the CTU using the standard procedures. Tie-in the IA to the reverse
skid to facilitate bleeding and/or pumping if IA issues are present. Rig up the hot oil unit
at this time if the program is requesting an IA thaw.
2. Perform pre-job walk around to ensure all equipment is properly spaced and that all
equipment is present and rigged up correctly. Specifically, identify any additional
hazards, SIMOPS, and discuss in safety meeting. Make changes as necessary to reduce
or mitigate the risks. Document any hazards in the AWGRS hazards tab.
3. Hold a safety meeting with all personnel before pressure testing the equipment and lines.
Discuss the program and risks associated with this type of job. Go over the importance
of holding a specific WHP at all times once the cleanout has begun. Assign roles and
responsibilities with each crew member. Go over “Coiled Tubing Problem
Procedures” section of the PE manual, emergency contacts, and muster area. Discuss
fluid transfers and spill prevention.
4. Coordinate with the drill site/pad operator and Production Control and let them know you
will be taking returns to the offset well through the jumper line. Confirm that the offset
well is lined out and if the flow line will need to be freeze protected at end of job.
5. If the well to be cleaned out is a producer and has live GLV’s, make sure the A/L is shut-
in at the tree prior to the start of the ice/hydrate cleanout. Bleed down the IA pressure to
1200 psi - 1500 psi so that when the plug is cleared, no additional gas from the IA will
enter the wellbore. Bleed gas down through the offset well jumper line.
6. Make up the BHA with dual checks, stingers and down jet nozzle.

7. Pressure test the BOP and lubricator per standard procedures with a low and high
pressure test holding each test for five (5) minutes. Document in the WSR the low and
high pressure test results. If the test passed, be sure to state that in the WSR otherwise
determine the cause of the failure and take the necessary steps to get a passing test
before proceeding with the job.
8. Verify that the wing valve and lateral valves are closed. Install the fusible cap and open
the swab counting turns. Confirm that the SSV and Master Valves are open. Confirm
annulus gauges are in communication with their respective annular spaces, confirm any
gauge reading (0) zero with another gauge to be sure of proper readings. Record all
annular pressures.
9. Come on line at minimum rate with 60/40 methanol water and crack the choke taking
returns to offset well. Slowly ramp up WHP and start to snub the coil into the hole. Make
every effort to have at least the required backpressure, based on the depth and pressure
under the plug, by the time you get near the expected depth of the plug. Under no
circumstances should you attempt to jet through an ice/hydrate plug without the
required WHP (backpressure or choke pressure). Knowing the depth to the plug will
give you an idea of how much time you have to work up WHP, adjust pack offs, and gain
some pipe weight. Whenever possible, apply more WHP than needed to further reduce
the upward force on the coil tubing at breakthrough. Use the Coil Limits plot at all times
while snubbing into the well. Ensure the operator keeps close watch on the packoffs and
pilot pressures while snubbing in.
10. Do not use the manual override button to get in the hole without immediate coiled
tubing contractor supervisor approval.
11. Continue RIH while pumping minimum rate until the ice plug is tagged.
12. Increase rate as necessary to jet or wash through the ice/hydrate plug. Maintain WHP as
required based on depth.
13. As jetting continues, sudden changes in WHP may be observed. In some cases this is
the result of small pockets of high pressure trapped gas being released and may or may
not indicate that the tubing has been cleared.
14. If the changes in WHP persist for more than one to two minutes, stop running in the hole
and slowly shut-in the well to see if communication has been established with the
reservoir. If no communication exists, slowly open the well to the required WHP and
continue RIH. Do not allow the well to flow once the plug has been thawed. It is possible
that only a small communication path exists and with gas and water or water production,
a new hydrate could form around the coil and freeze the coil in the well. This is a very
undesirable situation and can result in the coil being permanently frozen in the well if the
ability to pump is lost due to no injectivity. When PUH, it is possible that the plug is free
and can move with you. This will be seen on the weight indicator. Continue pumping and
try to work the plug back down while jetting.
15. Jet the ice/hydrate plug until communication can be established. In some cases, the plug
can persist down to 3500’ or even 4000’. Check the directional survey and always go
deeper when in doubt.
16. Once the plug is clear and communication has been established, leave the well shut-in,
stop pumping down the coil and start pumping at minimum rate down the T x CT annulus
to cap the well with 60/40 methanol water or neat methanol.
17. Continue RIH to at least 5500’, or the top gas lift valve depth.
 If the IA has a plug in it, the only method available to remove the plug is by
circulating hot fluids down the coil, pumping hot fluids down the tubing and relying on
the heat transfer from the pumped fluid, through the tubing, into the IA however
significant risks can be associated with this. The highest heat capacity fluids
available for this purpose are KCL and seawater. 60/40 methanol and neat methanol
should never be heated.
 Once the tubing is clear, POOH to surface with the coil.

CAUTION: Ensure tubing has live GLV’s or rig up S/L to install a live GLV for
pressure relief below the expected IA plug. Ensure the IA thaw operation to be
executed has been documented and reviewed with the Well Operations
Supervisor. The following steps are only a example of an IA thaw and may or may
not be applicable for your specific well.
 Bullhead sufficient KCL down the tubing to clear any gas from surface before starting
to jet with hot water, this serves to warm up the well, and may thaw the IA while
reducing the possibility of re-hydrating at surface while jetting with hot water.
 If after pumping down the tubing, and if the IA will still not take any fluid without
pressuring up, pressure test the hot oil unit lines and start pumping hot KCL down the
coil. Once hot KCL is at the nozzle, reduce rate to 0.5 BPM - 1.0 BPM and start
making slow reciprocations while RIH and slowly thawing the IA from the top down,
hold sufficient choke pressure to get 1:1 returns to the tanks and closely monitoring
IA and OA pressures.
 Monitor the IA pressure and make periodic checks by trying to pump into it. ALWAYS
pump a non freezable fluid into the IA while making these periodic checks. The
methanol triplex and diesel from its day tank, or the methanol pup can be rigged up
and used for this purpose.
 Once communication can be established, pump a neat methanol spear and then
freeze protect the IA.
18. POOH while freeze protecting the tubing with 60/40 methanol to the deepest depth
hydrates were seen.
19. If the well is a producer, cap the IA with 5 bbls of neat methanol before bringing on the
A/L.
20. If the well is an injector, a step rate injection test may be required to determine if the well
has sufficient injectivity to remain on injection without freezing off again.
21. Once at surface, freeze protect all surface lines, including the line to offset well if
necessary, and RD CTU.
22. Contact production control and DSO or pad operator with current well status and agree
on the forward plan to put the well back on production or injection.
Ice/Hydrate Plug Calculations
Example Problem:
Production Tubing Data : 4.5” OD, 3.958” ID
Depth to Plug : 1590’ MD, 1474’ TVD
Max BHP at Datum : 3500 psi
Depth to Datum : 7000’ TVD
Estimated Average Gas Gradient : 0.08 psi/ft
Working Fluid : 60/40 methanol water, 0.393 psi/ft
Maximum ID : Lubricator 6.13”
Maximum Allowable Force on CT : 7000 lbs (varies – contact coiled tubing contractor for
this value
based on wellbore, coil to be used, and rig up)
Calculations for Plug at Expected Depth

1. Cross Sectional Area of Production Tubing = (3.958 In ) 2 * 3.14159 / 4 = 12.304 sq in.
2. Maximum Potential WHP = 3500 psi – [7000 ft *(0.08 psi/ft)] = 2940 psi

2940 psi < 3500 psi so standard pressure control equipment will be used
3. Pressure Below Plug if all Gas = 3500 psi –[(7000 ft-1474 ft)*0.08 psi/ft] = 3057.9 psi
4. Force Below Plug = 3057.9 psi * 12.304 sq in = 37,624 lbf
5. Hydrostatic Pressure Above Plug = 1474 ft * 0.393 psi/ft = 579.3 psi
6. Choke Requirement = [(37,624 lbf – 7000 lbf) / 12.304 sq in ]– 579.3 psi = 1909.6 psi
(This will place 7000 lbs of upward force on the coiled tubing when the plug becomes
free)
7. Choke Requirement = (37,624 lbf / 12.304 sq in) – 579.3 psi = 2478.6 psi
(This will place zero lbs of upward force on the coiled tubing when the plug becomes
free)
8. Determine maximum allowable snubbing force with CCAT and compare with required
WHP
Calculations for Plug at Surface
1. Pressure Below Plug if all Gas = 3500 psi –(7000 ft*0.08 psi/ft) = 2940 psi
2. Force Below Plug = 2940 psi * 12.304 sq in = 36,174 lbf
3. Hydrostatic Pressure Above Plug = 0 psi
4. Choke Requirement = (37,174 lbf – 7000 lbf) / 12.304 sq in = 2452.4 psi
(This will place 7000 lbs of upward force on the coiled tubing when the plug becomes
free)
5. Choke Requirement = 37,174 lbf / 12.304 sq in = 3021.3 psi
(This will place zero lbs of upward force on the coiled tubing when the plug becomes free
however you can not snub in with this WHP w/1.75” CT)
6. Determine maximum allowable snubbing force with CCAT and compare with required
WHP
Plug Problem Basics

Plugs in wellbores pose special risks which must be considered anytime a plug, of any kind, is to
be removed. As a result of different fluid densities and temperature changes, migration of gas
and accumulation can occur under a plug. Once a plug is set, small amounts of gas can enter
the wellbore and slowly migrate up to the plug where they become trapped. During the upward
migration path to the bottom of the plug, the gas will expand as hydrostatic pressure above the
plug decreases. This expansion drives small amounts of fluid back into the formation. As this can
be a continuous process over time, it is possible that the entire volume of fluid under the plug
can be replaced with gas. This is especially true when the fluids are clear brines, crudes, or
wellbore fluids which do not have a bridging agent or will not form a filter cake. The end result is
that reservoir pressures are only offset by the force exerted by a gas gradient instead of a fluid
gradient. The resulting pressure under the plug with gas can be significantly higher than that
expected if a fluid column was still present under the plug.
An example of this can be readily seen when a well is killed. In GPB, the well is shut-in and killed
with 1.5 times the well volume and KCL and then left shut-in. In gassy wells, over the course of
just a few hours the wellhead pressure cam return to its original SIWHP pressure as gas swaps
with KCL. The plug in this case is the swab valve and the stabilized SIWHP is the pressure which
has accumulated under it. It is not uncommon to find high SIWHP’s across the field.

When removing a plug, the pressure exerted above the plug by the hydrostatic column, plus any
additional applied pressure at surface acts in the opposite direction as pressure underneath the
plug. This combined pressure will neutralize pressure below the plug in a direct “psi per psi” ratio.
The pressure exerted below the plug is assumed to act across the entire inside cross sectional
area of the tubular where it resides. The force which can be exerted on the coiled tubing is the
result of the entire cross sectional area of the plug times the pressure below as the plug could
become free transmitting entire force acting on the plug to the end of the coil. Hydrostatic plus
applied pressure and the resulting downward force will work in the opposite direction leaving only
the “net” force acting on the coil.
If no other data are available to the contrary, the force under the plug must be assumed to be
due to the reservoir pressure at the perforations, minus the pressure exerted by a gas gradient
from the perforations to the plug. The required additional backpressure must be calculated
accordingly. In some cases, the forces may be too great for the size, wall thickness or grade of
coiled tubing to safely remove a plug. In these instances, larger or heavier coil will need to be
used to safely remove the plug. As a general note, these calculations should be performed for
any plug which can not be equalized including cast iron bridge plugs (CIBP), composite plugs,
magna set plugs, ceramic shear disks, partial cement plugs, and of course, ice and hydrate
plugs.
A separate ice plug estimator has been developed to aide in the estimation of required choke
pressure for hydrate and ice plug cleanouts. This Excel file is called Ice Plug Estimator and will
be available in the master WellCalcs Excel file. An example of this sheet is shown below.

General Formulas
Area of Circle (Diameter, In)^2*(3.14159)/(4) = Area, Sq In.
Force (Area, Sq In) * (Pressure, Pounds/Sq In) = Pounds of Force
Hydrostatic Force (Fluid Gradient, PSI/Ft)*(Height of Column, Vertical Ft)*(Area,
Sq In) =
Pounds of Force
Fluid Gradient (Fluid Weight, ppg)/(8.33 ppg weight of water)*(0.433 psi/Ft gradient of
water) = Fluid Gradient, PSI/Ft
Fluid Density (Fluid Weight, ppg)/(8.33 ppg, density of water) = PSI/Ft.
Reference:
Fresh Water Weight 8.33 ppg (Pounds per gallon)
Fresh Water Gradient 0.433 PSI/Ft.(Pounds per square inch per vertical foot)

Appendix 3 – Fill Cleanouts with Slick and Gelled Diesel

Introduction
Performing a fill cleanout with slick and gelled diesel offers several advantages over cleanouts
with water based fluids however the logistics and cost of this type of cleanout need to be
carefully reviewed prior to implementation. In GPB, each aspect of this type of cleanout needs to
be thoroughly planned and well organized to ensure proper fluid temperatures, mixing
procedures, fluid storage both on location and where heated, fluid availability, and most
importantly disposal of both slick and gelled diesel. As a result of these constraints and resulting
additional cost, diesel cleanouts are only recommended if other methods are available or in the
rare event nitrified fluids may result in losses of incompatible water based fluids. Due to the
complexity and cost, diesel cleanouts are to be considered only as a last option, after all other
methods have been ruled out.
The primary advantage of a diesel cleanout is the reduced hydrostatic load on the formation
which allows wells with lower bottom hole pressures to be cleaned out. Experience has shown in
Kuparuk that cleanouts can be successfully performed with reservoir gradients as low as 0.33
psi/ft with diesel. Through the addition of N2 or gas lift even lower bottom hole pressures can be
achieved during the cleanout down to a reservoir gradient of 0.25 psi/ft.
As diesel is a non-freezable fluid, all of the freezing risks of working with water based fluids are
eliminated and the operation of the job becomes independent of ambient temperature. Common
problems with return lines, stripper, BOP’s, and surface lines freezing are no longer an issue. By
performing the entire cleanout with non-freezable fluids, a savings can be realized through the
reduced use of methanol. The job is further simplified without freezable fluids in surface lines,
tanks, etc. during cold winter months and the well is always freeze protected.
From a reservoir standpoint, diesel also provides formation protection in zones which are
sensitive to water. As diesel is a hydrocarbon, no interaction occurs with the shales or clays
present in the formation which may result in lost production if exposed to water based fluids.
During cleanout operations, some types of debris are more soluble in diesel and therefore there
is an added benefit from a cleanout perspective.
Diesel however can pose other problems which need to be considered. Diesel does not have as
high a solids carrying capacity as many other fluids. As a result, any fill needs to be carried with
the gelled diesel sweep and chased with diesel. As diesel is a non freezable fluid, care should be
taken when cold diesel can come in contact with water based fluids. Flash freezing can occur
and therefore 60/40 or 50/50 methanol water spacers should always be pumped ahead and
behind diesel pumping to reduce this risk. Diesel also has a lower heat capacity than water and
therefore does not hold its temperature as long as water.
Pre-Job Planning
The importance of pre planning is critical for a successful fill cleanout using diesel. In addition to
all of the aspects previously consider for any fill cleanout, fluid heating and mixing, storage,
preparation, and disposal must be planned in advance.
As of this writing, very few cleanouts with diesel have been performed in recent times within
GPB. As a result, a sufficient number of jobs required to standardize a procedure will need to be
completed prior to a final writing. At this time only the current practices are shown here. As
learning is developed pertinent to this activity it should be documented by the PE for each job in
order to develop the recommended best practices for this type of work. As environmental
impacts can be high for disposal of fluids, always check handling and disposal plans with the
GPB HSE Environmental Advisor prior to stating this type of job.

The sections below describe the best practices to date as well as points to consider when
planning this type of cleanout:
 Disposal of used and unused fluids
 Heating of diesel
 Storage and handling
 Gelled diesel and slick diesel mixing and equipment
 Gelled diesel and slick diesel chemicals and mixing procedures
 Test separator or tank farm to catch solids and gelled diesel sweeps
 Flammability hazards
 Job execution
Disposal of Used and Unused Gelled/Slick Diesel

Well returns from a gelled diesel cleanout are E&P exempt and can therefore be disposed of just
like any other fluids returned from the wellbore. These returned fluids do not pose any special
offloading or processing problems at Pad 3. At this time these fluids can not be recycled due to
the adverse effect gelled diesel has on the production facility process stream. The gelled diesel
may be broken with W-060 but no work has been done to determine if the broken gelled diesel
can be sent to the facilities. Gelled diesel should be captured through the use of tanks or the test
separator if one is utilized during the job. Well returns from these cleanouts should not be sent
down the flowline to the facility until further work is done to determine if the gels can be
effectively broken.
Unused gelled diesel is hazardous and CAN NOT be disposed of if it has not been downhole
however there is an alternative. As gelled diesel is used extensively in Kuparuk, make
arrangements with the Kuparuk Well Operations Supervisor to take any left over gelled diesel.
With advance notice and coordination, they can take our unused gelled diesel and put it to good
use in their field. Determine how much they can handle, who the points of contact are, and what
arrangements are necessary through wells support to deliver these fluids. Good pre job planning
with respect to this issue will alleviate the disposal problem of unused gelled diesel.
Unused slick diesel does not pose nearly the same problem as unused gelled diesel. Although
any diesel which has not been down hole can not be disposed of, slick diesel can be recycled as
long as it is not contaminated with other products. A manifest will be required as usual and it can
then be sent to GC-2 for recycle. Alternatively, it can be given to Kuparuk at the end of the job.
Heating of Diesel
As with any hydrocarbon, flammability hazards need to be understood and managed accordingly.
Recent practice has been to keep heating temperatures to 15 Deg F below the flash point. The
published flash point of diesel is 105 Deg F therefore the maximum heating temperature for
diesel at atmospheric conditions should never exceed 90 Deg F. When ordering out location
equipment, include a 150# fire extinguisher. While on the job ensure flammability risks are
reviewed and kept in mind at all times. A thorough risk assessment should be conducted on
location to ensure site specific issues are included in the assessment.
The heat capacity of diesel is significantly lower than that of water. As a result, the timing of
heating, storage and delivery of diesel to location is important. In addition to heat loss, there are
questions as to how effective the drag reducer is in gelled diesel after long waiting periods if not
agitated.
The heating of diesel for mixing can be done with a hot oil unit. Remember, this is an added cost
to the operation, takes resources from other jobs, and therefore needs to be carefully
coordinated.

Storage and Handling

To reduce the number of transports necessary to support this type of cleanout, hydrocarbon
uprights should be used. In the past, special arrangements have been made with Kuparuk to
borrow these uprights. They have been most gracious to support our operations when possible.
Once again, careful planning needs to be done ahead of time to utilize this resource. As another
part of the planning, anytime a tank comes into the field, CIC needs to be involved to ensure the
tank meets the required tank regulations and is current on inspections for use within the field.
Additionally, hydrocarbon service uprights need to be in containment if they have a capacity over
10,000 gallons (238 bbls). The recommendation is two hydrocarbon uprights if they can be
borrowed from Kuparuk.
Gelled Diesel and Slick Diesel Mixing and Equipment

With a single hydrocarbon upright, plan on the following support equipment:
 1 clean slick diesel transport
 1 gelled diesel transport staged on location
 1 truck hauling slick diesel – alternating with the transport on location
 1 methanol truck staged on location
 2 to 4 dirty transports hauling fluids away
 150# fire extinguisher
 Static mixer with stinger hose for the drag reducing agent
In total, a minimum of 6 to 8 transports are required. This will limit other field operations and
should be considered when scheduling this type of cleanout operation.
Gelled and Slick Diesel Chemicals and Recommended Mixing Procedures

Slick Diesel
The chemical used to slick diesel is called Liquid Power Arctic Grade (Also called DRA - drag
reducing agent) and is a Conoco Phillips product. The Conoco Phillips contacts are
www.liquidpower.com or by phone at 281-794-3734. Currently there is a supply of this product in
Prudhoe which is stored in the “Sauna” at Wells Support.
To properly slick diesel, two (2) gallons per 290 bbls of warm diesel are used. The additive cost is
approximately 29$/gallon. The total cost for a load of slick diesel is about double that for XS
KCL, not including mixing and support equipment.
The process to mix a load of slick diesel is time consuming, equipment and labor intensive. It
requires one diesel transport, a hot oil unit (LRS) to heat the diesel if cold, one vac truck to mix
additives, and the static mixer sub and stinger. This takes 4 - 6 hours to have a load ready for
delivery, depending on the temperature of diesel from the COTU, and another 2- 4 hours to
round trip assuming, there are trucks and drivers available.
The most critical part of the entire fill cleanout process is the proper mixing of the fluids for both
slick and gelled diesel. Poor mixing techniques can result in loss of solids carrying capacity in the
gelled diesel, and little or no reduction in friction pressures with the slick diesel. Additionally, poor
mixing can result in stringers in the fluid which can plug screens or create other pumping
problems during the job. The procedures below are designed to reduce the risk of having
improperly mixed fluids on location.

For Slick Diesel the recipe is: 290 bbls warm diesel (60 Deg F to 80 Deg F)
Mixing Procedure
 Load 290 bbls of warm diesel in a tanker.
 Hook up a suction hose and static mixer to another vac truck with agitator.
 Vac on 30 bbls of warm diesel and get agitators running.
 Begin sucking on the DRA (2 gallons / 290 bbls of diesel) from the container with the
rubber hose attached to the static mixer which will be pulling a vacuum.
 Slip stream in the DRA very slowly to try and space it out over the remaining 260 bbls
left to transfer. Pulling the hose out and sucking air once in a while doesn’t hurt anything.
This is the most important aspect of mixing the diesel.
 After all fluids are loaded, continue agitating as long as possible. For instance if the slick
diesel is made up the night before the job, leave in the truck to agitate until it is needed
on location, then transfer it to an upright or pull it straight off the truck.
Slick diesel will need to be agitated if it becomes cold. If in a vac truck, using the agitators will
prove sufficient. If in an upright, blowing air through the fluid has proven effective.
Gelled Diesel
The J4-52 and J6-01 additive for GELLED diesel is a Schlumberger product and is available at
SLB Bulk Plant (659-6160) in five (5) gallon containers. To properly gel diesel requires 37 gals
J4-52 and 19 gals J6-01 per 290 bbls of warm diesel.
For Gelled Diesel the recipe is: 290 bbls warm diesel (50 Deg F to 90 Deg F)
37 gallons of J4-52
19 gallons of J6-01
Mixing Procedure
 Load up 290 bbls of warm diesel onto vac truck and get agitators running
 Suck up the 37 gals of J4-52 (Gelling agent)
 Agitate in truck for a minimum of 2-3 hours
 Offload into upright through the static mixer
 As you are offloading into the upright suck up the 19 gal of J6-01 (Activator) with the
rubber hose attached to the static mixer.
Gelled diesel, once mixed, will maintain its properties if allowed to cool. The only note of caution
is that the first few sweeps may be very viscous and difficult to pump if extremely cold.
Gelled Diesel Breakers

Should a need to ‘break’ slick/gelled diesel occur, WO-60 is a Schlumberger product and is
available at SLB Bulk Plant (659-6160) in five (5) gallon containers. Conoco-Phillips in Kuparuk
uses two (2) gallons W060 per 290 bbl load of returned fluids. The exact amount is five (5)
gallons per 1,000 gallons of pure gelled diesel.
The gel breaker can be injected with a chemical pump to returns or added to flow back tanks.
This will break the gelled diesel immediately back to diesel. W060 is the recommended breaker
for this application. In the event W060 is not available, the alternative breaker is W054, also a
non-emulsifier, which will provide the same results as W060. Both of these breakers are in liquid
form. A powder breaker exists and is J603. This breaker however requires time to break the gel
and is not recommended if alternative breakers are available. Lab work should be performed
before using this breaker to get the proper loading based on expected return fluid temperatures
and ambient conditions.

Execution
Performing a gelled diesel cleanout is similar to any other cleanout. The main consideration here
is that unlike Biozan, gelled diesel sweeps have a fallout rate which is higher. For example data
from Kuparuk shows 1.5# to 2.0# Biozan has a solids fallout rate of approximately 12% to 18%,
whereas gelled diesel is reported to have a solids fallout rate of approximately 18% to 24%. In
order to compensate for this, more time and additional fluid is required to complete a diesel
cleanout as compared to a water and gel cleanout.
The basic practice for gelled diesel cleanouts is 25’ to 50’ of fill in 7” can be cleaned out with 10
to 20 bbls sweeps of gelled diesel. This is similar to Biozan or Flo Pro however the sweeps need
to be strung out further to ensure good hole cleaning. Longer time spent chasing each sweep up
hole is recommended compared to Biozan or Flo Pro cleanouts with extra slick water. Good
cleanout technique includes jetting through fill only when gelled diesel is exiting the nozzle and
parking the coil as the last 1 bbl of gelled diesel exits before chasing up hole. Chasing up hole
should be performed at lower speeds than with water based fluids.
As very few diesel cleanouts have been performed in recent times, limited information is
available to be presented here. The expectation is that as more jobs are executed, this section of
the manual will be expanded and updated based on the submitted “lessons learned”.
As this type of cleanout is not a routine operation at GPB. Develop a detailed job procedure and
a risk analysis prior to beginning the job. Obtain approvals from the Well Operations Supervisor
and the BPG HSE Environmental Advisor.


Fill Clean Outs

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Fill Clean Outs

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Recommended Practice: Wells: CTU Operations - Cleanout Procedures Page 1 of 47

Alaska Drilling and Wells

NSU ADW Wells NSU ADW Wells

INTELLECTUAL PROPERTY AND CONFIDENTIALITY NOTICE

Note: Section 7.0 contains Lessons Learned from the field.

3.0 General Requirements

4.0 Key Responsibilities

Well Operations Supervisor is:

Wellsite Leaders are:

5.1.1 Normal Cleanout:

5.1.2 Reverse Cleanout:

Note on Injection Wells:

Note on MMS wells at Northstar:

5.2 Job Preparation

b) Estimate amount and type of fill to be cleaned out.

3-1/2” Tubing 4-1/2” Tubing 5-1/2” Tubing 7” Casing

BP Confidential and © 2009 BP America Inc.

e) Determine the fluid(s) to be used for cleanout operation.

BP Confidential and © 2009 BP America Inc.

g) Nozzle size and jet configuration.

BP Confidential and © 2009 BP America Inc.

i) Reverse Circulation Cleanouts

BP Confidential and © 2009 BP America Inc.

j) Low Pressure Skid (LPS)

5.3 Recommended Equipment

BP Confidential and © 2009 BP America Inc.

2. Normal cleanout with returns to tanks:

4. Low Pressure Skid (LPS)

5. Nitrogen – if needed (only if normal cleanout)

5.4 Execution - Normal (or Live Well) Cleanouts

BP Confidential and © 2009 BP America Inc.

BP Confidential and © 2009 BP America Inc.

BP Confidential and © 2009 BP America Inc.

5.5 Execution - Reverse Circulation

BP Confidential and © 2009 BP America Inc.

5.6 Injector Cleanouts at Milne Point

8. Put well on injection as soon as the coil is out of the hole.

5.7 Risk Analysis

5.8 Wellbore Fluid Tracking Sheet

5.9 Keeping Track of Trucks

BP Confidential and © 2009 BP America Inc.

Fill Cleanout Risk Assessment

Potential for Injury / Probability of Risk Occurring

BP Confidential and © 2009 BP America Inc.

Potential for Injury / Probability of Risk Occurring

BP Confidential and © 2009 BP America Inc.

Potential for Injury / Probability of Risk Occurring

BP Confidential and © 2009 BP America Inc.

Potential for Injury / Probability of Risk Occurring

BP Confidential and © 2009 BP America Inc.

Potential for Injury / Probability of Risk Occurring

BP Confidential and © 2009 BP America Inc.

Potential for Injury / Probability of Risk Occurring

Economic – damage to Very low Occurrence – High

BP Confidential and © 2009 BP America Inc.

Potential for Injury / Probability of Risk Occurring

BP Confidential and © 2009 BP America Inc.

Potential for Injury / Probability of Risk Occurring

BP Confidential and © 2009 BP America Inc.

Potential for Injury / Probability of Risk Occurring

BP Confidential and © 2009 BP America Inc.

6.0 Key Documents/Tools/References

7.0 Lessons Learned

1) TeamLink LL #10133, October 2007