CT EO Manual

Coiled Tubing
Equipment Operator
Training Manual
Page i
Table of Contents
1.0 MANUAL INTRODUCTION................................................................1

1.1 Manual Description..............................................................................................1
1.2 Manual Objectives................................................................................................2
1.3 Company Mission Statement...............................................................................3
1.3.1 BJ Canada Values....................................................................................3
1.4 Coiled Tubing Equipment Operator Responsibilities...........................................4
1.5 Competency Assessment......................................................................................4
2.0 HEALTH, SAFETY, AND ENVIRONMENT......................................7

2.1 General Safety......................................................................................................7
2.1.1 Safety: Measures of Success...................................................................7
2.1.2 Personal Responsibilities for Safety........................................................8
2.1.3 Sources of Safety Information.................................................................9
2.1.4 Hazard Analysis and Identification.......................................................10
2.2 Main Hazards of Coiled Tubing Operations.......................................................11
2.2.1 Pressurized Contents of Piping and Related Equipment.......................12
2.3 Personal Protective Equipment (PPE) Requirements Chart...............................12
2.4 Driving...............................................................................................................14
2.4.1 Pre-trip Inspections................................................................................14
2.4.2 Vehicle Documentation..........................................................................14
2.4.3 Seat Belts...............................................................................................15
2.4.4 Speed Limits..........................................................................................15
2.4.5 Backing and Reversing..........................................................................15
2.4.6 Hand Signals for Directing Vehicles.....................................................16
2.4.7 Hand Signal Illustrations.......................................................................18
2.4.8 Convoy Rules........................................................................................21
2.4.9 Adverse Conditions...............................................................................23
2.4.10 Tire Chains...........................................................................................23
2.4.11 Onsite Hazards.....................................................................................24
2.4.12 Post-trip Inspections............................................................................25
2.5 Environmental Responsibilities..........................................................................25
2.5.1 Minimizing Our Effect on the Environment..........................................26
2.5.2 Waste Management................................................................................26
2.5.3 The Four R’s: Reduce, Reuse, Recycle, and Recover...........................27
2.5.4 Environmental Rules.............................................................................27
2.6 Emergency Response.........................................................................................28
2.6.1 General ERP..........................................................................................29
2.6.2 Facility Specific ERP............................................................................29
2.6.3 Priorities in the Event of an Emergency................................................29
2.6.4 Basic Emergency Response Guidelines for Injuries..............................30
2.6.5 Emergency Response Guidelines for Motor Vehicle Accidents............31
EO Coiled Tubing Training Manual

Revision Date: 03/03
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2.6.6 Environmental Spills and Releases.......................................................32

2.6.7 Basic Emergency Response Guidelines for Radiation Leaks................33
2.7 General Reporting Procedures for Accidents and Injuries.................................34
2.7.1 Reporting Procedures for Accidents or Incidents..................................35
2.7.2 Reporting Procedures for Injury or Illness............................................35
2.7.3 Reporting First Aid and Non-Treatment Injuries...................................35
3.0 EQUIPMENT USED IN COILED TUBING OPERATIONS..........37

3.1 Injector...............................................................................................................38
3.1.1 Stuffing Box..........................................................................................40
3.2 Goosenecks.........................................................................................................41
3.3 Coiled Tubing Reels...........................................................................................42
3.3.1 Connecting Reels to Injectors................................................................45
3.4 Cranes.................................................................................................................47
3.5 Blow Out Preventers..........................................................................................47
3.5.1 Quad-Ram BOP.....................................................................................48
3.5.2 Combi BOP...........................................................................................51
3.5.3 BOP Control System..............................................................................51
3.5.4 Annular Preventers................................................................................52
3.5.5 The Industry-used Annular BOP...........................................................53
3.6 Power Systems and Controls..............................................................................54
3.6.1 Operating Cabin.....................................................................................54
3.7 Wellhead Connections........................................................................................55
3.7.1 Swages...................................................................................................55
3.7.2 Flow Tees...............................................................................................56
3.8 Preventing Damage to Coiled Tubing................................................................57
4.0 DOWNHOLE TOOLS..........................................................................59

4.1 Jet Tools..............................................................................................................59
4.2 Wash Tools.........................................................................................................60
4.3 Check Valves......................................................................................................60
4.3.1 Ball and Seat Check Valves...................................................................61
4.3.2 Tandem Check Valves with Jet Tool and Cold Roll Connectors...........61
4.3.3 Double Flapper Check Valves...............................................................61
4.3.4 Double Dart Check Valve......................................................................62
4.4 Connectors..........................................................................................................63
4.4.1 Tubing End Connectors.........................................................................63
4.4.2 Cold Roll Connectors............................................................................65
4.4.3 Tubing-to-Tubing Connectors...............................................................65
4.5 Hydraulic Disconnects.......................................................................................65
4.6 Centralizers.........................................................................................................66
5.0 OPERATIONAL PROCEDURES FOR COILED TUBING............67

5.1 Requirements of the Job.....................................................................................67

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5.2 Pre-Job Considerations.......................................................................................67

5.2.1 Driving to the Work Site........................................................................69
5.2.2 Positioning Equipment on the Lease.....................................................69
5.2.3 Pre Rig-Up Meeting..............................................................................71
5.2.4 Rig-up Procedures for Coiled Tubing Operations.................................71
5.2.5 General Safety Guide for Rig-up Procedures........................................72
5.2.6 Rigging the Crane Unit..........................................................................73
5.2.7 Preparation Of Reel Unit.......................................................................74
5.2.8 Installation Of Blowout Preventers (BOP)............................................74
5.2.9 Rigging Up............................................................................................76
5.2.10 Connecting the Injector to the BOP's:.................................................78
5.2.11 Pre-Job Safety Meeting........................................................................78
5.2.12 Procedures To Control The Hazards:...................................................79
5.3 Job Execution Procedures..................................................................................80
5.3.1 Pressure Test..........................................................................................81
5.3.2 Running Coil Tubing Into The Well......................................................83
5.3.3 Pulling Coil Tubing Out Of The Well....................................................84
5.4 Post Job Procedures............................................................................................84
5.4.1 Driving...................................................................................................87
5.4.2 Post-trip Inspection................................................................................87
5.4.3 Paperwork..............................................................................................87
5.5 Maintenance on Coiled Tubing Equipment........................................................87
5.5.1 Blowout Preventers (BOP's)..................................................................87
5.5.2 Stuffing Box..........................................................................................88
5.5.3 Work Reels.............................................................................................88
5.5.4 Injectors.................................................................................................89
5.5.5 Gooseneck (Tubing Guide Arch)...........................................................90
5.6 Emergency Procedures.......................................................................................90
5.6.1 Emergency BOP Operation...................................................................91
5.6.2 Actuating the BOP System....................................................................92
5.6.3 Leak in Coiled Tubing At Surface.........................................................93
5.6.4 Leak In Coiled Tubing Below Surface..................................................94
5.6.5 Leak In Surface Pressure Control Equipment.......................................95
5.6.6 Tubing Runs Away Into The Well..........................................................97
5.6.7 Tubing Runs Away Out Of The Well.....................................................98
5.6.8 Tubing Is Pulled Out Of The Stuffing Box............................................99
5.6.9 Tubing Collapsed At Surface.................................................................99
5.6.10 Tubing Breaks On Surface.................................................................100
5.6.11 Coiled Tubing Reel Drive Fails.........................................................101
5.6.12 Power Pack Failure............................................................................102
6.0 INTERPERSONAL SKILLS.............................................................105

6.1 Objectives.........................................................................................................105
6.2 Communication Techniques.............................................................................105

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6.2.1 Listening..............................................................................................106
6.2.2 Speaking..............................................................................................107
6.2.3 General Tips to Improve Communication...........................................108
6.3 Building Relationships.....................................................................................108
6.4 Job-Site Scenarios............................................................................................109
7.0 APPENDIX 1: BASIC MATH AND WELL SERVICING

CALCULATIONS...............................................................................113
7.1 Basic Mathematical Operations........................................................................114
7.1.1 The Decimal System............................................................................114
7.1.2 Addition...............................................................................................115
7.1.3 Subtraction...........................................................................................115
7.1.4 Multiplication......................................................................................116
7.1.5 Division................................................................................................118
7.1.6 Squaring a Number..............................................................................119
7.1.7 Square Root.........................................................................................120
7.1.8 The Circle............................................................................................121
7.1.9 Area of a Rectangle.............................................................................122
7.1.10 Area of a Square................................................................................123
7.1.11 Area of a Circle..................................................................................123
7.1.12 Volume of a Rectangular Solid..........................................................124
7.1.13 Volume of a Cube..............................................................................125
7.1.14 Volume of a Sphere............................................................................126
7.1.15 Volume of a Cylinder.........................................................................127
7.2 Basic Density and Pressure Calculations used in Well Service Operations.....127
7.2.1 Density.................................................................................................128
7.2.2 Specific Gravity (S.G.)........................................................................130
7.2.3 Calculating Specific Gravity...............................................................130
7.2.4 Using Specific Gravity To Calculate Density......................................131
7.3 Hydrostatics......................................................................................................133
7.3.1 Pressure................................................................................................133
7.3.2 Applied Pressure..................................................................................133
7.3.3 Hydrostatic Pressure (H.P.)..................................................................134
7.3.4 Hydrostatic Pressure Gradients...........................................................135
7.3.5 Calculating Hydrostatic Pressure Involving Other Fluids...................137
7.4 A.P.I. Gravity....................................................................................................141
7.5 Differential Pressure.........................................................................................145
7.6 Bottom Hole Pressure.......................................................................................153
7.6.1 Bottom Hole Treating Pressure...........................................................153
7.6.2 Bottom Hole Pressure..........................................................................154
7.6.3 Frac Gradients.....................................................................................157
7.7 Hydraulic Pumping Power...............................................................................158
8.0 APPENDIX 2: AUXILIARY EQUIPMENT.....................................163

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8.1 Swivel Joints (Chiksans)..................................................................................163

8.1.1 Disassembling the Swivel Joint...........................................................164
8.1.2 Disassembling Parts.............................................................................164
8.1.3 Cleaning and Inspecting the Parts.......................................................165
8.1.4 Assembling the Swivel Joint...............................................................165
8.1.5 Lubricating the Swivel joint................................................................166
8.2 Plug Valves.......................................................................................................167
8.2.1 Disassembling the Plug Valves............................................................167
8.2.2 Repairing the Plug Valves....................................................................169
8.2.3 Assembling the Plug Valves................................................................169
8.3 Check Valves....................................................................................................170
8.3.1 Disassembling Check Valves...............................................................171
8.3.2 Assembling Check Valves...................................................................171
8.4 Iron Truck.........................................................................................................171
8.4.1 Operation and Maintenance.................................................................172
8.4.2 Hydraulic Booms.................................................................................172
8.5 Winch Tractor Operations................................................................................173
8.6 Wire Rope and Cable........................................................................................174
9.0 APPENDIX 3: GLOSSARY OF TERMS..........................................179
10.0 APPENDIX 4: MANUAL EVALUATION FORM.........................191

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Page 1
1.0 MANUAL INTRODUCTION

Welcome to the Coiled Tubing Equipment Operator training program. This represents a
major step in your career, and we hope there will be many more to follow. You have
shown the ability to learn and the desire to advance your skill levels. This program
represents part of BJ Canada's dedication to provide you with the training necessary to
support your career progression. Ultimately, we hope to see your career aspirations grow
with the company, and we will help you as much as possible.
1.1 MANUAL DESCRIPTION

The purpose of this manual is to provide basic information that allows you to perform
your job as a Coiled Tubing Equipment Operator (EO). Although the manual attempts to
cover most aspects of your job, it is important to remember that the experience you gain
working in the field represents a significant portion of your training. If you are in doubt
about any of the job procedures or company policies, do not hesitate to ask for
clarification from your supervisor or a more experienced employee. They are a valuable
resource with field experience. Use them. This manual is not a rulebook since few jobs
are entirely routine; however, it is a useful reference guide.
The manual is organized into 6 sections, including:

1. Manual Introduction
2. Health, Safety, and Environment
3. Introduction to Coiled Tubing
4. Operational Procedures for Coiled Tubing
5. Interpersonal Skills
6. Appendices
 Appendix 1: Basic Math and Well Servicing Calculations
 Appendix 2: Auxiliary Equipment
 Appendix 3: Glossary of Terms

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 Appendix 4: Manual Evaluation Form
1.2 MANUAL OBJECTIVES

There are two types of objectives included in this manual. General manual objectives
state the goals of the entire manual, and specific module objectives state the goals of
individual modules. The purpose of the objectives is to indicate the specific knowledge
and skills you are expected to learn while going through the manual. In other words,
objectives are statements about what is to be accomplished by the manual or module.
Pay particular attention to the objectives, as they outline the most important aspects of
each topic, and also indicate the duties you will be expected to perform after completing
the module.
General Manual Objectives

The general objectives of this manual are to help you:
1. understand BJ Canada's health, safety, and environmental policies
2. learn and practice safety procedures in all aspects of the job
3. understand the working hazards associated coiled tubing operations
4. perform proper pre-job procedures
5. perform proper job execution procedures
6. perform proper post job procedures
7. understand basic interpersonal skills
8. perform basic calculations associated with well servicing operations

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1.3 COMPANY MISSION STATEMENT

The following is the BJ Services Mission Statement.
We strive to serve our customer's needs with high quality, value added products and
services.
We will attract and retain the best people and foster an environment throughout our
organization of openness and trust which empowers all of us to contribute to our full
potential.
We are committed to operate our business as a valued neighbour in the communities in

which we reside.
We believe that integrity and honesty are essential and we will not compromise them in
our business.
We will continually improve everything we do more efficiently and better than our
competitors.
We strive to achieve superior return on equity and superior earnings growth for our
stockholders, both short term and long term.
1.3.1 BJ Canada Values

We are a service company driven by a desire to meet and exceed the requirements and
expectations of our customers. We believe our customers deserve our complete attention,
dedication, knowledge, and effort.
BJ Canada owes a large part of our success to the quality and commitment of our
employees, wherever they work. As a representative of this organization, you are in a
unique position to play an important part in promoting the company's reputation for
reliability, integrity, competence, and professionalism.
Our service attitude is represented by hard work, a positive attitude, a willingness to

continually improve, and the ongoing search for the best solutions to our customer's
problems. We count on your contribution, and expect that as a professional, you will
always represent BJ Canada in an appropriate and courteous manner.

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1.4 COILED TUBING EQUIPMENT OPERATOR RESPONSIBILITIES

As a Coiled Tubing Equipment Operator, you are responsible for the following:
 report for work mentally and physically alert
 ensure assigned equipment meets operational and safety requirements
 review daily activity list with your Supervisor to ensure work assignments are
carried out as required
 understand and practice safety policies and procedures in accordance with the
HSE Resource Book
 report all operational deficiencies to your Supervisor and maintenance personnel
 perform pre-trip inspection of the unit you are driving
 practice safe driving procedures when travelling to and from work location
 follow proper rig up procedures
 operate equipment in accordance with company procedures
 ensure all job operations are carried out as per Supervisor's instructions
 follow proper rig-out and travel procedures
 perform post-trip inspection of the unit you are driving
 perform operator portion of the 400 hour inspection
 complete all necessary paperwork and forward to appropriate personnel
 participate in continued training
1.5 COMPETENCY ASSESSMENT

Competency assessment refers to a procedure that determines whether or not a person
possesses the required knowledge and skills to perform a specific task. As an EO,
competency assessment is important to you in the following ways:
1. it provides the means by which your job performance is evaluated, and thus
allows you to gain the necessary certification for specific job classifications
2. it reveals gaps in your training, and indicates to you and your supervisor the
knowledge and skill areas in which you need upgrading
3. it serves as one means to indicate your readiness for advancement

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You will encounter two measures of competency: corporate tests, and applied skills
evaluations. Each one is discussed below.
Corporate Tests
In order to advance to the next job classification level, you must complete all tests
associated with the service line and job level. For example, to complete the requirements
of the EO2 level in the Coiled Tubing service line, you must write the following tests:
 CT Reels and Spoolers - tests your knowledge about reels and spoolers
 CT Cranes - tests your knowledge about cranes and crane operation
 CT Blowout Preventers - tests your knowledge about BOP's used in coiled tubing
operations
Note that at the EO2 level, you must also become registered as an apprentice boom truck
operator.
To complete the requirements for the EO3 level, you just write the following tests:
 Nitrogen Pumping - tests your knowledge about nitrogen pumping operations
You are also required to complete the COP's course, which involves classroom time as
well as a final test.
At the EO4 level, you are required to write the following tests:
 CT Tools and Hydraulics - tests your knowledge about the tools and hydraulic
systems used in coiled tubing operations
At this level, you will also finish your apprenticeship as a boom truck operator.
Each test consists of 7 sections, and each of these sections represent a competency
associated with your job. The 7 sections, or competencies, are listed below.
 Section 1: Health, Safety, and Environment
 Section 2: Emergency Response
 Section 3: Maintenance

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 Section 4: Pre-Job Procedures

 Section 5: Job Execution
 Section 6: Post-Job Procedures
 Section 7: Interpersonal Skills
A passing grade on the tests is 80%.
Applied Skills Evaluations

Each test is also accompanied by an Applied Skills Evaluation Form, which is completed
by your supervisor. The purpose of the evaluation is to assess whether or not you can
perform many of the tasks discussed in this manual. This form asks a series of questions
relating to the specific "hands-on" skills and tasks that your job requires. For example, a
question might be: Did EO perform a proper pre-trip inspection on his/her unit? It is the
responsibility of the supervisor to indicate either yes or no to the questions.
All Applied Skills Evaluations consist of the same 7 sections, or competencies, as the
tests. A passing grade for the evaluations is 80%.

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2.0 HEALTH, SAFETY, AND ENVIRONMENT

The health and safety of people, protection of the environment, and the minimization of
loss to equipment or property are the key priorities that form the basis for BJ Canada’s
Health, Safety, & Environment management system. Employees at all levels are
expected to reflect these priorities during the performance of their work activities.
Objectives
The objectives of this module are to help you:
1. understand your new responsibilities as a Coiled Tubing Equipment Operator
2. identify main hazards associated Coiled Tubing processes
3. know company’s safety standards
4. know when and where to use personal protective equipment
5. understand the general rules of operating BJ Services Canada vehicles
6. explain your responsibilities in regards to environmental rules and regulations
7. know how to respond to an emergency situation
2.1 GENERAL SAFETY

This section discusses the general safety issues associated with your job as an EO in the
Coiled Tubing service line.
2.1.1 Safety: Measures of Success

The following “Measures of Success” are beliefs that management and employees must
share to foster a positive, proactive, and continually improving HSE culture.
Understanding them help you to operate within the expectations of BJ Canada's safety
policies and procedures:
 accidents/incidents are preventable
 operational and transport exposures can be reasonably safeguarded
 safety is a shared responsibility between management and employees

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 safety is a line management function and all levels of authority are accountable
for events and conditions under their control
 preventing accidents/incidents is good business
 working safely is a condition of employment
Never forget that safety should remain your top priority; in other words, safety is part of
your job. At times, you might be tempted to cut corners. Do not do it! You could be
endangering your life and the lives of your colleagues, and you could lose your job. BJ
Canada considers safety to be of the utmost importance, and is committed to providing
the safest work environment possible. Accordingly, we expect our employees to conduct
themselves and their work in a manner that reflects this commitment.
2.1.2 Personal Responsibilities for Safety

 Take reasonable care to protect your health and safety, other workers, or anyone
exposed to our operations.
 Comply with and perform work activities according to established HSE standards,
procedures, and practices.
 Refuse to perform work that poses or may pose imminent danger to yourself or to
any other individual. “Imminent Danger” means a danger that is not normal for a
worker’s occupation or a danger under which a person engaged in that occupation
would not normally perform his or her work. If you refuse to perform work that
might be dangerous, promptly inform your supervisor or manager. They will
investigate the situation, and take actions as necessary to eliminate the hazards.
 Report all potential hazards, unsafe work practices, accidents/incidents, injuries,
illness, spills/releases, violations, and non-conformances to your immediate
supervisor.
 Use and maintain designated safety and personal protective equipment as required
to minimize or control hazards.
Ask your supervisor or manager for clarification and direction when you are
unsure about a specific task or operation.

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2.1.3 Sources of Safety Information

The following list outlines sources of information you can access to find information
relating to safety. Check with your supervisor if you experience difficulty locating any of
the sources.
BJ Canada Health, Safety, and Environment (HSE) Resource Book

The purpose of this book is to supply BJ Canada employees and contractor employees
with the basic rules that apply to our operations. It is your responsibility to be aware of
the HSE requirements pertaining to your work, and to follow safe and environmentally
responsible work practices at all times. The HSE Resource Book also contains
information about the Transportation of Dangerous Goods (TDG) and Workplace
Hazardous Information System (WHMIS) regulations.
Safety Standards Manual

The purpose of the Safety Standards Manual is to provide information about known work
hazards, and the best means of minimizing the hazards to create a safe work environment.
This manual is a more formal representation of BJ Canada's safety rules, and tends to
supplement the local, provincial, and federal regulations that guide and influence our
work.
Radiation Safety Manual for Operators

The purpose of this manual is to provide the information required for Operators to work
safely when handling and operating density gauges. Manuals are assigned to all units
with fixed gauges as part of their pumping equipment and to Frac Vans. The manuals
must stay with the Unit at all times and lost manuals must be replaced immediately. In
addition to the Units, all bases will have at least one copy of the manual available in the
office or coffee room.
Material Safety Data Sheet (MSDS)

The MSDS's are documents designed to provide product information that is easily
accessible, and includes data about the product supplier, emergency phone numbers,
hazardous ingredients, physical and chemical properties, fire and explosion data, stability

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and reactivity, toxicological properties, preventative measures, first aid measures,

classification, and preparation information. Although you are not expected to know all of
the materials, it is recommended that you become familiar with the ones you will work
with most often. Many of these materials are highly toxic and very dangerous when the
correct handling procedures are not followed.
2.1.4 Hazard Analysis and Identification

Although this manual attempts to alert you to potential hazards you encounter on a daily
basis, it is important that you develop skills to help you identify hazards on your own.
Each year, our company records numerous instances where employees are hurt because
improper procedures were followed, or because there was a lack of care and attention
exercised during the job. Remember that the person who benefits the most from
practicing safe work habits and identifying hazards before they become accidents is you.
Performing a hazard analysis and identification should become part of your daily work
routine. It is not difficult to do. One way to keep alert and aware of the potential risk is
to ask yourself a series of questions. These questions can fall into three distinct
categories: identify, assess, and control.
Identify
 Do I clearly understand my task?
 Am I physically and mentally prepared to do the task?
 What could go wrong?
 Is there a risk to myself or others?
 What can change that could create a new risk?
 Could other crews, workers, or conditions pose a risk to me?
Assess
 How bad could this be?
 How likely is it to happen?

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Control
 Who should I contact for help?
 Are permits, written practices, procedures, etc. required?
 What can I do to control the risk?
 Will the control affect another part of the task being done?
 Do I need to tell anyone else?
 Are emergency response plans required?
If you are concerned about any of the answers to these questions, contact your supervisor
for clarification and direction.
2.2 MAIN HAZARDS OF COILED TUBING OPERATIONS

Part of your job as a Coiled Tubing EO involves working with products and chemicals
that present very real hazards to your physical health. The high pressures involved with
pumping operations also present serious hazards. Other hazards occur when employees
become careless, and fail to follow the proper procedures when conducting a specific job
operation. Regardless of the service line you are assigned to, it is critical that you report
for work mentally and physically prepared to do your job, and exercise care and caution
at all times. The following sections outline the main hazards associated with Coiled
Tubing operations: learn them and be aware of potential consequences.
Equipment
A number of hazards are associated with the equipment used in Coiled Tubing operations.
These include, but are not limited to, the following:
 crane and associated hazards
 spooler and reel and associated hazards
 injector and associated hazards
 coiled tubing unit and associated hazards
 blowout preventers (BOPs) and associated hazards
 working at heights and associated hazards
 working with equipment from other service lines and associated hazards

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H2S
Coiled Tubing Equipment Operators must be aware of hydrogen sulphide (H2S),
commonly known as "sour gas", which can be encountered in coil tubing operations.
Exposure to H2S can be lethal. Hydrogen sulphide is potentially explosive when mixed
with the right proportion of air or oxygen. It burns readily with a distinctive blue flame
producing Sulphur Dioxide (SO2), another hazardous gas that irritates the eyes and lungs.
Fluids
Coiled Tubing Equipment Operators should also be aware of the hazards presented by the
fluids, which include:
 acid-based products used on jobs
 risk of fire resulting from flammable fluids used under pressure
 risks involved in pumping corrosive fluids
2.2.1 Pressurized Contents of Piping and Related Equipment

There is a rupture hazard related to pumping through high-pressure lines. Ruptures can
result from:
 pumping against a closed valve
 reversed check valve
 use of incorrect equipment
 hammering/tightening unions under pressure
2.3 PERSONAL PROTECTIVE EQUIPMENT (PPE) REQUIREMENTS CHART

Listed below are the minimum PPE requirements for specific work-sites and / or
operations. These PPE requirements are based on normal operations, and must be worn
for every job. When additional, new, or abnormal hazards are present, supplementary
equipment may be required. For example, dust masks, respirator equipment, and / or
safety goggles may be required on a regular basis. Always protect yourself against
known hazards, and comply with the personal protective equipment requirements.

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The chart below indicates the required PPE for each service line; in addition, it indicates
those PPE items that must be utilized on an "as required" basis.
(X) Denotes required PPE

(AR) Denotes PPE as required by the potential hazard
Cementing
Acidizing
Fracturing
Sand Handling
Coiled Tubing
Coiled Tubing Drilling
Lab
Process & Pipeline Services
Shops
Yards
Pipeline Inspection Services

Warehouse, Bulk Plant
N2 / CO2
Field Operators (minimum)
PERSONAL PROTECTIVE
REQUIREMENTS
EQUIPMENT
Hard Hats X X X X X X X X X AR AR X X AR
Work Boots X X X X X X X X X X X X X X
Rubber Boots AR AR AR AR AR AR AR AR AR AR AR AR AR
Fire Retardant Coveralls X X X X X X X X X X X X X AR
Chemical Resistant Clothes AR X AR AR AR AR AR AR AR AR AR AR
Dusk Mask AR AR AR AR AR
Respiratory Protection AR AR AR AR AR AR AR AR AR AR AR AR AR
SABA / SCBA AR AR AR AR AR AR AR AR AR AR AR AR AR
Chemical Resistant Gloves AR X AR AR AR AR AR AR AR X
Insulated Gloves AR AR X X X X AR AR X X AR
Hearing Protection AR AR AR X AR X X AR AR AR X X AR
CSA Safety Glasses X X X X X X X X X X X X X X
CSA Approved Face Shields AR AR AR AR AR AR AR AR AR AR AR AR
CSA Approved Goggles AR AR AR AR AR AR AR AR AR AR AR AR AR
CSA Approved Fall AR AR AR AR AR AR AR AR AR AR AR AR AR
Protection

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2.4 DRIVING
You are expected to drive and operate BJ Canada vehicles in a lawful and defensive
manner, and comply with all regulatory requirements.
2.4.1 Pre-trip Inspections

Federal and provincial regulations require all truck drivers to complete a driver vehicle
inspection and condition report of their vehicle. The form BJ Canada uses also includes
checklists relating to pre-job, post-job, and end of trip (post-trip) inspections. These
additional checks help to keep the equipment in safe and reliable operating condition. As
an equipment operator and driver, you are responsible and accountable for the safety and
maintenance of the equipment.
The inspection must be completed before each trip, and at the start of each subsequent
day of the trip. If a trailer is exchanged, then another complete driver vehicle inspection
and condition report must be performed, including those items relating to the tractor.
Regulations state that if a safety related problem is detected during the pre-trip
inspection, it must be repaired before driving. The government enforces these standards
through roadside inspections and facility audits, so it is critical that you carry a copy of
the inspection report in the unit. It is also necessary to carry a copy of the previous
inspection report in order to indicate that any identified safety defects or problems have
been repaired.
2.4.2 Vehicle Documentation

Vehicle documentation requirements can vary between provinces, the type of unit, and
the kind of equipment mounted on the unit. All permits, forms, and other required
documentation are stored in the truck library. It is your responsibility to be familiar with
the contents of the truck library so that you can supply the material when requested to do
so by an inspection officer. If you have any questions about the truck library, ask your
supervisor for assistance.

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2.4.3 Seat Belts

All occupants in a company vehicle must wear seat belts. The number of seat belts in the
vehicle determines the number of occupants that can ride in the unit. If a sleeper berth is
equipped with a belt restraint system, the individual in the berth must wear the restraint
system while the vehicle is in operation.
2.4.4 Speed Limits

The maximum speed limit for all BJ Canada light vehicles is the posted speed limit. The
maximum speed limit for all BJ Canada heavy vehicles is the posted speed limit or 100
km/hr, whichever is less.
Every driver is responsible for matching vehicle speed to the conditions:

 adjust speed downward for adverse weather and/or road conditions, lease roads,
and unpaved roads
 on non-posted gravel roads, the maximum allowable speed limit is 80 km/hr if
road and/or weather conditions permit
 where there are no posted highway speed limits, the maximum allowable speed is
100 km/hr. for heavy vehicles and 110 km/hr. for light vehicles (these speeds
apply to ideal conditions, and drivers must adjust speed downward for adverse
road, weather, and traffic conditions)
The maximum speed limit in all BJ Canada yards is 20 km/hr, unless otherwise posted.
2.4.5 Backing and Reversing

Pre-plan an approach to minimize or avoid backing. If possible and practical, BJ vehicles
should be parked so that the first move out of a parking space is forward.
When backing a unit, follow these guidelines:

 whenever possible, ask another person to act as your guide (stationed to the left
rear of your vehicle and visible in the mirror to direct your movements)

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 agree beforehand on the method and meaning of signals

 if a location requires two guides, designate one to communicate to the driver
 if no guide is available, get out of the vehicle to examine the route and place a
safety reflective triangle as a reference point before backing (if it is dark, use a
flashlight in conjunction with the triangle)
 prior to backing up a heavy vehicle, sound the horn twice to warn other persons in
the area
 stop the vehicle if you lose sight of the guide when backing
 when available, use only BJ Canada employees to guide, back, or spot trucks and
equipment in yards and on well site locations
2.4.6 Hand Signals for Directing Vehicles

In an effort to prevent accidents and injures that occur due to blind spots and undetected
movement of personnel and equipment, the Canadian Petroleum Safety Council has
developed a set of hand signals to use when vehicles are in motion. These signals have
been adopted as Industry Recommended Practices that provide a common set of signals
for everyone to use. The signals are discussed below, and it is your responsibility to learn
and use them on a daily basis.
On-the-Job Hazard Assessment

Prior to moving the vehicle:
 plan the move to reduce backing
 conduct a visual inspection of the desired path
 the driver and the guide have a responsibility to identify potential hazards in the
vehicles path, such as, overhead lines, ruts, wellhead, personnel, etc.
 hazard control measures:
- ensure driver and guide understand the signals to be used
- ensure driver and guide understand the rules to be used
- ensure driver and guide are both aware of hazards
- plan the movement to control or eliminate the hazards

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General Considerations
When backing, drivers should:
 where possible, always use a guide
 stop backing immediately if:
- the guide is not fully visible
- visual contact is lost with other workers
- an emergency stop signal is received from anyone in the area
 resume backing only after visual contact is restored with the guide or workers
 use a co-worker as a guide
 sound horn before starting to move the vehicle
 stop all vehicle movement while the guide is repositioning
Other workers should:
 remember large vehicles have significant blind spots
 remain clear of the vehicle unless needed to act as a guide
 never cross or step behind the vehicle when it is backing or when its backup
signals are on
Guides should:
 remain visible to the driver at all times
 wear high visibility clothing
 establish and maintain eye contact with the driver
 position yourself to maintain as clear a view as possible of the intended path of
the vehicle
 stay clear of the vehicle's path
 avoid walking backward
 use standard hand signals to communicate with the driver
 be sure that no one is riding on the outside of the vehicle before signaling the
driver to begin moving
 immediately signal the driver to stop if any person or object enters the vehicles
intended path

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 signal the driver to stop if the guide must change positions; the guide should then
reposition and when ready signal the driver to continue
 use distinct and deliberate body movements
 be aware of blind spots
No one should cross or step behind a vehicle when the backup warning device is
activated.
2.4.7 Hand Signal Illustrations

When it's necessary to move a vehicle, it is important that everyone understands exactly
what is being done. This ensures the safety of everyone involved in the operation. There
should be no confusion about the hand signals to be used. Make sure workers involved
understand who is directing the move and the procedures to be followed. Review all the
hazards associated with this particular move and the precautions taken to minimize or
eliminate them. Use the following 7 signals to assist you when repositioning vehicles.
SIGNAL #1: PROCEED SLOWLY - STRAIGHT FORWARD OR BACKWARD

Purpose: To move the vehicle in a straight line either forward or backward.
Actions: Both arms extended forward and slightly wider than the body, parallel to the
ground. Palms facing the direction of desired travel. Together bend both arms
repeatedly toward the head and chest then extend.

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SIGNAL #2 & 3 TURN

Purpose: To move the vehicle either to the right or left while the vehicle is moving.
Actions: Direction arm is held extended from the side of the body, parallel to the
ground indicating the direction the vehicle or equipment is to travel. The
motioning arm is extended in the opposite direction (palm upward) and
repeatedly bent towards the head indicating the desired direction of travel.
SIGNAL #4: DISTANCE TO STOPPING POINT

Purpose: To provide the driver a visual
reference for the distance to the
stop point.
Actions: Both arms extended sideways with
elbows bent upward at 90 degrees.
Palms facing forwards. Keep hands
above head bring elbows forward as
the distance narrows. As the
elbows reach the straightforward
position continue the hands coming together above the head to indicate the
stop point is being reached. Upon reaching the stop point, give the STOP
signal (Signal #5).

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SIGNAL #5: STOP

Purpose: Stop all movement of the vehicle, await further
instructions.
Actions: Cross arms at the wrists (forearms) above the
head, and hold in position until the vehicle
stops moving.
SIGNAL #6: EMERGENCY STOP

Purpose: To stop all movement of
the vehicle immediately.
Actions: Both arms extended
above the head with
crossed arms at the
wrists, palms forward.
Both arms waved
repeatedly down until
parallel to the ground
then return to the stop position above the head (Signal #5) until the vehicle
stops moving.
Note: The driver shall stop the vehicle if anyone signals an emergency stop.

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SIGNAL #7: CLEAR TO LEAVE THE AREA

Purpose: To show the driver the vehicle is clear of obstructions and is cleared to
leave the area in the direction indicated.
Actions: Stage 1: Point to the driver of the vehicle that is cleared to leave, make eye
contact to ensure the driver knows he is the one to depart.
Stage 2: Both arms extended to the side of the body with elbows bent
upward at 90 degrees. Turn to face the direction of desired travel, extend
the arms forward until they are parallel to the ground indicating the
direction to be used on leaving.
2.4.8 Convoy Rules

When two or more vehicles travel to or from a job, or between districts at the same time,
they shall travel in convoy and follow established convoy rules and procedures. The
exception to this rule is cement bulkers, since they often travel solo to the job site. The
principle of a convoy is to provide direct supervision and increase the level of control for
vehicles in the convoy. It also reduces the potential of job delays due to drivers getting
lost or driving on unauthorized roads or locations. Travelling in convoy also eliminates
confusion and delay in spotting equipment due to units arriving in the wrong spotting
sequence. In the event of a breakdown or an accident, a convoy allows for emergency
communications and provides additional resources to effectively deal with the emergency

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situation. When traveling in a convoy, ensure that you comply with the following rules
and procedures:
 be courteous and make allowances for other motorists
 the driver of the first vehicle in the convoy, as designated by the Service
Supervisor, controls the speed of the convoy
 adjust speed downward as required to match driver skills and road, traffic, or
weather conditions
 when a convoy comprises of one light and one heavy vehicle, the light vehicle
leads the convoy
 always turn headlights on when driving
 one BJ Canada unit is not to pass another BJ Canada unit when in convoy
 during clear weather conditions, the proper distance to follow from the unit ahead
is 8 to 10 seconds, and the space between vehicles should never be less than 300
meters on paved roads or out of the dust cloud on dusty gravel roads
 when moving at slow speeds on secondary lease roads, the distance between
vehicles should never be less than 150 meters
 adjust spacing requirements to maintain safe driving conditions when adverse
road or environmental conditions exist
 slow down at turns and activate the vehicle’s turn signal so the driver in the
vehicle behind is aware of the upcoming turn (do not proceed until you have
received confirmation)
 all drivers are to keep in visual contact with the vehicle ahead
 if one unit makes a stop, all vehicles are to stop when it is safe to do so
 in the event that one vehicle is slower, the convoy must wait at the next
predetermined rest stop for that vehicle
 on lease roads with steep hills, do not drive vehicles onto the slope of a hill until
the vehicle ahead has reached the top or bottom
 park vehicles safely where they will not cause danger to other road users (perform
en route inspection at stops)

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 two or more convoys are not to join together for a trip
2.4.9 Adverse Conditions

All drivers must be prepared to adjust their driving speed and actions to accommodate
adverse conditions. Adverse conditions include those created by weather changes (snow,
ice, rain, etc.), environment changes (steep hills, narrow roads, etc.), and physical
conditions of the driver (stress, tiredness, etc.). The table below is a summary of the most
common adverse conditions you will encounter.
Adverse Driving Condition Driver’s Response
Congested Highways slow down to speed of the surrounding traffic; do

not exceed speed limit
Winding Roads reduce speed and plan braking
Unpaved Road reduce speed to maintain control on gravel and
other rough road conditions
Night Driving reduce speed; you will need more time to react
due to reduced visibility
Muddy or Slippery Highways reduce speed to prevent skidding; appropriate use
of Jake brake and service brakes
Driving When Physically Tired stop as soon as possible and rest
Icy Conditions install chains at a suitable location
Fog reduce speed; use low beam headlights
Rain, Snow, or Sleet decrease speed to prevent skidding
2.4.10 Tire Chains

Tire chains help prevent vehicle accidents and damage resulting from the loss of control
due to muddy or icy conditions. Tire chains provide:
 greater stability when traveling on muddy or icy roads by providing additional
traction
 better control of the unit on roads with high crowns and slippery or icy surfaces
Attempt to determine the road and lease conditions before you embark, and plan for
chaining requirements in advance. As you cannot always predict the driving environment

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due to changes in weather and road conditions, always be prepared to stop and install the
tire chains when required. Ensure that your unit is equipped with the required chains,
chain repair kit, chain pliers, tarp straps, and appropriate chain tightening tools. For units
travelling in convoy, this equipment may be stored in the crew cab.
The minimum chain requirements are outlined below.
 tandem and single axle units: 1 steering chain, triple chains for all drive wheels
 tractors: 1 steering chain, triple chains for all drive wheels
 trailers: 2 single chains (one axle) or 1 triple chain
 jeeps: 2 single chains (one axle)
There are several situations that may determine the requirement to chain up:
 in advance by the dispatcher or manager
 by the service supervisor
 by the customer
 by the driver after observing road conditions or after consultation with other
drivers
When chaining up, use the following guidelines:

 select a hard flat area, out of the traffic flow and with good visibility in both
traffic directions
 wear coveralls with reflective striping to ensure visibility
 protect against traffic hazards by positioning a light duty vehicle equipped with an
amber strobe light at the rear of the unit(s) being chained up, or designate a flag
person
Remember that wheel chains are easy to install before you are stuck; they are very
difficult to install after you are stuck. If in doubt, chain up.
2.4.11 Onsite Hazards

When driving onto leases or work sites, always be alert and check for hazards that may
be present. Some of these include:

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 holes or soft spots

 anchors
 guy lines
 overhead power lines
 lines on the ground
 any other equipment or debris which may create a hazard
 congestion of people, vehicles, and / or equipment
If possible, remove the potential hazard; otherwise, cover or mark them in order to alert
other drivers on the worksite.
2.4.12 Post-trip Inspections

Equipment operators and drivers are expected to perform post-trip inspections on the
units. As indicated earlier, BJ Canada includes this as part of the Driver Vehicle
Inspection and Condition Report (Pre-trip form). The post-trip inspection includes the
following essential checks:
 fuel unit
 wash unit and battery components
 check for air leaks
 drain air tanks
 fill alcohol pot
 pull battery disconnects
Part of the post-trip inspection also includes reporting to the maintenance department any
equipment problems you may have encountered or noticed during the job. It is part of
your job duties to assist with any repairs as required.
2.5 ENVIRONMENTAL RESPONSIBILITIES

BJ Canada is committed to minimizing the impact of our operations on the natural
environment. This commitment requires the participation and dedication of all

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employees. It is everyone’s responsibility to ensure that his or her work activities are
conducted in a manner that will not harm the environment. If you are unsure of the
potential impact of a particular action or activity, do not hesitate to ask your supervisor,
manager, or a member of the QS&E Department for assistance. There is no penalty for
asking questions; we are all penalized if unsound practices occur.
2.5.1 Minimizing Our Effect on the Environment

The most critical aspect of our operations that may impact the natural environment is the
handling of chemicals and the wastes we generate. When improperly handled, many of
the products and chemicals we use can pose a serious risk to the environment and worker
safety. Even materials that are relatively safe to handle can pose a threat to the natural
environment. Following company procedures for handling chemicals, spill response, and
waste management are the most effective ways to protect the environment.
2.5.2 Waste Management

Under Canadian law, BJ Canada is responsible for its wastes “from cradle to grave”. This
means that we are responsible for any negative impact of our waste on the environment,
even years after the disposal. It is strict company policy that BJ Canada’s wastes and the
wastes generated by BJ Canada contractors be handled in the proper manner, and
disposed of only by properly authorized and licensed third parties.
“Waste” is defined as any material that is no longer suited for its initial purpose, and
includes materials that will be reused, recycled, or disposed of. A “Hazardous Waste” is
one that exhibits any of the following characteristics:
 ignitable
 flammable
 corrosive
 reactive
 toxic
 infectious

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Employees and contractor employees can expect to encounter all types of hazardous
wastes, except infectious. Refer to MSDS information or ask for clarification if you are
unsure if a waste is hazardous.
2.5.3 The Four R’s: Reduce, Reuse, Recycle, and Recover

BJ Canada manages its waste through application of the 4 R’s:
Reduce
Reducing the amount of waste we generate is the most effective means of waste
management. One of the largest sources of chemical waste is from unlabelled, partially
filled pails returning from the field. In order to minimize this type of waste, all pails shall
be labeled when they are returned to bulk plants.
Reuse
If a waste is produced, every effort should be made to reuse it. For example, if properly
labeled and uncontaminated, unused chemicals can be re-used.
Recycling
Recycling is the preferred option over disposal where it can be done in an
environmentally and economically sound manner. Any waste that cannot be reused, must
be examined to determine whether it can be recycled. For example, it is a BJ Canada
practice to recycle used motor oil, filters, and obsolete batteries.
Recover
If a waste cannot be reused or recycled, it may be recovered. For example, cleaning
solvents can be processed through filtration systems and recovered.
2.5.4 Environmental Rules

As an employee of BJ Canada, you are part of a company committed to minimizing the
effects of our operations on the natural environment. Our success as a company in

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protecting the environment rests, to a large part, in your hands. It is the day to day care
and effort of field operations that will determine in the long-term whether we have done
all that we can to protect the environment. It is important that you make every attempt to
comply with the following set of general environmental rules:
 attach proper labels to indicate the contents of all pails, drums, and containers
(including pails returning from work-sites and pails used to store waste)
 all containers stored outside must have a lid or be properly sealed
 do not mix hazardous waste with non-hazardous waste
 do not place hydrocarbons, antifreeze, or other hazardous chemicals into shop or
facility sumps
 consolidate partial drums to make full drums before disposal
 when possible, flush service equipment on location, and dispose
of the flushed fluids in a vacuum truck or a pre-approved
operating company tank or line
 flush hazardous residues at approved flushing facilities prior to entering a
maintenance facility for repair
 do not drain or flush equipment containing hazardous liquids on the ground or on
a lease (if the equipment cannot be flushed, contain residual liquids in pails when
disconnecting lines)
 keep facility yards free of chemical, oil, hydraulic fluid, and diesel spills
 report and clean up all applicable spills in the proper manner (consult the HSE
Resource Book for more detailed information)
 do not dump waste chemicals or fluids on the ground (use approved disposal or
flushing facilities)
2.6 EMERGENCY RESPONSE

BJ Canada has General and Facility Specific Emergency Response Plans (ERP’s). The
ERP’s provide guidelines to respond effectively to any foreseeable emergency that may
arise at BJ Canada facilities or during BJ Canada transport operations. The plans provide

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guidance and information when responding to an emergency situation, and are available
at your facility.
2.6.1 General ERP

The BJ Canada General ERP specifies:
 reporting/notification requirements
 response duties and responsibilities
 communications and emergency contact phone numbers
 response guidelines, which specify personal protective equipment requirements,
hazard controls, and procedures to follow when addressing specific types of
emergencies
2.6.2 Facility Specific ERP

The Facility Specific ERP’s compliment the General ERP's. The facility ERP’s include:
 local emergency contact numbers
 facility schematics which specify emergency meeting areas
 warehouse product lists
 neighboring business addresses and phone numbers
 contractor and rental service company listings and phone numbers for the
applicable area
2.6.3 Priorities in the Event of an Emergency

The order of priorities in the event of an emergency is:
1. the safety and well being of all employees and others
2. the minimization of damage to the environment, equipment, and facilities
3. recovery from the emergency and resumption of normal operations as expedient
as possible
4. effective reporting, investigation, documentation, and follow-up in order to
prevent a reoccurrence from the same basic or underlying causes

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Note: BJ CANADA’S HEADOFFICE EMERGENCY RESPONSE PHONE NUMBER

IS (403) 531-5151.
2.6.4 Basic Emergency Response Guidelines for Injuries

Seriously injured persons should only be moved if their life is threatened by a hazard. In
the event of a serious injury or fatality:
 suspend operations
 keep the injured person motionless and provide first aid if trained to do so (basic
first aid information can be found in the first aid guide located in the first aid kit)
 call or send for help
 if required, arrange for an ambulance or medical evacuation
 report the accident to the District or Facility Manager, Field Supervisor, or Safety
Coordinator
 direct available manpower to:
- secure the site
- ensure unimpeded access to the site for emergency vehicles
- direct emergency vehicles as required
- initiate the ERP
The first priority in any injury or medical emergency situation is to ensure the injured are
properly treated, and the danger of further injury is minimized. Transport any individuals
at the work site requiring treatment by a doctor or medical facility without delay.
In the event of a serious injury or near miss incident, the scene must not be disturbed until
the applicable authorities have granted permission. Exceptions where one may disturb an
accident scene include:
 attending to injured persons
 preventing further injury
 protecting property that is endangered as a result of the accident

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2.6.5 Emergency Response Guidelines for Motor Vehicle Accidents

Each BJ Canada’s vehicle should have a Vehicle Accident Booklet and a disposable
camera for taking pictures of an accident scene. In the event of a motor vehicle accident,
use the booklet as a guideline as well as the following steps:
 stop as close to the scene as possible without restricting traffic flow and
immediately shut off the engine
 turn on the four-way flashers if on a road or shoulder
 in the event of a rollover, disconnect batteries if safe to do so
 do not smoke near the scene
 in case of fire, extinguish if safe to do so
 care for the injured and provide necessary first aid
 arrange for appropriate emergency response personnel (police, ambulance, and
fire department)
 place reflective triangles 30 meters to the front and rear of the unit where they are
clearly visible to oncoming traffic (during darkness, place the triangles 75 meters
from the scene; on divided highways, triangles are only required at the rear of the
unit)
 contact the nearest base and inform the district or facility manager, field
supervisor, or safety coordinator of the accident
 obtain names and addresses of other parties involved, injured individuals, and
witnesses
 record license plate numbers, insurance information, and the names of other
drivers involved
 take required pictures and complete all required information as specified in the
Vehicle Accident Booklet that is kept in the glove compartment of the vehicle
 provide your name and address, license number, vehicle registration number,
company name and address, and insurance card information to anyone sustaining
loss or injury (if requested to do so, supply the information to a witness or a peace
officer)

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 record the names, badge numbers, and the home station of police officers who
respond to the scene (the attending police officers will usually provide you with a
copy of the police report, if it has been completed; attach it the accident report
forms, and request a copy of any statements given to police)
 if a fixed object or unattended vehicle is involved, attempt to locate the owner (if
you cannot locate the owner, leave a note giving your name, the company name
and address, and a brief description of what happened)
 cooperate with police and emergency response personnel
 do NOT discuss liability with anyone, and make no statements to anyone except
police officers, company supervisors, or BJ Canada insurance representatives
2.6.6 Environmental Spills and Releases

In the event of a spill/release, the first consideration is the protection of human life.
Do not attempt spill containment if it poses a health risk to yourself, your co-workers, or
others.
Yards and Leases

 move by-standers out of harm's way
 identify the spilled or leaking product
 use the required personal protective equipment as specified on the MSDS for the
product
 use a spill kit to contain, stop, or divert the spilled product from entering any
waterway, sewer, or spreading over a large area
 establish a repository (bin or drum) to collect and store rags, absorbents, and other
spill related materials
 report the spill or release to your supervisor as soon as possible, and provide the
following information:
- date, time, and location of the spill or release
- injuries incurred

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- product released, including product name and UN numbers from MSDS or

loading sheet
- estimated volume of release
- current status, and potential for additional danger and harm to people or the
environment
Spills/Releases on Roadways (Accidental Releases)

 keep people away
 reduce the degree of hazard by closing or blocking off the spill area
 do not discuss the liability with anyone
 notify and co-operate with the police, fire department, etc.
 stay on the scene until relieved by a senior employee
 notify the district manager at the nearest base or the applicable safety coordinator
 specify the call as an Emergency Response (Accidental Release) and relay the
following information:
- nature of the problem
- location of the problem
- amount and type of chemical
- whether it is a spill or a spill and vehicle accident
- injuries, if any
- what corrective action has been taken
- what agencies have been notified (fire, police, etc.)
 keep a log of all communications and actions
2.6.7 Basic Emergency Response Guidelines for Radiation Leaks

Take the following steps in the case of an accident, damage to a gauge, or if you are
uncertain about what to do:
 Cease work immediately.
 Evacuate and secure the area. Keep people at least 5 meters (approximately 16
feet) away from the densitometer until a radiation survey can be performed to

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determine radiation levels. The test must be performed after any incident that
may result in source damage. Guard and barricade (ribbon) the 5 meter zone. Do
not risk your personal safety to maintain the zone of control. The 5 meter control
zone is not to be dismantled until the leak test has been performed and the area
declared safe.
 Inform emergency personnel (police, fire, paramedics, etc.) of a possible radiation
leak and of the control zone requirements. Do not discuss possible radiation leaks
with the public at this time; simply keep them out of the control zone. Due to the
heavy construction of the instrument casing, a leak is unlikely; however, take all
necessary precautions until a leak test can be performed.
 Contact the radiation safety officer, district manager, field supervisor, or a
member of the QS&E department as soon as possible to inform them of the event.
These individuals will assist in making arrangements to have a leak test
performed.
 In the event that a radiation leak is confirmed, follow the procedures outlined in
the General ERP.
2.7 GENERAL REPORTING PROCEDURES FOR ACCIDENTS AND INJURIES

The reporting procedures for accidents, incidents, injuries, and illnesses are detailed in
the Health, Safety, and Environmental Resource Book. In the simplest sense, if you are
involved in an accident or receive an injury, you MUST report it to your supervisor or the
nearest base as soon as possible.
The company also participates in a Managed Care Program with the Workers
Compensation Board. Although the process of working through the various forms can be
complex, each base has a copy of the Managed Care Process supplied by the company's
Occupational Nurse. The purpose of this package is to outline the required procedures
and forms when reporting an injury or Short Term Disability. All employees who
experience incidents involving lost time, modified work, medical-aid injuries, or illnesses

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are required to follow the steps outlined in the Managed Care package. Your supervisor
or Safety Coordinator will provide you with assistance.
2.7.1 Reporting Procedures for Accidents or Incidents

All motor vehicle accidents must be reported to your immediate supervisor as soon after
the event as possible. If the supervisor is not present, report the occurrence to the
applicable manager, safety coordinator, or dispatch. In some instances, this may
necessitate a notification by telephone. Failure to report a vehicle accident or
environmental spill in a prompt manner may result in disciplinary action up to and
including termination.
2.7.2 Reporting Procedures for Injury or Illness

Report all work-related injuries and illnesses to your on site supervisor immediately
following the occurrence. If an injury accident occurs where the supervisor is not
present, report the occurrence to your manager or applicable Safety Coordinator. In some
instances, this may necessitate a notification by telephone.
2.7.3 Reporting First Aid and Non-Treatment Injuries

Report all first aid and non-treatment injuries to the applicable Safety Coordinator,
District or Facility Manager, or Field Supervisor immediately upon returning to the base.
First aid and non-treatment accidents or incidents with the potential for causing serious
injury or damage are treated as near misses, which means they are investigated to
determine:
 the immediate causes of the event, usually attributed to an unsafe act or an unsafe
condition (these are the hazards which were present immediately preceding and at
the time of the accident/incident)
 the underlying causes of the event, usually related to personal or job factors (these
can be classified as the real causes behind the symptoms or event)
When all the causes are known, the company can implement measures to prevent a
similar accident or incident from reoccurring.

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3.0 EQUIPMENT USED IN COILED TUBING

OPERATIONS
Coiled tubing components used by BJ Services consist of injectors, goosenecks, reels,
cranes, BOPs, and power packs. Figure 3.1 illustrates a typical "stack" of coiled tubing
equipment located on the wellhead.
Figure 3.1: Wellhead Stack

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3.1 INJECTOR
The coiled tubing injector is the major component of the coiled tubing
unit. The injector inserts and extracts the coiled tubing from the
wellbore.
The injector is equipped with two or more large hydraulic motors that are synchronised
by timing gears. These motors drive two large chains with blocks machined to match the
size of tubing used on the unit. The chains grip the tubing and push or pull it into or out
of the well.
The injector (see figure 3.1 below) is also equipped with an appropriate sized gooseneck
to allow the tubing to be run in and out of the well under pressure and to avoid excessive
damage to the tubing.
Figure 3.2: Typical Injector

The injector works as follows:
1. The tubing is transported down or up the wellbore by a pair of counter-acting
chains which apply firm pressure to the opposite sides of the tubing to keep it
firmly in place. One chain rotates clockwise, the other anti-clockwise.

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2. Gripper blocks attached to the inside of the chain and are curve shaped to match
the outside diameter of the tubing. Almost the entire outside area of the tubing is
surrounded by the gripper blocks, providing excellent grip.
3. The force on the chains is supplied by skate tension cylinders which press the
skates against the chains.
4. The chains are driven by one or more hydraulic motors. They are synchronized
with timing gears, preventing one motor from doing more work than the other.
Less chain skate tension is then needed which results in longer chain life.
5. As the chains rotate, the hydraulic skate tension cylinders apply constant pressure
to the skates. The gripper blocks provide friction between the chains and the
tubing.
6. The skate tension accumulator stabilizes fluctuations in hydraulic pressure due to
the movements of the chains. The stabilization prevents the chains from vibrating
excessively.
7. The purpose of the outside chain tension cylinders is to apply pressure to the
outside of the chains to take up any slack in the chains due to chain stretch.
8. The drive unit with all the cylinders, etc. is mounted on a subframe, which is
connected to the base of the injector. The subframe is supported on one side by
two hinge bolts and on the other by a weight indicator.
9. The purpose of the weight indicator is to monitor the weight of the string. It is
attached to the base of the injector. As the tubing is run into the wellbore or pulled
up, the weight of the tubing is transmitted to the weight indicator. If there’s a
problem, the weight indicator will show it immediately and the operator can take
action.
A front and side view diagram of a HR-440 injector, commonly used by BJ Services, is
illustrated below.

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Figure 3.3: HR440 Injector
3.1.1 Stuffing Box

The stuffing box is at the base of the injector. Its function is to isolate the well pressure
down the hole. The stuffing box is equipped with stripper rubbers that seal wellbore
fluids and gases inside the well. These rubbers can be replaced even during a well-
servicing operation. If you have to replace the stripper rubber, there is a ridge on the top
of the rubber for installation purposes.

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The pressure seal consists of a set of polyurethane packer inserts that are compressed
around the tubing by a hydraulic cylinder or piston. When the cylinder is pumped up, it
compresses the inserts inward against the
tubing providing a seal. You have to use the
proper size rubber inserts and brass inserts
for each size of tubing. The stripper pack-
off also contains a hydraulic circuit that has
a small accumulator which helps make up
small differences in chamber size due to
the tubing depleting the rubber elements.
The maximum working pressure for the Coiled

Tubing
stripper pack-off is 69 MPa (10,000 psi). Lower
Packing
Bushing
The maximum hydraulic pressure is 41.4
“M” Seals
MPa (6,000 psi). Do not apply too much
pressure to the cylinder. If you do, you can
deform the tubing.
Fi
gure 3.4: Stuffing Box
3.2 GOOSENECKS
Goosenecks aid in aligning tubing with injector heads. Before tubing can enter an
injector, it must be bent until it is vertical. This is accomplished by feeding the tubing
through a gooseneck or tubing guide. The gooseneck consists of a large steel track with
beveled rollers that bend the tubing until it is vertical. The larger the diameter of tubing,
the larger the radius of the gooseneck must be to properly bend it. If the radius of the
gooseneck is too small for a particular tubing diameter, the tubing will fatigue rapidly.

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Figure 3.5: Gooseneck
3.3 COILED TUBING REELS

Tubing reels are used to spool and unspool tubing. A side view of a reel showing the
various components follows:

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Figure 3.6: Reel Side View
Coiled tubing, when coiled up, is essentially a giant coiled spring, so it is very important
to have sufficient reel tension. This is provided by the reel drive motor and prevents the
tubing from uncoiling. If tubing is poorly spooled on the reel it can partially uncoil and
be damaged. Coiled tubing can also be damaged while being transported if the tubing is
not spooled tightly or if there are crossovers. This damage is the result of the tubing
rubbing against itself.
The purpose of the parts is as follows: A hydraulic reel drive motor is connected to the
crown gear by a chain drive (or a planetary gear box). To drive the reel, the reel drive
motor transmits a torque to the crown gear, which is attached to the center axle.
When the tubing is inserted into the wellbore, the reel drive motor applies a force which
opposes the reel’s rotation, slowing it down and, if necessary, stopping it. When the
tubing is pulled out of the wellbore, the motor applies more force causing the reel to
rotate in the opposite direction. This will wind the coil back onto the reel. The larger the
diameter of the tubing, the larger the core diameter of the reel must be to prevent damage
to the tubing.
To aid in spooling and unspooling coiled tubing, each reel is equipped with a worm gear.
The worm gear is connected by a series of chains and sprockets to a hydraulic motor. The
sprockets are matched so that the worm gear is synchronized with the rotation of the reel.
This so-called override system allows the operator to dictate the direction of the spooling
head on the worm gear. The override system, if used properly, ensures that coiled tubing
is always spooled uniformly across the width of the reel.

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The level wind allows an operator to move the spooler to adjust the angle of the coiled
tubing going toward the injector. It is very important to always have the tubing run in a
straight line from the reel to the injector. Even a small amount of deviation causes
inaccuracies in the depth counter and causes additional fatigue to the tubing.
The spooler, shown in the top of following diagram, is attached to the level wind. It
consist of a counter, counter air ram, electronic decoder, and a tubing brake pod.
The depth counter is located on top of the counter head as shown on the bottom diagram.
It consists of a mechanical counter and a digital encoder. They are both attached to a
counter wheel, which is forced against the tubing by the counter air ram. The air ram
assures that sufficient pressure is always applied to the counter wheel to prevent the
counter wheel from skipping or sliding on the tubing.
Figure 3.7: Counter Head

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For more information about reels and spoolers, see the Yard Spooler and Work Reel
Study Guide Manual (available from your district trainer).
3.3.1 Connecting Reels to Injectors

The following diagrams shows side views and top views of reels connected to injectors
with proper and improper tubing angles.
Figure 3.8: Side View: Proper Tubing Angle
Figure 3.9: Side View: Improper Tubing Angle

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Figure 3.10: Tubing Alignment through Injector
3.4 CRANES
See the Crane Safety Manual for basic information about safety, rigging, and job
procedures. This manual is available from your district trainer. Also remember that
registration in the government's Apprentice Boom Truck Operator program is part of your
Coiled Tubing EO1 requirements.
3.5 BLOW OUT PREVENTERS

The primary purpose of the blowout prevention system is to allow control of the well
whenever wellhead pressures develop. If this is to be achieved effectively, the system
must provide the following:
 a means of closing the hole with pipe in or out
 a means of releasing fluids under control
 a means of pumping fluid into the hole
 provide redundancy in case of failure

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It is important to realize that a blowout prevention system is only as strong as its weakest
component. For example a 35 MPa blowout preventer bolted onto a tubing spool rated to
21 MPa will only produce a system capable of handling pressures up to 21 MPa. In other
words, if service operations are to be carried out on a well with a wellhead rated at 35 MPa,
then the blowout preventers, spools, lines, etc. must be rated to 35 MPa.
BOPs are always installed on top of the well head, or the service rig BOP stack. There
are many types and sizes of BOPs. For small tubing sizes and bottom hole assemblies
use either a Quad ram or a Combi ram. The BOP is for well control only. You should
never use it for lubrication (as a device to rig up tool strings) because the blind ram
cannot close in case there’s a problem, or as part of a flow return line.
When they are closed, well pressure acting on the rear seals of the blind and pipe rams
aid in keeping them in the closed position. If the well pressure is great enough, the blind
and/or pipe ram may not open until the well pressure is equalized across them, as the
BOP system pressure is typically 16.5 MPa to 18.6 MPa (2400 to 2700 psi). There may
be 34.5 MPa (5000 psi) on the wellhead but it will only take a fraction of the system
pressure to close the rams.
3.5.1 Quad-Ram BOP

A Quad-ram BOP is shown in Figure 3.11 below. As the name suggests, the BOP has
four sets of rams. From bottom to top they are pipe rams, slip rams, shear rams, and blind
rams.

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Top
Equaliz
BLINDS
ing
Kill Port
SHEARS
Valve
Bottom
SLIP Equalizing
Valve
PIPE
Figure 3.11: Quad BOP
Pipe Rams
Pipe rams are the bottom set of rams that serve to seal around the tubing, thus isolating
the wellbore pressure below the rams. The pipe ram puts a positive seal around the pipe
keeping the wellbore pressure below it. This allows you to change the stripper pack-off
inserts or remove the injector while the tubing is in the wellbore.
Slip Rams
Slip rams are the third set of rams that serve to hold the tubing securely in place in the
event of injector failure, stripper pack-off box failure, or above ground tubing failure.
Shear Rams
The shear ram is used in the event that you need to cut the tubing.
Blind Rams
The blind ram allows you to close and seal the wellbore, without the use of coiled tubing.

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If there’s anything obstructing the blind ram, it won’t seal.
Basic Ram Operation

Ram-type preventers derive this name because the closing elements are two rams, which
move from the retracted position clear of the bore into a position where they seal the
hole. The rams operate in pairs from opposite sides of the hole, and when closed they
shut off the space below them. The rams are closed by means of hydraulic pressure that
is applied to pistons in the preventer assembly. Once closed, the rams can be locked by a
hand wheel, or by an optional hydraulic locking unit. In the event of a hydraulic system
failure, the rams can be closed and locked manually unless they are equipped with
hydraulic ram locks.
Once the rams in a hydraulic preventer are closed, they can be opened only with
hydraulic pressure. There is no means of opening the rams by hand. Therefore each
preventer is equipped with a closing line and an opening line; in other words, it requires
two hoses to operate the ram.
An
important
feature of
ram-type
preventers
is that they
are

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designed to allow wellbore pressure to reach the back side

of the rams, thus helping to hold the rams closed. In most
designs, this pressure is sufficient to hold the rams closed
without assistance from the closing line hydraulic system.
Another feature of ram-type preventers is the direction of pressure seal. Most are
designed to hold pressure from the lower side only. This means that the preventer will
not seal if it is installed upside down, and it will not pressure test from the top side. For
this reason, care should be taken to ensure that the BOP is installed properly. The
manufacturer's nameplate
should be right side up, and
if the preventer is equipped
with side outlets, they
should always be located
below the rams. It should be
noted that ram type
preventers must always be
pressure tested from the
bottom side.
Figure 3.12: Quad BOP
3.5.2 Combi BOP

As shown in the following diagram a Combi BOP has two sets of rams. The bottom set
controls the tubing and slip functions. The top set controls the blind and shear functions.

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Figure 3.13: Combi BOP
3.5.3 BOP Control System

The BOP controls are in the operating cabin or on the operators panel (on shallow hole
units). The hydraulic oil supply system has an accumulator system. An accumulator is
shown in the following diagram.
Figure 3.14: Accumulator

The purpose of the accumulator is to provide BOP control in case there’s a hydraulic
failure. The number of accumulators being used depends on the size or oil volume of the
BOP actuating rams.
As shown in the above diagram, inside the accumulator bottle is a rubber bladder that
contains compressed nitrogen. The size of the bottle determines the quantity of nitrogen
stored. The nitrogen serves as a reserve energy boost system as follows:

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 When the accumulator system is operating, oil is pushed into the accumulator
bottles compressing the nitrogen to pressures ranging from 16.5 to 18.6 MPa
(2400 to 2700 psi).
 In the event of an hydraulic failure, there is enough oil and pressure in the bottle
to operate all the BOP functions against wellbore pressure at least one and a half
times.
3.5.4 Annular Preventers

The purpose of an annular preventer is to seal off the tubing and other objects protruding
from the wellbore. It conforms to any size. It is similar to a stripper pack-off in many
ways, but is used mainly when working in large bore holes. It is put between the BOP and
stripper pack-off. The drawing below illustrates the Hydril.
Figure 3.15: Hydril Annular Preventer

As shown in the diagram above, the annular preventer contains a large rubber bag that is
pushed out into the wellbore when hydraulic pressure is supplied. When it touches an
object in the wellbore, the bag quickly surrounds and seals it. If there is no object in the

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wellbore, the bag will completely close and seal the wellbore. The Hydril, like the Quad
ram or Combi, also uses well pressure to help keep the bag closed.
3.5.5 The Industry-used Annular BOP

Like the Hydril BOP, the Annular BOP contains a bag that can be pressurized to seal off a
wellbore. But unlike the Hydril it is designed to seal off tubing in a wellbore. It also is a
sealed system and wellbore pressure cannot be used to help close it. The OD of the tubing
must not be less than 19.1 mm (3/4") for an effective seal.
As shown it has an hydraulic injection port to close the element. It also has a 2” (5.1 cm)
line pipe flow port for producing from the annulus. It can also be used to pump kill fluid.
This type of BOP is typically used on low

pressure wells with less than 14 MPa (2000
psi) because it needs approximately 3.5
MPa (500 psi) pressure over well pressure
to effect a seal. For example, if the well
pressure is 7 MPa (1000 psi), a pressure of
10.3 MPa (1500 psi) is needed to provide a
proper seal. As the typical BOP system
pressure is 16.6 to 18.6 MPa (2400 to 2700
psi), they are only used on low pressure
wells.
Figure 3.16: Annular BOP

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3.6 POWER SYSTEMS AND CONTROLS

To operate the hydraulic equipment on a coiled tubing unit, a proper power source and
operating station (cabin or council) is required. The hydraulic power is typically
generated by the unit’s engine, which drives hydraulic pumps. Sometimes another source
is used, for example a power pack.
All the pumps draw oil from a common reservoir located on the unit. The equipment uses
either an open loop or a closed loop system. A open loop system does not circulate the
hydraulic fluid in a loop, whereas the closed system does.
All of the circuits have high and low pressure oil filters for cleaning purposes. The
hydraulic oil is cooled with an air-cooled heat exchanger located on the unit.
3.6.1 Operating Cabin

The operating cabin/council is the control center for all coiled tubing applications. It
contains all the controls for the hydraulic pumps and the well control system. Most
cabins/councils also contain a data acquisition system for monitoring all activities.
The injector is controlled with a bi-directional stick and two pressure relieving valves.
With the stick you can control the amount of oil going to the injector. This controls the
speed of the injector. With the relieving valves, or Denison valves, you can control the
pressure of the supplied oil. By setting the pressure to a certain value you can restrict the
pull or push to a desired limit. Relief valves that are not set properly can cause damage
to the equipment.
The reel is controlled by a pressure-relief valve. The units that run the larger tubing have
considerably more hydraulic power. The relief valve controls the amount of back pressure
the reel drive motor receives. It should be less for running the pipe into a hole and more
for retrieving the pipe from a hole to keep the tubing tightly wrapped on the drum.

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The control panel also contains the controls for the BOP and for the annular BOP
functions. They include Open/Close and neutral positions. The hydraulic fluid and
pressure needed to activate the accumulators is not controlled by the operator but
automatically provided by the system.
The stripper pack-off controls consist of a bi-directional valve and a pressure relief valve.
With the bi-directional valve you can compress or decompress the inserts and with the
pressure relief valve you can determine the applied pressure.
The data acquisition system consists of either on-board or remotely mounted computers.
All of them use pressure transducers to determine various outputs, such as pressure,
weight, and temperature. Not all coiled tubing units are equipped with data acquisition.
The purpose of the frequency encoder on the depth counter is to digitally display the
running speed and depth of the coiled tubing as it enters or leaves the wellbore.
Frequency inputs are also used to monitor pump rates from other units.
3.7 WELLHEAD CONNECTIONS
3.7.1 Swages
In order to rig up to a well head, either a swage or a flanged connection is used. When
using a swadge it is threaded into the top of the well head. Either a BOP or a Flow Tee is
then connected to it and is held in place by a hand union.
If a flanged connection is used, it is placed below the BOP, hand sealed, and hammered
tight. A flanged connection is shown in the drawing below.

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Flange Connection
Swage Connection
Figure 3.17: Flange and Swage Connection
3.7.2 Flow Tees

A Flow Tee is used when returns will be coming back from the well and the customer
does not have a return system in place or they want
to use ours. A drawing of a flow tee showing the
return flow port is shown on the left. The Flow Tee
is always placed under the BOP stack.
Figure 3.18: Flow Tee

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3.8 PREVENTING DAMAGE TO COILED TUBING

During the course of a job, coiled tubing is subjected to large stresses due to frequent
bending as the tubing is unspooled off the reel, straightened, bent over the gooseneck and
straightened again when going through the injector chains into the wellbore and vise
versa. Since most coiled tubing is composed of high strength, low alloy steel, it wears
out, or fatigues, with time and number of cycles used.
To reduce these stresses as much as possible it is very important that you unspool and
spool coiled tubing only when the tubing runs straight from the reel to the injector,
making no angle at the spooler.
Treating pressures inside the tubing, while cycling, also greatly increases the rate of
tubing fatigue. For instance with no pressure in a pipe you can expect to get about 100
cycles over the gooseneck before failure but with an inside pressure of 35 MPa (5076 psi)
you may only get 50 cycles. BJ Services limits treating pressure to a maximum of 28
MPa (4061 psi) at the rotating joint.
In addition to damage that can occur as a result of improper operation of the reels, high
well temperatures, and treating pressures, there are many other factors that fatigue or
wear out the tubing. Some of the major ones are listed below:
 coiled tubing should always be properly aligned in the gooseneck
 sand clean-outs are very corrosive, especially when using nitrogen in a gas well as
there is no fluid to help protect and lubricate the tubing
 acid jobs are very corrosive, so it is important to use the correct type of metal
inhibitor
 high wellbore temperatures when H2S is present can be very damaging to tubing
 injector problems such as broken bearings or too much chain tension can damage
tubing
 tubing can be gouged or damaged by wellbore offsets

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 if the annular or wellbore pressure is 10 MPa (1450 psi) greater than the tubing
pressure, it can cause the tubing to collapse

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4.0 DOWNHOLE TOOLS

Downhole tools are specialized tools, designed for a specific job, which are attached to
the end of coiled tubing. The following are downhole tools commonly used by BJ
Services.
4.1 JET TOOLS

Jet tools are used when a powerful jetting action is required. They are used for de-scaling
and removing sand and other fill obstructions from tubing and casing. There are many
different jet tools and each one is designed for a specific job. Examples of some jet tools
are shown below.
Figure 4.1 shows a jet tool typically used for removing sand or other fill from tubing and
casing having an OD of less than 139.7 mm (5.5”). It has only one jet opening, which
points down. Figure 4.2 illustrates a jet tool, which is typically used for cleaning casing
larger than 139.7 mm (5.5”). It has one jet opening pointing down and four at a 45-
degree angle.
Figure 4.1 Figure 4.2

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Figure 4.3 shows a jet tool used for de-scaling hydrogen sulfide from tubing and casing.
It has one jet opening pointing down and several pointing sideways. The tip of the jet
starts a hole in the obstruction then the ones pointing sideways clean it out.
The de-scaling process is like first drilling a

pilot hole and then using a larger bit to drill
the final hole. The surface area of the holes in
this nozzle is equal to the coiled tubing size.
This maximizes the pressure at the nozzles.
Figure 4.3
4.2 WASH TOOLS

Wash tools produce very powerful fluid jets and are used to wash perforations, for
spotting cement, or density-layering in fluids. Figure 4.4 shows an example of a wash
tool. It has seven jets, six at a 90-degree angle to the tubing and one at its tip.
Figure 4.4
4.3 CHECK VALVES

Check valves are used to prevent well fluids and gases from flowing to the surface during
a coiled tubing job in the event that the tubing at the surface develops a leak. They are
installed on the end of the tubing, for safety always in pairs, as part of well control.

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There are many different types of check valves available. BJ Services uses ball and seat
check valves and flapper check valves. They are run in a tandem configuration or in
two’s.
4.3.1 Ball and Seat Check Valves

A ball and seat check valve consist of a body, steel ball and cage. The cage is used to
keep the ball from sealing against the bottom of valve body during pumping operations.
When pumping stops pressure from the wellbore forces the ball up so it seals against the
upper seat.
4.3.2 Tandem Check Valves with Jet Tool and Cold Roll Connectors
The following drawing shows how various downhole tools may be connected. A jet tool
is on the left, two check valves are in the center, and a cold roll connector (described
later) on the right.
Figure 4.5: Tandem Check Valve
4.3.3 Double Flapper Check Valves

A double flapper check valve consists of a body, which contains two spring-loaded
flappers. The springs keep the flappers closed until pumping starts or continues. As soon
as the pumping stops the flappers close.
Flapper check valves are used mostly in conjunction with hydraulic disconnect tools
(described in Hydraulic Disconnects below). The shear ball that operates the disconnect

Page 62
tool can be pumped through a flapper check valve and this will allow well control to be
maintained after disconnecting from the bottom hole assembly BHA.
Figure 4.6: Double Flapper Check Valve
4.3.4 Double Dart Check Valve

A Double Dart Check Valve is used on Coiled Tubing tool strings that are required to
have a slick, slim O.D. These types of strings are usually used for simple
clean-out operations. The O.D. is limited to the size of the coiled tubing
being used.
The tool consists of two darts in tandem which allow flow from the
coiled tubing to the annulus but are pushed back onto their seats should
there be any back flow. This prevents the well from producing up the
coiled tubing if there is a break in the coiled tubing at surface. Activation
balls cannot be pumped beyond the darts.
Figure 4.7: Double Dart Check Valve

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4.4 CONNECTORS
Connectors are used to connect check valves and light BHA to coiled tubing or for
joining tubing. There are several different types of connectors available. An example of a
cold roll connector, tubing-to-tubing connector, and dimple connector is shown below.
4.4.1 Tubing End Connectors

Tubing end connectors are either inline, dimple, or outline connectors.
Inline Connectors (Roll-On Connectors):

Roll-on connections are used to attach tools to the bottom of the coiled tubing string. Be
sure to use the correct roll-on fitting for the wall thickness and size of tubing being used.
Also make sure that you use the right size of roller reel to apply the roll-on fittings.
The tubing needs to be sized to fit the roll-on

fitting and the lip from where the cut was made
as well as the weld seam must be removed so that
the O-rings do not get cut.
This type of connection can have threads for

attachment to tools or act as a double roll-on for
splicing a string of coiled tubing in the event of a
break when pulling out of the hole. The double
roll-on should only be used in an emergency to
spool tubing onto the reel.
Figure 4.8: Roll-on Connector

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Dimple Connectors
Dimpleon  Connector is the BJ recommended connector. It is used the same as the roll-
on connectors; however, it is reliable in high torque or H2S environments. This
connector also has a larger bore hole than the rool-on and is re-useable.
Figure 4.9: Dimpleon  Connector
Outline Connectors (External Grapple Connector):

This connector uses a set of grapples outside of the
tubing to secure itself to the coiled tubing. An external
grapple is an extremely strong connection when properly
installed: the harder the pull, the tighter the grapples bite
into the walls of the tubing.
Two of the drawbacks to this type of connection are the

cost and the fact that it cannot be run through an injector
and stuffing box, since it increases the OD of the tubing.
If this connection is made up below the injector and
stuffing box, it can be run with no loss of flow area
through the tool or tubing at the connection.
Figure 4.9: External Connector

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The tubing needs to be cleaned thoroughly, removing any oxidization from the pipe to
allow for a good seal from the O-rings and grapples.
4.4.2 Cold Roll Connectors

With this connector you typically connect check valves or light BHAs to coiled tubing.
To make the connection you first insert the
cold roll connector into the tubing. Then, by
using a pipe roller you force the coiled
tubing into the three groves of the cold roll
connector.
Figure 4.10: Cold Roll
4.4.3 Tubing-to-Tubing Connectors

This cold roll connector is used for joining two sections of tubing. It is often used for
retrieving tubing from a well or for
connecting tubing before spooling.
This connector must never be run
inside a well.
Figure 4.11: Tubing Connector
4.5 HYDRAULIC DISCONNECTS

A hydraulic disconnect is a safety device connected to a BHA that allows the tubing to be
disconnected in the event that it becomes stuck.
Figure 4.12: Hydraulic Disconnect

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To disconnect, a steel ball is circulated through the tubing to the disconnect. Once the ball
reaches the disconnect, it rests on the sliding seat or piston mandrel of the disconnect.
Then pressure is applied until the shear screws shear, allowing the piston to
move down. This releases the coiled tubing from the BHA.
4.6 CENTRALIZERS
Centralizers are used, as the name implies, for
keeping the BHA in the center of the casing or
tubing. They usually have bow springs that are
collapsible, allowing the centralizer to pass
through small IDs. The bow springs can be
hydraulically or spring operated.
Centralizers are also often used for retrieving

downhole tools and in fishing operations.
Figure 4.13: Centralizer

Page 67

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5.0 OPERATIONAL PROCEDURES FOR COILED TUBING
5.1 REQUIREMENTS OF THE JOB

Two pieces of information are vital in preparing for any coil tubing operation. These are
briefly discussed below.
1. An evaluation of the physical characteristics of the well.

A well profile, indicating the well's specific characteristics (vertical or horizontal,
production tubing, length of casing, open hole size and length, stresses expected
on the coil), will be provided for every coil tubing operation. For example, if the
well is horizontal, a CIRCA computer simulation must be run to:
a. determine if the job can be performed effectively
b. calculate injection rates, pressures, bottom up times throughout the entire
well
2. The type of job that BJ Canada has been contracted to perform.

The precise nature of the job is also required by Coiled Tubing Equipment
Operators in helping them to adequately prepare for a job. This information will
enable Equipment Operators to prepare their trucks and coil tubing units for
particular jobs.
5.2 PRE-JOB CONSIDERATIONS

There are a number of items that require your attention before you leave the base to travel
to the job location. Use the following as a checklist to ensure you are properly prepared:
 arrive at work mentally and physically alert
 perform a complete pre-trip on the unit
 ensure your PPE is in good condition, and meets the requirements for the job
 pack clothing that suits the weather conditions
 ensure all required equipment is loaded and secure on the unit

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 ensure you have your driver's logbook, and that it is current

 ensure all paperwork is in order (loading tickets, MSDS, etc.)
 position placards on the unit, if required
 clarify directions to the job location
 assist the service supervisor as required
The duties and responsibilities of Coiled Tubing Equipment Operators at the base in
preparation for a coil tubing operation are listed below:
1. Ensure that the following tools are on the units:
 tubing cutters
 rollers
 drift
 dye grind
 pipe wrenches
 hammer
 proper size polish rod clamps
 complete set of hand tools
 ladder
 spare stripper rubbers
 complete range of nozzles & no-go's
 boss tool kit
 double flapper check valve kit
 standard check valves
These items are used in the assembly of tools at the end of the coil.
2. Ensure that adequate supplies of methanol are on the unit if pressure testing with
water in the winter. Inhibitors may also need to be transported to the site.
3. Ensure that spare check valves and the correct flanges are on the units.
4. Ensure that an adequate length of coil tubing is onboard the coil tubing unit. This
will be determined by the well profile characteristics.

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5. Where required, arrange for a fire truck and shower unit to be present during the
job.
6. Check hydraulic motors.
7. Check all hose fittings and connections.
8. Pressure test all tie-in valves on the reel when the tubing string is changed.
9. Ensure that the rotating joint on the reel is adequately greased.
10. Service injector head and check roller for wear.
11. If night work is required, ensure adequate lighting will be available
12. B.O.P.’s should be cycled and tested at shop. Riser lengths should be tested
regularly to ensure service-ability
13. Each employee must ensure that his/her P.P.E. is in good condition and appropriate
for the particular job assignment.
14. A daily log must be kept by the driver of each motor vehicle being used in a field
operation.
15. A pre-trip inspection must be completed for each unit that will be used in a field
operation.
16. Ensure that all specific equipment used in coil tubing operations is included. For
example, stripper rubbers and O-rings needed to be carried as spares.
5.2.1 Driving to the Work Site

Module 2 of this manual reviewed the basic guidelines to follow when driving BJ
Services Canada units. It is your responsibility to understand these guidelines clearly,
and to practice them on a daily basis.
5.2.2 Positioning Equipment on the Lease

When you arrive at the job location, stop your unit before entering the site and wait for
further instructions from your supervisor. Do NOT drive onto the job site before the
supervisor determines the desired position for your unit. There are a number of safety
guides that apply every time BJ Canada equipment is spotted on a job site.

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The coil tubing units should be parked at the edge of the lease until the Service
Supervisor determines precisely where they are to be located. Normally the crane truck
is spotted first. It should be located as close as possible to the wellhead in order to take
full advantage of the crane's lifting capabilities. The coiled tubing unit should be spotted
next. To reduce the risk of property damage or personal injury in the event of an
accident, always attempt to locate the reel unit:
1. upwind of the wellhead
2. in such a way that the wellhead wing valve is facing away from the unit
3. in such a way that its rotary joint is pointed away from other units and equipment
R IG T A N K
N IT R O G E N o r
F L U ID P U M P E R
REEL TRUCK TRUC E R IG
W ELLH EAD
K
SAFE
CRAN
AREA
Figure 4.6: Typical Coil Tubing Jobsite
5.2.3 Pre Rig-Up Meeting

Prior to actually rigging up, BJ Canada's Service Supervisor meets with the customer's
representative to:

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1. confirm that the Service Supervisor's well profile matches the customer's well
profile
2. determine if the well is "alive" or "dead" (sour or sweet)
3. determine if pressure needs to be bled off or if testers are going to bleed to the
closed system
4. determine if BJ Canada is supposed to swage or flange into the wellhead.
When all personnel, service units, and equipment have arrived at the site, the supervisor
in charge of the jobsite conducts a pre-rig-up meeting. You will need to attend this
meeting dressed in appropriate PPE. The purpose of this meeting is to ensure that the
proper procedures will be followed in preparation for and during the rig-up, pumping the
job, and the rig-down procedure. Topics that will be covered at this time include:
1. an overview of the rig-up procedure, pumping the job, and the rig-down
2. assignment of specific tasks to BJ Canada personnel during the rig-up procedure
3. proper use of safety and fire fighting equipment
4. the required PPE
At "sour" locations, the safety supervisor of the site will outline the special equipment
and procedures that are required.
5.2.4 Rig-up Procedures for Coiled Tubing Operations

The following rig-up procedures apply to coiled tubing operations. It is important for
you to become familiar with the safety aspects before you attempt to perform the
procedures.
5.2.5 General Safety Guide for Rig-up Procedures

Rig-up procedures refer to the activities you perform in preparing to pump the job. The
following general safety rules apply to all job-site activities. It is your responsibility to
learn these safety rules, and to incorporate them into your every-day work. In other

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words, develop safe working habits. For more detailed information concerning safety,
consult the HSE Resource Book.
a) do not attempt to lift or move treating

iron alone (see Figure on the right)
b) when making up unions, railway-
style hammering is not permitted
(this means no double hammering)
c) use caution when working on uneven
ground or where snow, ice, or mud
conditions make the ground surface
at the worksite slippery
d) exercise caution when working on cat walks, since they are made from steel and
can get very slippery
e) be alert when working around moving or rolling equipment and pipe to avoid
pinching fingers
f) always pay attention when pipe or equipment is being hoisted above your head
(e.g.: pipe-racks)
g) do not attempt to rig-in when other workers are running casing
h) when pumping flammable fluids, do not place discharge lines under units
i) place radioactive warning signs in any area where nuclear gauges are being used
j) position all gasoline and diesel engines without positive air intake engine shut off
devices a minimum distance of 25 meters from well heads, open flammable fluid
storage tanks, or other sources of ignitable vapor which could cause a fire or
explosion
k) always check with your supervisor or a more experienced employee if you are in
doubt about any aspect of your job duties
Safety Guides
When locating equipment on a lease, the adhere to the following guidelines:

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 check with the supervisor to determine if a particular unit position is required

 take your time and drive slowly onto the lease
 watch for and avoid holes, anchors, overhead power lines, guy lines, lines on the
ground, or any other debris that may be on the site
 always use a guide when backing the unit into the correct position
 park away from the main traffic on the lease (if possible)
 locate upwind from the wellhead (if possible)
5.2.6 Rigging the Crane Unit

The hydraulic crane unit is used to hold the blowout protector and injector at the
wellhead during:
1. rigging-in
2. running into the well
3. treating the well
4. pulling out of the well
5. rigging out
The cranes are manufactured in various configurations and load ratings. Equipment
operators should read the manufacturer's specifications to determine the proper operating
procedures for each crane unit.
When the crane unit is "spotted" at the wellhead, the Service Supervisor will direct the
EO employee to:
1. block the unit's wheels
2. unhook the crane's hook from its travel position
3. put outriggers down
5.2.7 Preparation Of Reel Unit

When the reel unit is "spotted" at the wellhead, the Service Supervisor will direct Service
Operator employees to:
1. set maxi brakes

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2. block wheels
3. engage rear power and PTOs as required
5.2.8 Installation Of Blowout Preventers (BOP)

The Blowout Preventer (BOP) is the primary safety apparatus designed to prevent the
uncontrolled release of wellbore fluids or gases. While BOPs are connected to the
wellhead during coil tubing operations, they are essentially part of the reel unit. That is,
the rams of BOPs are activated by hydraulic hoses connected to the coiled tubing unit.
Figure 4.7: BOP Stack
Test the performance of the BOP before it is connected to the wellhead:

1. Lift the BOP from the reel unit with the crane.
2. Connect all hydraulic hoses from the coil tubing unit to the BOP.
3. Visually check the operation of the BOP by cycling its rams as indicated below:
 Shut the Tubing Rams to ensure that they sit tightly against the test piece of
tubing.
 Shut the Slip Rams to ensure that they close properly on the test piece of tubing.
 Shut the Blind Rams (without tubing) in the BOP to ensure that the blinds are
totally together to seal against an open hole.

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Connect the BOP to the wellhead in the following manner:

1. Wear appropriate breathing apparatus where wells are "sour". Check the well for
leakage at the master valves.
2. Shut the well in by closing the top master valve.
3. Bleed down the wellhead pressure. Ensure that the wellhead pressure is at zero.
4. To connect/secure the BOP to the wellhead either:
(a) Take the top cap off and swage it into the top of the wellhead, or,
(b) Take the existing wellhead top (flange) off and set the BOP with a changeover
spool on top of the wellhead. Place a new ring gasket between the two
flanges. "Button up" the flange to the wellhead in a manner similar to the way
wheels are put on a car. To do that, turn opposites until all bolts are tightened
loosely. Then systematically tighten bolts gradually one after another until the
flange is properly secured. To avoid leakage, the flange must be evenly seated
on both sides.
5. Place the B.O.P. over the wellhead. Never place B.O.P. over wellhead unless ready
to make final connection.
6. Close the Blind Rams on the BOP. This is a safety measure to prevent any leakage
of gas into the immediate environment should the wellhead master valve have a
slow leak or be accidentally opened during the remainder of the rig up process.
7. If B.O.P.s are left on wellhead overnight in this manner, put night cap with needle
valve on top connection.

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5.2.9 Rigging Up
The next step in the rig-up process is to place and secure the injector onto the BOP. The
tubing injector (see Figure 4.8 below) forces the coiled tubing into the well and pulls it
from the well on the coil tubing jobs. It has two large hydraulic powered motors, both
synchronized through the use of timing gears. These motors drive two large chains
(inside and outside chains) with blocks machined out to the diameter of the tubing being
run on the job. Through
the use of chain tensioners,
these chains grip the
tubing and push or pull it
in or out of the well. The
injector is equipped with
an appropriately sized
gooseneck and stuffing
box to allow the tubing to
be run in and out of the
well under pressure. The
procedure for installing the
injector is outlined below.
Figure 4.8: Injector onto BOP
Procedures
1. Pick up the injector with the crane. You must be a certified crane operator or a
registered apprentice to complete this task.
2. Ensure that all cables and quick-connect hydraulic hoses are properly connected.
3. Remove travel blocks and lower Injector to the load cell (pin in place).
4. Lift (with crane) and pin gooseneck into place. Some goosenecks are deployed
hydraulically.

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5. Examine "skates" and rollers closely to make sure that they are all in the correct
position.
6. Cycle chains (in outside direction) to ensure that they will operate properly (see
outside chain tension).
7. Set down support legs
8. Connect the "snake" to the threaded fitting in the end of the coil tubing.
NOTE: A "snake" is a wire cable with a threaded fitting that is connected to an
existing threaded fitting in the end of the coil tubing. The "snake" is used to
bring the coil tubing through the injector.
9. Remove stripper rubbers from the stuffing box to prevent "bird caging" the wire
cable "snake".
10. Remove the clamps restraining the coiled tubing.
11. Run the "snake" slowly through the injector until the coil tubing end comes down
through the stuffing box (have observer monitor the process to prevent damage).
12. Disconnect the "snake" and run coil tubing back up above the stuffing box until it
is just below the chains.
13. Install a tapered nozzle on the end of the coil tubing to prevent damage to the
interior surfaces of the stripper rubbers.
14. Install new stripper rubbers in the stuffing box. The stripper rubbers seal the
wellbore fluids and gases in the well.
15. Cut the existing "roll-on" off. To do that, cut off the end fitting that was on the coil
tubing from the previous job. Then install a new one. This length may vary from
one to ten meters. Drift and dye-grind the tubing.
16. Install cold-roll fitting on the tubing.
17. Install double check-valves, end fittings and straight bars (after a visual check to
make sure darts are new and properly installed).
18. Run tubing back up into the injector so that the end fitting is just inside the bottom
of the stuffing box. Complete a pull test on end connection. After pull test
complete a visual inspection on threads.

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5.2.10 Connecting the Injector to the BOP's:

1. Rig the injector onto the BOP with a 5,000 or 10,000 Bowen connector, or a
quick latch.
2. Cross-chain down the back and front to stabilize the installation.
3. Set stabilizer legs down the front and back.
5.2.11 Pre-Job Safety Meeting

The Service Supervisor conducts a pre-job safety meeting for all BJ Canada employees,
as well as any other contractor employees on location and involved in the work. Pre-job
safety meetings are held prior to beginning all field-related jobs, at the beginning of each
shift, prior to performing any job that may be unfamiliar to employees performing the
work, and whenever there is a change in job scope. The purpose of this meeting is to
ensure that all personnel on the work site are aware of the hazards that may endanger
personnel and equipment. These meetings include the following topics:
 outline step by step job procedures
 identify potential hazards and procedures to control the hazards (e.g. H2S, high
pressure, oxygen deficiency or toxic atmosphere, hazardous chemicals, flammable
fluids)
 define pressure limits for testing and treating
 give instructions for pressure testing
 instruct on use of personal protective equipment
 outline the duties of each person during the treatment, including equipment
operation, mixing of chemicals, operation of valves, bulk delivery, etc.
 instruct on emergency procedures and, if applicable, allow paramedics, firemen,
or safety shower attendants to describe their emergency procedures
 define the escape route in the event of an incident or an H2S, CO2, N2 release
 identify the assembly and smoking area
 instruct personnel not required for the job to remain in the safe area
 delegate individual assignments; for example, first aid attendant, an individual to
conduct a head count in the safe area in the event of an incident

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 discuss emergency kill procedures, who is responsible for the control valves, and
who is responsible to close tank valves in the event of an incident
 explain fire extinguisher placement, discuss fire fighting assignments and
readiness of fire trucks
 review the safety requirements, expectations, procedures, and controls for the job
If you have any questions or concerns regarding the job operation or individual
assignments, discuss them at the pre job safety meeting. Remember that you need to
understand the procedures before the job starts.
5.2.12 Procedures To Control The Hazards:

 The coil tubing unit shall not be left unattended while the lubricator/injector head
assembly is connected to the well head. The hydraulic may seep and the weight
of the injector head will then be fully on the wellhead. The injector is often
removed from the wellhead and securely fastened on the ground. A "night cap" is
often placed on the BOP's after the injector is removed from the wellhead. Box
and pin protectors should be installed when pulling and standing back tubing.
 The area between the pump or the tubing reel and the wellhead shall be avoided
until the entire job is completed. This 10-15 meters is a danger area for any
equipment malfunctions.
 Appropriate warning signs shall be posted.
 Personnel shall be forewarned that a failure can still occur and the potential
danger shall be avoided.
 High pressure in-line injectors are run close to the wellhead to minimize damage
in the event of a blow-off. In such a case, shut down equipment and move to a
safety area.
 The coil tubing BOP stack shall have a "kill line" connection. This is not to be
used as a circulating line at any time. The "kill line" connection must include a
valve and pressure indicator to register wellhead pressure readings.

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 Fluids must be removed from reels following a coil tubing operation. Service
operators do this by allowing the fluid to "flow back" from the tubing into above
ground storage tanks or rig tanks at the worksite. In the event of a spill, follow
the procedures outlined above.
5.3 JOB EXECUTION PROCEDURES

Nitrogen coil tubing clean out jobs use nitrogen during pressure testing. Nitrogen
pressure tests can be performed for all jobs involving coiled tubing.
The following rules apply to all coiled tubing pressure tests regardless of the exact nature
of the job:
1. While running into the well, a differential pressure across the coiled tubing shall
not exceed the burst or collapse rating of the coiled tubing.
2. The check valve shall be back pressure tested to 7 mPa prior to running into the
well.
3. Box and pin protectors should be installed when pulling and standing back coil
tubing; that is, protection of all tool connections is vital.
4. Pressure tests shall include the following coil tubing components:
 reel and plumbing
 open/close valve
 tandem tubing check valve
 isolation valve
 rotary swivel
 coiled tubing
 BOP stack
 flow tee and valve
 stuffing box
 any downhole equipment used in the coil tubing job
 all surface lines including return line

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The specific duties and responsibilities of coiled tubing operators, when pressure tests are
conducted on coil tubing jobs, include:
1. ensuring that the BOP controls are in open position
2. setting the outside chain tension to the manufacturer's specification
3. setting the inside chain tension as per specifications
4. increasing stuffing box pressure as required
5. setting depthometers to "zero"
6. pressure testing the system in two stages:
(i) The first stage consists of a pressure test at 1,400 kPa for the complete system
for five minutes.
(ii) The second stage consists of a pressure test at 10% greater than the estimated
potential shut-in-tubing head pressure. The pressure test should not exceed
the maximum working pressure of the coiled tubing or any other
component. This test should be continued for 10 minutes.
Note: typical coil tubing systems are pressure tested to 31 mPa.
7. checking all connections for leaks
8. bleeding the pressure down to the wellhead pressure at the flow "T" or through the
testers closed system.
5.3.1 Pressure Test

Pressure tests on jobs using coil tubing shall include the following equipment:
 reel
 open/close valve
 tandem tubing check valve
 isolation valve
 rotary swivel
 coiled tubing
 BOP stack
 flow free with valve

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 stuffing box
 any downhole equipment used on the coiled tubing string above the check valve
During the pressure testing, clear the area of all personnel in case of a failure. The area in
front of the coil has to be cleared of personnel. Vehicles should not be parked in front of
the rotating joint as there is a possibility of rupture.
Where mixed equipment is on a location, such as N2, the nitrogen line shall be pressure
tested up to the tie-in with the main treating line. The main treating line (the coil tubing
using a rotating joint – swivel) shall then be tested using the following steps:
 dress free end of coiled tubing with suitable adapter (roll-on fitting to check
valve)
 connect pressure test unit to inlet plumbing of the rotating joint - swivel if
necessary with valve, check valve, bleeder valve and pressure recording
equipment
 connect bleeder valve to the coiled tubing
 anchor the coiled tubing and continue as described above
Pressure tests shall be carried out with a low viscosity/non-flammable fluid to detect any
leaks in the system. Owing to its availability nitrogen is the preferred fluid used in coil
tubing operations.
The following additional conditions will apply to pressure tests:

1. A differential pressure across the coiled tubing shall not exceed the burst or
collapse ratio of the coiled tubing
2. A pull test of 2,200 daN shall be completed on all coil tubing end connections.
This value shall not exceed 80% of the pipe yield for specialty jobs (e.g. logging
and horizontal wells)

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3. The check valve shall be back pressure tested to 7 mPa prior to running in the
hole. The check valve on the string is used so that no fluid is pumped back up into
the string.
5.3.2 Running Coil Tubing Into The Well

Following successful pressure testing, the coil tubing is run into the well. The steps listed
below are those required where the purpose of the job is to unload the well of any
wellbore fluids but not of any significant amounts of solids. Note: If the well being
unloaded is sour (H2S), ensure that appropriate P.P.E. is worn by all personnel.
1. Ensure that the accumulator pressure is sufficient (17.2 - 21 mPa) to operate one
and one-half complete cycles of the BOP.
2. Set weight indicator to zero.
3. Apply 700 - 2000 kPa back pressure to the reel for running tubing into the well.
4. Open the master valve. Count the number of turns required to open it fully and
record.
5. Run the first 100 meters of tubing into the hole SLOWLY to ensure that the
tubing passes any subsurface safety valves or obstructions safely.
6. Run tubing into the well at a rate of 20 to 25 meters per minute.
7. Start pumping N2 at the rate indicated by the Service Supervisor when required.
8. Monitor wellhead flow-in pressures closely.
9. Perform a "pull test" during the operation at approximately every 1000 meters
during the run-in at depths designated by Service Supervisor. Vary the increments
so that the coiled tubing does not experience fatiguing at the same point each time
the pull test is performed.
11. Run in the tubing to a predetermined over balance point and monitor returns.
12. If fluid returns are lost you may have to run tubing in deeper (sometimes as far as
the perforations).

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5.3.3 Pulling Coil Tubing Out Of The Well

1. Ensure that once on the bottom enough N2 is retained to maintain pressure in the
tubing while pulling out of the well.
2. Increase reel back-pressure to 4200 - 6900 kPa.
3. Run coil tubing out of the well at 25-35 meters per minute.
4. Monitor weight indicators carefully to avoid exceeding maximum pull pressure.
5. For the last 100 meters of tubing in the well, reduce pull-out pressure and run
tubing out of the well at a slow rate (for example, 8-10 meters per minute).
6. Withdraw the last 20 meters of tubing at a "crawl" rate.
7. The tubing will stop running out of the well (the weight indicator registers an
increase) when the check valve (No.80) pulls into the stuffing box.
5.4 POST JOB PROCEDURES

The first procedure in rigging out is to "bleed" the coil tubing system of fluids. The area
between the injector and a reel unit is an extremely hazardous area to be in, especially if
N2 is being pumped. In situations where a string is being pressure tested, the affluent end
is usually blanked off using a swadge-lok fitting and a valve.
Under no circumstances shall pressure be bled off through this valve. The swadge-lok
fitting is not totally reliable and until the pressure is completely bled off, this area shall be
avoided. The operational check valve in the rotating joint on the hub of the reel shall be
removed prior to the pressure test. A "T" and valve shall be installed in the N2 line and
the pressure bled off at this point.
Coiled Tubing Equipment Operators must wear appropriate PPE including eye protection
during the rig-out procedure.

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There must be one Coiled Tubing Equipment Operator in the control cabin operating the
injector, one operator working the crane and an operator on the ground coordinating the
rig-out procedure.
The steps involved in rigging out include:

1. Close master valve on the wellhead. The valve should be closed with the same
number of turns as was required to open it. If 20 turns were required to open the
master valve, but only 10 turns are required to close it, then we know that there is
something stuck in the valve preventing it from being completely closed.
2. Bleed the hole well pressure and the coil pressure above the master valve down to
the rig tank or test unit then close wing valve.
3. Open ("crack") the BOP bleeder valve slightly to ensure that the BOP is bled down
completely (check for H2S).
4. Take the connection off between the top of the BOP and the bottom of the stuffing
box.
5. Take the injector off wellhead. Back off stripper pressure.
6. Run the pipe out and remove the end connection.
7. Connect the wire cable (the "snake") to the tubing end.
8. Ensure that the reel tension is adequate.
9. Route this cable back up through the injector to spool all of the pipe back onto the
reel except for approximately half a meter.
10. Stop the injector.
11. Secure a clamp on the tubing as indicated.
12. Tie down the coil tubing securely on the reel.
13. Run the cable further through the injector until it slackens.
14. Disconnect the "snake" from the end of the coil tubing.
15. "Pump off" (reduce) the inside chain tension on the injector.
16. "Pump off" (reduce) the outside chain tension on the injector.

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17. The "snake" may remain in the injector. Some Coiled Tubing Equipment
Operators may choose to remove the "snake" at this time.
18. Lower the (hydraulic) gooseneck.
19. Disengage hydraulics. Disconnect hydraulic hoses from the injector in proper
sequence. Disconnect the case drain last.
20. Ensure that the weight indicator is secured (“pinned out”) to avoid damage during
transport.
21. The crane lifts the injector and stores it.
22. Use the crane to set the BOP in its cradle on the coiled tubing unit.
23. Replace wellhead flange or swage cap.
24. Spool the (injector) hoses onto their reels on the coiled tubing unit.
25. Secure the crane boom, crane hook, outriggers and blocks on the crane truck.
26. Inspect units to ensure reels are properly secured to prevent movement during
transport.
27. Ensure that all tools are properly stored on the coil tubing unit and the crane truck.
28. Ensure that power is shut off to the PTO and hydraulics at the back of the coiled
tubing unit.
29. Conduct a final “walkaround” to ensure that all equipment and tools are properly
secured and stored.
30. Tidy up location.
31. The Service Supervisor will direct the coil tubing unit and crane truck from the
lease individually.
The following tasks must be completed by Coiled Tubing Equipment Operators when
they return to base:
 refuel coil tubing unit
 conduct Post Trip Vehicle Inspection on unit
 report any maintenance problems to supervisors
 inspect and repair/replace damaged P.P.E.

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5.4.1 Driving
When returning to the base or traveling to another job-site, follow the same driving
guidelines outlined in section 2 of this manual. If you make any stops during the trip,
remember to perform an en route inspection of the unit.
5.4.2 Post-trip Inspection

As an operator and driver, you are expected to perform a post-trip inspection of the unit.
Use the guidelines as indicated on the Pre-trip inspection form. If you encountered any
equipment malfunctions during the job, inform your supervisor or the base maintenance
department so the problem may be repaired before the next job.
5.4.3 Paperwork
Ensure all necessary paperwork is completed. This includes driver logbooks and fuel
envelopes.
5.5 MAINTENANCE ON COILED TUBING EQUIPMENT

The following are general guidelines for performing maintenance to the equipment
associated with coiled tubing operations. There are also regularly scheduled inspections
performed as part of Preventive Maintenance (PM). In these situations, remember that
the daily maintenance is also performed as part of the scheduled PM; for example, you
would lubricate or grease bearings daily as well as part of the PM inspection.
5.5.1 Blowout Preventers (BOP's)

Minimum maintenance to the BOP before and after each job includes:
 hydraulically and mechanically activate all rams
 confirm correct inserts are installed
 remove ram bonnets and visually inspect, clean, and repair as required before
each rig-up
After every 250 hours or 6 months (which ever comes first), BOP maintenance includes:
 totally strip, inspect, clean, and replace as required all components

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 pressure test to maximum rated working pressure (usually done in the yard
against a test stump)
 full body pressure test to its maximum rated working pressure
 testing of blind rams to their maximum rated working pressure
 testing of pipe rams to their maximum rated working pressure
 testing of slips to 80% minimum yield of hang-off and 50% minimum yield of
snub using maximum wall, OD, and rated pressure
 testing of cutting capacity at maximum working pressure, wall, OD, and yield
(use old blades if possible for this test)
 testing of equalizing valves
 drift bore of BOP body to ensure it is within specifications for BOP
5.5.2 Stuffing Box

Minimum maintenance to the stuffing box before and after each job includes:
 disassemble and visually inspect, clean, and repair as required before each rig-up
 hydraulically and mechanically activate
 confirm correct brass and packer inserts
 check bushings to ensure wear is not more than 0.05"
After every 250 hours, or 6 months (whichever comes first), stuffing box maintenance
includes:
 totally strip, inspect (visual or NDT), clean, and replace all components as
required
 function / integrity pressure test to maximum rated working pressure (usually
done in the yard against a test stump)
 full body pressure test to its maximum rated working pressure
 full up and down movement of the hydraulic ram
5.5.3 Work Reels

Minimum maintenance to work reels before and after every job includes:
 check all retaining bolts and set screws on all components

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 lubricate all bearings and sprockets

 check the alignment of all gears and sprockets on the work reel and level wind
 inspect the weep hole on the reel swivel for evidence of leaks and ensure that it is
not blocked or obstructed
 inspect the reel motor and braking system
 inspect the depth measurement equipment
 inspect and refill the tubing lubrication system as required
After 250,000 running feet, or every 3 months (whichever comes first), work reel
maintenance includes:
 check all retaining bolts and set screws on all components
 lubricate all bearings and sprockets
 remove all drive chains and check condition of chains, gears, and sprockets
 check the operation and settings of the system relief valves and pop-off valves
where fitted (hydraulic and tubing lubrication systems)
 check the efficiency of the reel drive and braking systems
 remove, disassemble, and redress the reel swivel
 remove and check the condition of all chains and sprockets on the level wind
 remove the level wind yoke cover and inspect the condition of the yoke and lead
screw
 check the condition of the level wind trolley
 raise and lower the level wind, inspect the condition of the hydraulic rams
 check the condition of the depth measurement device (eg: measuring wheel,
bearings, chain, and reduction gears)
5.5.4 Injectors
Minimum maintenance to injectors before and after every job includes:
 inspect and grease all bearings and bearing carriages
 check all chain tension rams for leaks and ensure they operate fully
 check the injector chain roller bearing or roller carriages and lubricate as required

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 check the gripper blocks for damage or excessive war and clean gripping
surfaces (do not steam clean)
 check chain tension accumulator pressures
 check the weight indicator system and pump up if required
 inspect the depth measurement devices (if equipped)
 inspect and replace the gooseneck rollers, and lubricate as necessary
After 250,000 running feet, or every 3 months (whichever comes first), injector
maintenance includes:
 remove the injector chains from the injector head, and inspect all bearings,
gripper blocks, and chain components for wear or damage (lubricate as required)
 check for free play or slack in the chain (the limit is 3% stretch)
 with the chain removed, check the condition of the skate for excessive wear or
damage (reverse or replace as necessary)
 check the rollers and roller carriages, and lubricate
 check the nitrogen pre-charge on the chain tension circuit accumulators (adhere
to manufacturer's recommended pressures at all times)
 perform pull test
 inspect the weight indicator system
 inspect the depth measurement devices (if equipped)
 check the gooseneck and rollers for excessive wear or damage, and lubricate
5.5.5 Gooseneck (Tubing Guide Arch)

Minimum maintenance to the gooseneck before and after every job includes:
 check and grease all rollers and bearings as applicable
5.6 EMERGENCY PROCEDURES

These procedures describe the actions that must be taken under the following abnormal or
emergency situations. In all cases, quickness of action is vital and for this reason all

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tubing operators shall make themselves familiar with these emergency procedures. These
procedures will be reviewed by coiled tubing personnel before each job to ensure they
understand what is required and know how to put these procedures into action within the
working environment of the job.
5.6.1 Emergency BOP Operation

In the event of an emergency arising and the well having to be secured, the following
steps should be taken:
1. Stop tubing movement, close the slip and tubing rams, and slack off string weight
to ensure slips are holding. If time permits, review all options with the company
representative. (Ensure that rams with guides are activated first to avoid
damaging the tubing.)
2. Stop pumping.
3. Close the shear rams to cut the coiled tubing.
4. Pull the coiled tubing out of the BOP to a point above the blind rams but below
the stuffing box.
5. Close the blind rams.
6. Set up to circu1ate well to kill fluid through the coiled tubing remaining in the
well.
7. Make arrangements necessary to fish the coiled tubing from the BOP.
The decision to proceed past step 1, should normally be made after consultation with the
company representative unless there is an immediate and serious danger to personnel
and/or equipment and the company representative is not immediately available to be
involved in the decision.
Note: When actuating any ram in the BOP system, the corresponding manual lock should
be closed behind it to prevent accidental release in the event of total loss of hydraulic
power. It should be pointed out that in all but the smallest BOP systems 2 % in (63.5

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mm) the locks can not be used to actuate the rams. The force required to close the rams
manually against pressure can not be supplied by turning in the locks. Use of a pipe
wrench, cheater bars or snipes will damage the internal workings of the ram actuators.
Some form of hydraulic power is required to operate the actuators. This pressure can be
supplied via a hand pump, hydraulic pump from any other piece of equipment on
location, including a fluid pumper.
5.6.2 Actuating the BOP System
Hydraulic Controls
 Move the control lever to the desired position.
 Push the BOP activate button supplying pressure to the circuit.
 Observe the pressure drop in the hydraulic circuit and subsequent pressuring
back up to system pressure as ram opens or closes completely.
 Observe the ram indicator pins to verify the operation of the ram.
 Open or close in the manual locks. Flag system to indicate position of rams.
Electric Over Hydraulic With Remote Panel

Main Control Panel
 Move the function lever to the desired position: Open or Closed.
 Move the activating switch to the ”on” position.
 Observe that the ram has fully opened or closed, as indicated by position of the
ram indicator pins and/or hydraulic pressure returning to system operating
pressure.
 Return the activate switch to the ”off’ position. Flag system to indicate position
of rams.
DO NOT LEAVE THE ELECTRIC ACTIVATE SWITCH IN THE ”ON” POSITION.
Remote Control Panel
1. With the main control panel activate switch in the ”off” position. The remote
panel can be functioned fully and independently.

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2. At the remote panel move the function control levers to the open or closed
positions, as required. Flag system to indicate position of rams.
Note: Prior to the commencement of the job, determine the maximum operating pressure
required for the BOP system. This will vary depending on the pipe diameter, wall
thickness, and wellhead pressure. Excessive hydraulic pressure might damage
light walled tubing.
When function testing annular BOP’s, tubing, or slip rams, always insert a test bar or test
piece of tubing into the BOP. Slips may permanently damage tubing.
5.6.3 Leak in Coiled Tubing At Surface

 Call local alert (site and unit specific) and ensure all personnel are removed from
the operational area. In particular make sure all personnel remain clear of the area
between the injector head and the coiled tubing reel.
 If the leak is small or a pin hole leak, pull out of the hole slowly and position the
leak on the lower part of the coiled tubing reel as soon as possible. Be careful
when area of the leak is bent onto the reel as catastrophic failure may occur.
Make arrangements to have a water hose present to wash away any fluid from the
reel which may be hazardous. Make arrangements to start pumping water through
the coiled tubing reel. De-pressurize reel as much as conditions allow without
exceeding collapse limitations of tubing.
 Notify the company representative of the problem and determine the best method
to make the area safe. If the leak is minor and water can be displaced to the leak,
continue to pull out of the hole and change the reel.
 If the leak is considered to be too serious to displace to water and pull out of hole,
or uncontrolled leakage of hydrocarbons or hazardous materials prevents this (i.e.
check valves not holding), set the coiled tubing slips and pipe rams and activate
the cutters. Pull the coiled tubing stub piece clear of the blind rams, then activate
the blind rams (manually lock in place).

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 De-pressurize the coiled tubing reel through the riser. If hydrocarbons are present
in the reel, displace the reel to water and empty the contents via the riser to
specified safe disposal area.
5.6.4 Leak In Coiled Tubing Below Surface

 If a leak occurs in the tubing below the stuffing box during downhole operations,
(usually indicated by a drop in pump pressure or loss of string weight), suspend
tubing operations and alert the company representative. It must be assumed that
the coiled tubing has a hole somewhere downhole at an unknown depth. This
circumstance will mean that at any time during pull out of the hole, the tubing
could be pulled open ended or leaking out of the stuffing box.
 Once the company representative has been alerted, clear all personnel from the
immediate area of the coiled tubing around the injector head and between the
injector head and the coiled tubing reel.
 Displace the coiled tubing to water and commence to pull out of hole at not more
than 15 A/min (5 meters/min). Ensure at all times that all personnel are clear of
the immediate area as the possibility exists of pulling the tubing out of the stuffing
box. Continue pumping water at a slow rate through the coiled tubing.
 When the leak in the coiled tubing appears above the stuffing box, stop the
injector and hold the leaking section of coiled tubing between the chains and the
stuffing box.
 Inspect the leak. If the leak is minor, continue to pull out of hole as in section
4.8.1, being careful as the tubing is being bent over the gooseneck and onto the
reel as catastrophic failure may occur.
 If the leak is major, or the tubing is actually severed or the wellbore fluids are
escaping through the tubing, proceed as in section 8.0, cut the tubing and shut the
blind rams.

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5.6.5 Leak In Surface Pressure Control Equipment
Stuffing Box
 Stop coiled tubing movement and close the pipe and slip rams to seal the coiled
tubing annulus. Set the manual locks.
 Notify the oil company representative.
 Ensure that the injector is in neutral and that the brake is engaged.
 Bleed off the pressure above the pipe rams.
 Bleed off closing pressure on the stuffing box and rep1ace the seal elements. Re-
apply pressure to the stuffing box.
 Pressure test the stuffing box through the kill/injection line. NOTE: avoid
collapsed pipe situation.
 If the test is satisfactory, equalize the pressure and open the pipe and slip rams.
Release the manual locks.
Replacement of Elements In Conventional Top Entry Stuffing Box

1. Unscrew the split cap or remove the pins and lift out
2. Remove the old stripper elements
3. Inspect the upper bushings for wear. Replace if required.
4. Insert new stripper elements.
5. Replace the split cap and energize the stuffing box assembly.
Replacement of Elements in the Side Door Stuffing Box

1. Open side doors.
2. Apply 100 – 200 psi (700 - 1,400 kPa) hydraulic pressure to the packer cylinder to
open the sleeve upward.
3. Remove the stripper element halves. Be aware that the upper brass bushings may
fall down into the window once the stripper elements have been removed.
4. Remove the split Teflon non-extrusion ring.
5. Remove and inspect the brass bushings above and below, replace if required.

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6. Insert the bushings and the split Teflon non-extrusion ring.

7. Insert new stripper elements.
8. Release the packer cylinder hydraulic pressure, allowing the sleeve to close.
9. Close the side doors and manually lock.
Surface Leak Other Than Stuffing Box

Rotating Joint
Close the reel isolation valve inside the power reel and repair or replace the rotating joint
as required. Re-test and resume operations.
Leak Below the Blow Out Preventer

If the 1eak is minor, coiled tubing is in the hole and the shear/seal rams are below the
leak:
 Call a local alert and notify the oil company representative.
 Clear all non-essential personnel away from the area.
 Hook up the pumper to the kill line of the BOP and pump fresh water slowly
down the annulus. Note: Avoid collapse situation.
 Continue to pull out of the hole and monitor the situation closely.
 Close the swab valve and blind rams once the coiled tubing is in the riser and
repair the leak.
 Perform a reinstatement test on surface equipment after the leak has been
repaired.
If the coiled tubing is in the well and no shear/seal rams below the leak, or the leak is
considered serious:
 Call a local alert and notify the oil company representative.
 Ensure that all personnel are removed from the area.
 Ensure that the coiled tubing is sufficiently off bottom so that when the shear seal
rams are activated the pipe will drop below the Xmas tree manual master valve.
If at all possible, the decision to cut the tubing and activate the system will be
taken by the oil company representative in charge of the operation. This may not

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always be possible. If the situation is extremely dangerous and requires a quick

decision, the coiled tubing supervisor in charge should make this decision.
 Close the shear/seal rams in the safety head to cut the pipe and allow it to drop. If
the shear /seal rams have separate shear and blind rams, close the shear rams to
cut the pipe, pull up the coiled tubing and close the blind rams.
 Close the swab valve on the Xmas tree.
 Close the master valve on the Xmas tree.
 Repair the leak and pressure test the riser.
 Plan fishing operations.
5.6.6 Tubing Runs Away Into The Well

If the inside chain tension system on the injector head should be insufficient for any
reason, and tubing is pulled into the well under its own weight with no control the
following procedure should be followed:
 Call a local alert (site and unit specific).
 Attempt to speed the injector up to match the speed of the descending tubing.
 Increase the inside chain tension to increase friction on tubing.
 Increase the Stuffing Box pressure to exert more friction on the tubing.
 If these actions fail to make any difference, reduce the injector hydraulic pressure
to zero. This may cause the safety brake in the motors to actuate and the counter
balance valves to close, stopping the injector. Under certain circumstances, if the
runaway tubing is at a speed above the critical speed, the back pressure created
by the circulating hydraulic fluid may prevent the injector motor brakes from
actuating. If this situation occurs, select the pull mode for the injector and
increase system hydraulic pressure until the tubing comes to a standstill.
 If the tubing is not too far off bottom it may be practical to let it fall to bottom,
then investigate the causes and repair. This can only be done if there is sufficient
tubing on the reel to reach bottom. Note: Tubing may helix when hitting bottom
making it difficult to pull into tail pipe.

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 In the event that there is insufficient tubing on the reel to reach total depth, close
the tubing slips. This is the preferred option to using the pipe rams as these will
become damaged and a primary well control system will be lost.
 Note: This might damage the tubing and the slips.
 Once the tubing has been controlled, examine the injector head for damage,
including the chains, and pull out of the hole.
 The tubing runaway may be caused by the injector becoming overloaded with the
weight of the coiled tubing and fluid in the tubing. This situation should not
occur if proper pre-job planning is done. Correct selection of injector head or
ensuring coiled tubing is full of nitrogen would prevent this situation from
occurring
5.6.7 Tubing Runs Away Out Of The Well

This situation may arise if there is significant wellhead pressure and little coiled tubing in
the well. In other words the up thrust due to wellbore pressure exceeds the weight of the
tubing and injector chain to pipe friction. If the injector chains should fail to grip the
coiled tubing in this situation, the tubing will start to move out of the well in an
uncontrolled fashion.
 Call a local alert (site and unit specific).
 Attempt to match the speed of the tubing and apply additional inside chain
tension and stuffing box pressure to slow the tubing if it is slipping through the
chains.
 Increase reel hydraulic pressure.
 Prepare to close the master valve in the event that the coiled tubing is blown out
of the well.
 Should the above fail, close the tubing slips. If the slips do not work, the BHA
will hit and potentially jam in the stuffing box.
 Once the tubing has stopped moving close the tubing rams.
 Evaluate the situation and determine the reason for the loss of injector control.
 Correct the problem.

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 Spool any excess tubing back onto the ree1. Open the tubing and slip rams.
 Continue to pull out of the hole.
Note: The tubing might be damaged where the slips grabbed it. This may have weakened
(wall loss) the pipe or scarred it, causing problems with the stuffing box.
5.6.8 Tubing Is Pulled Out Of The Stuffing Box

This situation is most likely to occur when the tubing is being pulled into the riser
section. If the bottom hole assembly is lost, including the end connector there will be no
external upset to prevent the tubing from passing through the stuffing box. If this
situation occurs, stop the injector before the tubing passes through the chains and close
the blind rams.
5.6.9 Tubing Collapsed At Surface

Collapsed coiled tubing at surface will be obvious by the escape of wellbore fluids from
the stuffing box, as the strippers will no longer seal round the deformed pipe. In addition
to this the collapsed pipe will not allow the injector head to grip the tubing due to its
change in shape. Usually collapsed tubing will not pull through the bottom brass
bushings on the stuffing box.
If pulling out of the hole:

 Immediately run the tubing back in the well a sufficient distance to make sure that
round pipe is in contact with the stuffing box and across the BOP.
 Call a local alert (site and unit specific) and notify the company representative.
 Immediately reduce the wellhead pressure by all safe means possible. Either flow
the well through a choke at a higher rate or stop the annular fluid injection if
reverse circulating.
 Increase the coiled tubing internal pressure by attempting to circulate.
 Once pressure conditions inside and outside the coiled tubing have been
optimized, a decision can be taken on how to proceed (i.e. kill well, etc.).

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If it is not possible to position the un-collapsed pipe across the stripper rubbers,(i.e. well
contents are escaping from the stripper rubbers):
 Call an alert and notify the company representative.
 Close the pipe rams in an effort to reduce the flow of fluid/gas around coiled
tubing.
 Remove all non essential personnel from the immediate area.
 Under authority from the company representative, kill the well.
Note: If it is not possible to control the well the tubing will have to be cut and the blind
rams closed.
 Arrange for clamps to be fitted to the coiled tubing above the injector head.
 Release the pressure from the stuffing box and open the pipe rams.
 Cut the tubing at the gooseneck and use the rig or a crane to pull the tubing
through the injector. Re-clamp the tubing above the injector head and cut off in
30 ft (10 m) sections (or as appropriate to the crane or rig).
 Continue pulling and cutting tubing until the tubing pulled to surface can be
pulled by the injector head.
 Once tubing in good condition (i.e., not collapsed) is at surface, set the tubing
slips and pipe rams and make up a dual roll on connector to the tubing on the reel.
 Continue to pull out of the hole.
5.6.10 Tubing Breaks On Surface

If the coiled tubing breaks at surface into two separate sections:
 Stop the injector and set the slips.
 Stop pumping operations.
 Call an alert and notify the company representative. Ensure that all non-essential
personnel are cleared from the area and that the area is secure.
 Secure the coiled tubing at the reel and attempt to spool any slack tubing back
onto the reel.

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 After consulting with the company representative, remove the damaged section of
tubing and insert an inline dual roll-on connector and continue to pull out of the
hole.
 If it is not possible to spool the tubing in the well back onto the reel, (no surplus
capacity on reel), then it will be necessary to cut the tubing and continue as per
Section 4.7.3 to cut the tubing while holding it in the BOPs. After this action, it
will be necessary to fish the tubing and spool it onto another reel with sufficient
capacity to hold the tubing remaining in the well.
 If this course of action is considered inappropriate or dangerous due to well
conditions or the condition of the coiled tubing still in the well (i.e. check valve
not holding pressure), continue as per Section 4.7.1.
5.6.11 Coiled Tubing Reel Drive Fails

If the drive is lost to the coiled tubing reel, it is no longer possible to maintain back
tension on the coiled tubing between the injector head and the reel. The effect of this will
be for the reel to un-spool and for the tubing on the reel to attempt to unravel and adopt a
curvature larger than the reel diameter. The potential danger of this situation is that any
personnel in the vicinity of the tubing could be struck by the unraveling coiled tubing. In
this situation:
 Call an alert (site and unit specific).
 Immediately stop the injector.
 Ensure that the coiled tubing is securely held by the injector, and close and lock
the tubing and slip rams.
 Apply the tubing reel brake if fitted.
 Inspect the coiled tubing reel and effect repair. Inspect the coiled tubing for
damage.
 If the coiled tubing is damaged, proceed as per Section 4.7.3 (coiled tubing leak
on surface).
 Once the reel drive mechanism is operational, run the tubing in the hole as far as
possible to remove the unwrapped tubing from the reel (applying tension will not

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re-tighten the tubing beyond the top wrap). Do not run any kinked tubing into
the well.
 Once all the unwrapped tubing has been removed from the reel, pull out of the
hole spooling the pipe correctly.
 If it is not possible to run the tubing further into the well, and it is not possible to
spool the tubing in the well back onto the reel, (no surplus capacity on reel) then it
will be necessary to cut the tubing and continue as per Section 4.7.3. After this
action, it will be necessary to fish the tubing and spool it onto another reel with
sufficient capacity to hold the tubing still in the well.
5.6.12 Power Pack Failure

If the hydraulic power unit breaks down, the injector head will cease to function in a fail-
safe condition. As the hydraulic pressure reduces to zero, the motor brakes will come on
and hold the tubing. If this situation occurs:
 Ensure injector brakes are supporting the tubing. If for some reason there is some
doubt as to the injector’s ability to do this either due to a faulty brake or a leak in
the inside chain tension system, close the tubing slips to hold the coiled tubing.
Manually lock with hand wheel. NOTE: the use of the tubing slips will cause
some localized damage to the tubing; therefore, this course of action should only
be taken if there is significant doubt about the injector’s ability to hold the string.
 Close the pipe rams and manually lock in place.
 Chain the tubing reel to prevent the tubing from un-spooling. This should only be
done in the event that the reel brake fails or there is leakage in the reel motor
system.
 Maintain circulation if required.
 Repair or replace the power pack. NOTE: if replacing the power pack, ensure that
the BOP accumulator on the replacement unit is fully charged before changing
over.
 Equalize the pressure across the pipe rams and open the slips.

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 If the slip rams were actuated, pick up the coiled tubing and inspect the area
around which slips were set. Clean and polish the surface with emery cloth. If
the tubing is seriously damaged, pull out of the well and repair or replace the
string.

Page 105

Page 106
6.0 INTERPERSONAL SKILLS

One of the competencies asked for by our customers is that of Interpersonal Skills. These
can be defined as the skills or ability to “interrelate” with other people on the job. This
includes fellow employees, supervisors, rig crews, customers, and so forth. The
following information is a review of some concepts relating to the interpersonal skills
that can assist you in the day-to-day interactions with others. As part of BJ Canada's
commitment to provide quality training, many of these concepts are expanded in courses
you will take as you progress in the company. Remember that no one enjoys negative
interactions with other people, so make an effort to do your part in keeping the interaction
positive. In the long term, this effort benefits everyone.
6.1 OBJECTIVES
This module will help you to:
1. identify common habits that hinder our listening ability
2. use “active” listening techniques
3. become a better communicator by using “I” statements
4. utilize various relationship-building techniques
5. transfer the skills to the job-site
6.2 COMMUNICATION TECHNIQUES

We are always communicating on a day-to-day basis, whether intentionally or not.
Everything we do conveys a message; therefore, it is important to be aware of the
messages we are giving.
Some studies indicate that the words we say only communicate 7% of the message. Our
body language and non-verbals deliver 55% of the message, and how we say words and
the sounds we make contribute 38% to the delivery of the message. Knowing this helps

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us to see beyond the words, and focus on what the person wants, not only on what the
person says.
6.2.1 Listening
Contrary to popular opinion, listening is not a passive activity. It requires full
concentration and active involvement and is, in fact, hard work. Communication often
breaks down because people make unchecked assumptions, or because they assume they
understand when they don't.
When it comes to listening, many of us are guilty of at least some bad habits. For
example:
 instead of listening, do you think about what you're going to say next while the
other person is still talking?
 are you easily distracted by the speaker's mannerisms or by what is going on
around you?
 do you frequently interrupt people before they have finished talking?
 do you drift off into daydreams because you are sure you know what the speaker
is going to say?
The characteristics of a good listener include:

 acknowledging what the other person is saying (e.g. nodding, smiling, etc.)
 watching for verbal and non-verbal clues as to the other person's state
 asking for clarification if unsure about what is said
 controlling the desire to interrupt
 withholding judgements about the other person (don't just assume you know what
they are like because of how they dress or how they appear)
 resisting the temptation to immediately correct the other person if there is some
disagreement
We have two ears and one mouth, and we should them in these proportions! If we are to
develop good communication skills, we must learn to listen.

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6.2.2 Speaking
When you are speaking or trying to communicate your ideas to someone else, it often
helps to incorporate the following points into your message:
 indicate the purpose of your message, and emphasize the main point
 include examples or points to help the other person understand
 make sure that the other person understands what you are saying by checking with
them
Using "I" Statements

When you are speaking to someone, try to use "I" statements as opposed to "you"
statements. The I statements describe your ideas and feelings; the you statements carry a
judgmental tone which puts the other person on the defensive.
"I" statements tend to:
 place responsibility with you, the speaker
 clarify your position, feelings, or opinions
 build trust by giving others information about yourself
"You" statements tend to:
 put people down
 place blame
 preach about how the other should think or feel
 elicit a negative or defensive response
Examples of "I" statements Examples of "You" statements

I couldn't understand what you said. You aren't making any sense.
I missed having your input at the team You didn't care enough to come to the
meeting. meeting.
I'm worried about meeting the deadline. You won't be able to make the
deadline.

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Re-framing the Message You Hear

One of the best tools to show others that you hear what they say and understand what
they mean is to re-state the message in your own words by using the following phrases:
 so, you are saying that…
 correct me if I am wrong, but do you mean to say that…
 what I think I am hearing is…
6.2.3 General Tips to Improve Communication

The following tips can help you become a better communicator:
 Don't always talk, and spend more time listening. People want a chance to get
their ideas and opinions communicated. A good listener lets them do it.
 Don't let yourself be distracted by the environment or by the speaker's appearance,
accent, mannerisms, or word usage.
 Provide feedback. Make eye contact with the speaker. Indicate you understand
the message by nodding your head, maintaining an upright posture, and if
appropriate, interjecting an occasional comment such as "I see" or "that's
interesting." The speaker will appreciate your interest and feel that you are really
listening.
6.3 BUILDING RELATIONSHIPS

We all want to be accepted by our peers, and work in a healthy environment. In order to
do this, we must foster positive interactions and participate in creating such atmospheres.
Below are a few techniques that will help you build a strong relationship with others:
Try to understand the individual and see beyond words. Give your time and try to “walk
in their shoes.” When we try to get our point across and fail to listen to the other person’s
point of view, we often create unnecessary roadblocks when trying to accomplish a job.

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When we keep our promises, we prove to our co-workers and to ourselves that we are
valuable employees. When others rely on our commitments and we fail to follow
through, they tend to view us as being untrustworthy.
In most cases, open communication eliminates misunderstandings and clarifies the

situation. Sometimes, over-communicating the information is better than having a person
guess what is required. When we invest time and effort in trying to clarify the
expectations, we are being proactive by preventing potential disappointments and
frustrations in the future. In other words, we address a situation before it becomes a
problem.
6.4 JOB-SITE SCENARIOS

The following discussion highlights every day situations you may encounter as an
Equipment Operator with BJ Services Canada. Take some time to think about these
situations and compare them to your own experiences. If you could re-visit some of these
experiences, are there ways in which you might improve the interpersonal
communications that unfolded?
Helping Others
After you have completed the required tasks for your unit, help others on the location. If
you notice that someone needs assistance, you do not need to wait until they ask you for
help.
For instance, you may see a driver backing up without a ground guide. Stop the driver
and explain the company policy. Then, help by guiding until the backing operation is
complete. You could just tell the Service Supervisor, but that action will not stop the
immediate danger.

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Listening at the Safety Meeting

Every job has a safety meeting prior to starting the operation. The instructions often
become repetitive in nature, and you may find you “know” what is going to be said
before it is spoken. However, sometimes the information is different than what you
expected. The proper way to take this kind of instruction is to listen. Don’t ignore it
even when you know what is happening. Remember, you are setting examples for more
junior employees; you are also allowing the Supervisor to accomplish his or her tasks in
an efficient manner. It is better to hold your questions until the Supervisor is finished or
until he indicates that it is time to ask questions. Don’t try to talk “over” the supervisor,
or attempt to talk at the same time. That only creates confusion.
Safety on Location
Safety is of paramount concern on location. Never act in an unsafe manner or perform
unsafe actions. Do not ignore our safety policies and procedures, even if the company
man tells you to do something. If you are unsure, ask your supervisor for instruction and
permission. If someone sees a serious problem, such as a major leak in the high-pressure
line, then they should let the supervisor know as soon as possible. If you are pumping
and you see a serious leak or are informed of a serious leak, you may shut down
pumping. Shutting down prevents a serious accident, and requires your judgement.
Regardless of the seriousness of an incident on location, always shut down a job if the
Service Supervisor tells you to do so. The key to knowing what to do is to always err on
the side of being safe.
Communicating with Co-Workers on Site

As an equipment operator, you need to communicate with the other workers on the job-
site. It is important that they understand the functions they are to perform. In your mind,
you may think you have given very clear instructions; however, it is best to have the other
person repeat the instructions to you. This ensures the other person clearly understands
what you said.

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People are naturally curious. The pump truck is often where “everything is happening,”
and other personnel may want to get up on the truck to see. For several reasons, the deck
of the pump truck needs to stay uncrowded. The Supervisor may need to be there, the
company representative may want to be there, but other people have no business being
there. In other words, you should keep visitors off the truck. There are exceptions to
this. If you should run into a situation that requires others to help, then you may invite
them up to give you a hand. Also, you may be training other people to operate the
equipment. Then, they may be on the unit.
Interacting with the Customer

Usually, the customers are quite pleasant: they may joke with you, ask questions, and
seemingly be your friend. Sometimes, the customers may not appear so pleasant. In
these situations, it is critical that you maintain your composure, and remain calm; in other
words, be pleasant with the customer and always maintain your professional image. If
the customer asks you about something, do not over-volunteer information, but do not
hesitate to answer the question. If you do not know the answer, do not pretend that you
know. Tell them you will find out, then ask the supervisor. The supervisor may choose to
answer the question, or give you the information to provide the answer. Generally, you
want to be open and honest without being one of those people who talk just to hear
themselves talk. Respond to questions, but don’t volunteer more than is asked.
Following these simple guidelines enhances the operation on location. They also help
create a quality job that is recognized by our customers, and promote a positive
atmosphere in which they are more inclined to do business with us. And the additional
business enhances your opportunities for promotion.

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7.0 APPENDIX 1: BASIC MATH AND WELL SERVICING

CALCULATIONS
This module discusses the principles of math and physics that will assist you in your
work at BJ Canada. The first section examines basic math principles (addition,
subtraction, multiplication, and division), areas, and volumes. The second section
examines some basic density and pressure calculations used in well service operations.
The material in this module is presented by:

 written explanations
 giving examples of situations from the worksite
 application through questions and answers
The module is divided into two main sections:

1. Basic mathematical concepts, formulas, and applications using:
 The Decimal System
 Addition
 Subtraction
 Multiplication
 Division
 Squaring of Numbers
 Square Root
 The Circle
 Area of a Rectangle
 Area of a Square
 Area of a Circle
 Volume of a Rectangular Solid
 Volume of a Cube
 Volume of a Sphere
 Volume of a Cylinder
2. Basic density and pressure calculations used in well service operations:

 Density  Bottom Hole Pressure
 Specific Gravity  Bottom Hole Treating Pressure
 Hydrostatic Pressure  Frac Gradient
 Hydrostatic Pressure Gradient  Hydraulic Pumping Power
 American Petroleum Institute
(API) Gravity
 Differential Pressure

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Objectives
The objectives specify what you should know by the end of this appendix. The
objectives for this module are:
1. understand basic math and physics that apply to well service operations
2. complete basic mathematical problems
3. determine the volumes of a rectangular solid, cube, sphere, and cylinder
4. calculate density, specific gravity, hydrostatic pressure, differential pressure,
bottom hole pressure, treating pressure, frac gradient, and hydraulic pumping
power
7.1 BASIC MATHEMATICAL OPERATIONS

This section reviews the basic math operations that are used on a daily basis as part of
your work. Knowledge of these basic operations help you to learn more complex math
applications, and directly aid in the calculations for well service operations.
Note: There are various methods of completing mathematical operations to achieve the
same result. The processes outlined in this module represent one way of completing the
mathematical operation. Another method involves the use of a calculator. The main
purpose of presenting the operations in the following way is to help you to understand the
mathematical process.
7.1.1 The Decimal System

The decimal system is based on the grouping of numbers by tens; therefore, we refer to it
as a base-ten system. Within this base system, each numeral will have a value dependent
on the place it holds in the number. For example, we can understand the number
4,198,237.4876 in the following way:
millions 4
hundred thousands 1
ten thousands 9
thousands 8
hundreds 2
tens 3
ones 7
decimal point 
tenths 4
hundredths 8
thousandths 7
ten thousandths 6
When a number is analyzed, it is important to remember that each digit has a direct
relationship with the value ten. The starting point for the number value begins at the
decimal point.
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To the left of the decimal point, the values of the digits increase by ten times the previous
digit. To the right of the decimal point, the values of the digits decrease by ten times the
previous digit. Calculators automatically align the decimals in the proper place.
7.1.2 Addition
The addition operation involves aligning or visualizing all the numbers in a column
according to the decimal point. This helps to ensure that the addition results in the proper
combination of numerals of specific values. In other words, aligning numbers vertically
with the decimal point in a straight line and using a comma to separate numbers into
thousands decreases the risk of error. For example:
473.27
84.1
7.68
304.9
869.95
In this example, the second number (84.1) has no hundreds or hundredths values. The
solution to this question is determined by adding the digits in the column, moving from
the right to left. Each digit on the right is one-tenth the value of the digit to the left. For
example, 7 hundredths and 8 hundredths added together result in 15 hundredths, which
equals one tenth and 5 hundredths.
Practice Examples
Add the following numbers:
1. 474.3 2. 797.2 3. 8,643.2

86.74 8.469 926.34
9.86 8,941.76
7.1.3 Subtraction
The subtraction operation involves the decreasing of one number by the specified value
of another number. Always align or visualize the two numbers using the decimal point as
the focus when subtracting.
For example:
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Decimal point is focus (in alignment)
7283.36
- 836.44
= 6446.92
Just as in the addition operation, the order of subtracting digits occurs from right to left.
7283.36 Subtraction occurs from right to left

- 836.44
= 6446.92
In the instance where a digit in a particular value is not large enough to be subtracted
(that is, the 3 tenths and 4 tenths digits), a whole value must be taken from the first digit
to the left in the number. This value is taken from the 3 leaving a 2. Remember that
digits to the left represent 10 times the value, so you are really “borrowing” 10 and
adding to the 3 to get 13. The 4 can now be subtracted from 13, leaving 9.
7283.136 Whole number borrowed from the first digit to the left
-836.44 allows the 4 to be subtracted from 13.
.92
Likewise the same principle would be followed subtracting 6 from 2, and 8 from 2.
6 2
71283.136 Whole number borrowed from the first digit to the left
- 836.44 allows 8 to be subtracted from 12.
6446.92
Practice Examples
Complete the following subtraction operations:
4. 4,789.63 5. 294.386 6. 97,432.6

- 3,845.72 - 47.657 - 3,784.72
7.1.4 Multiplication
The multiplication operation is basically a shortened form of the addition operation. That
is, 362 x 4 represents the number 362 added to itself four times (362+362+362+362).
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The actual multiplication operation is conducted by multiplying each of the digits in the
362 by the number 4 to result in the number 1,448 (300 x 4, 60 x 4, 2 x 4).
When completing the multiplication process manually, you should align the numbers in
the proper value columns (tenths, ones, tens, hundreds, etc.). The numbers being
multiplied should be performed in a sequential order: begin from the right and work
toward the left.
For example: 478.6

27.3 Begin multiplication with the first
Numbers aligned 14358 number (3), then move to the (7).
in proper value 33502
columns 9572
13065.78
The numbers of the multiplication process are best aligned under the value of the
multiplier. The position of the decimal is determined by adding the number of numerals
to the right of the decimal in the two numbers. In the example above, there are two digits
to the right of the decimal point: .6 and .3. This results in the answer having two digits to
the right of the decimal; that is, .78.
When the resulting value of the two numbers multiplied exceeds 10, you must carry over
the number of units which exceed 10. In the example above, 6 x 3 = 18; therefore, record
the 8 and add 1 to the product of the next two numbers. This results in 3 x 8 = 24 + 1
(carried from the previous product of 18) = 25. Repeat this process with the next
operation: 3 x 7 = 21 + 2 = 23.
Another example of how to position the decimal place involves the following:
274.36
4.21
27436
54872
109744
1155.0556
The four total places of decimal in the two numbers being multiplied results in 4 digits to
the right of the decimal point in the answer.
Practice Examples
Complete the following multiplication operations:
7. 273.45 8. 98.2 9. 864.3

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28.6 6.45 9.7
7.1.5 Division
The division operation can best be explained as the inverse of multiplication.
Example # 1: 3 x 6 = 18 Example # 2: 1,448  4 = 362

18  3 = 6 1,448  362 = 4
18  6 = 3 362 x 4 = 1,448
When completing division, it is important to move the decimal point (if one exists) in the
number doing the dividing to the end (right side) of the number. Also move an equal
number of places to the right in the number being divided. For example, if 144.8 is
divided by 36.2 the decimal point is moved from 36.2 to the end to result in 362;
likewise, the decimal in 144.8 must be moved to the end to create 1448.
362. 1448. Decimal point moved to the end of the number

to improve the ease of completing the division operation.
It is advisable to put the decimal point in the answer portion at the same time as the
decimals are moved in the other two numbers (see above equation).
Solving division questions involve the following processes:

1. Determine whether the dividing number (362), having three digits, can go into the
first three digits of the number being divided (144).
2. If yes, proceed. If no, then choose the next number to 144 and divide 362 into 1448.
3. The first number of the answer should be placed directly above the last number being
divided; for example, the 8 of 1448 (see equation below).
4. Multiplying the 362 by 4 results in 1448, therefore showing a balance of "0" when the
two numbers are subtracted.
4.
36.2 144.8 Moving the decimal points: 362. 1448.
1448.
0
The answer is 4.
Consider the following problem:

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A water line has to be laid from a canal to a rig in order to supply water for mud
production. The canal is 2.5 km. from the rig. Each length of pipe is 10 meters long.
How many lengths of pipe have to be ordered to lay the water line?
Answer: Total distance of rig to canal is 2.5 km. x 1000 m/km = 2500m.
Length of each pipe = 10 m.
Number of pipes required is 2500 m  10 m/pipe = 250 pipes.
Practice Examples
Solve the following division questions:
10. 10,626  22 = 11. 76,797  23 =
12. An oil rig is being moved from High Prairie to Bassano - a distance of 1160 km from
one site to the other. Tractors hauling the rig can travel at an average speed of 80 km/hr.
Can the equipment be moved in one 12 hour work day?
________________________________________________________________________
________________________________________________________________________
________________________________________________________________________
________________________________________________________________________
13. A company has developed a new form of mud to be used in drilling. The mixing ratio
to produce the mud is 1 kg. of dry compound to 20 liters of water. If a rig needs 10,000
liters of mud for adequate circulation, how many bags of dry compound are required to
produce the 10,000 liters of mud?
________________________________________________________________________
________________________________________________________________________
________________________________________________________________________
________________________________________________________________________
7.1.6 Squaring a Number

The system of squaring a number is a simple way of saying that the number is multiplied
by itself. It is denoted by a small '2' in the upper right side of a number; that is, 62 means
6 squared, or 6 x 6.
For example:
52 = 5 x 5 = 25
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42 = 4 x 4 = 16
102 = 10 x 10 = 100
1202 = 120 x 120 = 14,400
Practice Examples
Solve the following:
14. 162 = 15. 82 = 16. 1152 =
7.1.7 Square Root

The operation for determining the square root of a number is basically the reverse of a
square of a number. The mathematical process to find the square root is a form of
division. This explanation will demonstrate a method of estimating the result prior to
conducting the mathematical operation. A calculator is recommended for square root
problems.
The square root of a number is the calculating of a number, that when multiplied by itself,
will result in the original number. Square root functions are designated by the use of a
square root symbol:
For example, 25 = 5.
How can we estimate the square root of a number such as 15,376?
Answer: Estimate the solution. 100 x 100 = 10,000 and 200 x 200 = 40,000.
The answer, therefore, is somewhere between 100 and 200. In this instance you
could continue the process of estimation until you are close to 15, 376. As you
can see, this can be very time consuming, and this is the reason a calculator is
recommended to perform square root functions.
Practice Examples
Calculate the square roots of the following numbers.
17. 169 = 18. 324 =

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7.1.8 The Circle

The perimeter (distance around any geometric figure) is called the circumference
(denoted by C). A straight line drawn from one edge of the circle, through the center, to
the other edge is called the diameter (denoted as d) of the circle. The distance from the
center of the circle to the edge is called the radius (denoted as r). The radius is one-half
the length of the diameter.
There is a constant relationship between the circumference

(distance around) of a circle and the diameter (distance across) of
the circle. The circumference is 22/7 of the diameter of a circle;
therefore, C = 22/7 d. This relationship is called Pi, and is
represented by the Greek symbol . Since 22/7 is an improper
fraction, the accepted decimal form of this ratio is 3.14.
A formula to determine the circumference of a circle can be written as C= d or, since d

is twice the distance of the radius of a circle, C = 2r or C = 2 r.
For example, find the circumference of a circle that has a radius of 14 cm.
Solution: r = 14 cm. or d = 28 cm.

 = 22/7 or 3.14
C = d
= 3.14 x 28 = 87.92 cm.
= 22/7 x 28 = 88 cm.
Notice the slight differences in the two possible answers. This occurs because of the
rounding factors associated with converting 22/7 to a decimal number. Generally, it is
preferable to use the value of 3.14 because it makes the calculations easier to perform.
Practice Examples
Solve the following problems:
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19. The radius of a large pipe is 3.4 m. How long would a chain have to be to wrap
around it (for lifting purposes)?
________________________________________________________________________
________________________________________________________________________
________________________________________________________________________
________________________________________________________________________
20. The collar of a drill pipe has an inside diameter of 12.8 cm. If the collar is made of
steel that is 1.2 cm. thick, what is the outside circumference of the collar?
________________________________________________________________________
________________________________________________________________________
________________________________________________________________________
________________________________________________________________________
21. An automobile tire has an outside diameter of 68.6 cm. How many turns will the tire
make in travelling 1 km on a smooth road?
________________________________________________________________________
________________________________________________________________________
________________________________________________________________________
________________________________________________________________________
7.1.9 Area of a Rectangle

Area is defined as the total exposed surface of an object. It is measured in square units
since it represents the total surface of an object. A rectangle has length and width.
The figure below represents a thin sheet of steel 5 cm. wide and 10 cm. long. What is the
area of the sheet of steel?
Solution: Each single square covers an area 1 cm by 1 cm, called a square cm. Area is
represented by the term 'square' and this rectangle has a total number of 50
square centimeters. Hence the area = 50 sq. cm. or 50 cm2.
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To calculate the area of a rectangle the length (l) of the rectangle is multiplied by the
width (w). The resulting formula is:
Area = length x width

A= l x w
7.1.10 Area of a Square

A square is a special type of rectangle where the length and width are the same size. If
the symbol 's' is given to the length of the square, the same can be given to the width
(since the length and width are the same). Therefore, the area of a square can be
represented as:
A = l x w or s x s or s2
The unit of measurement of area is always in square units.
Practice Example:
If each side of a thin sheet of steel is 5 cm., what is the area of the sheet of steel?
Solution: A = s2
=5x5
= 25 sq. cm.
7.1.11 Area of a Circle

There is a relationship of the area of a square (s2) to the area of a circle (r2). The formula
that expresses the area of a circle is:
A = r2
For example, find the area of a circle with a diameter of 28 cm.
Solution: d = 28 cm.
r = 14 cm.
A =  r2
= 3.14 x 142
= 3.14 x 14 x 14
= 615.44 sq.cm.
Practice Examples
22. The face-off circle of a hockey rink has a radius of 3 m. Calculate the area of the
face-off circle.
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________________________________________________________________________
________________________________________________________________________
________________________________________________________________________
________________________________________________________________________
23. A rectangular field needs 684 m of fencing to enclose it. The width of the field is
42m.
(i) What is the length of the field?
(ii) If the field is to be covered with sod, how many square meters of sod will be needed?
________________________________________________________________________
________________________________________________________________________
________________________________________________________________________
________________________________________________________________________
________________________________________________________________________
24. The cleared area of a rig location is 12,100 square meters. If the cleared area is a
square, what is the length of each side?
________________________________________________________________________
________________________________________________________________________
________________________________________________________________________
________________________________________________________________________
25. The length of the side of a square is 70 cm. A circle is to be cut out of the square,
having a diameter of 70 cm. What area of the square is left after the circle has been cut
out of it?
________________________________________________________________________
________________________________________________________________________
________________________________________________________________________
________________________________________________________________________
7.1.12 Volume of a Rectangular Solid

To determine the volume of a rectangular solid it is important to know the sizes of the
three dimensions involved - length (l), width (w), and height/depth (h). The formula for
determining the volume of a rectangular solid is:
lxwxh
For example, determine the volume of water that would fit into a welder's trough that is
500 cm wide, 1 m long and .5 m deep.
Solution: w = 50 cm
l = 1 m = 100 cm
h = .5 m = 50 cm
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Volume = area of base (l x w) x height

=lxwxh
= 50 cm x 100 cm x 50 cm
= 2,500,000 cubic centimeters (cc or cm3 ) of water.
Another way to express volume is to convert cc’s to liters (L). One liter of water = 1,000
cubic centimeters (cc or c3); therefore 2,500,000 cc of water = 2500 L.
Practice Examples
26. Calculate the volume of a cardboard box that is .5 m wide, .75 m long and 2 m high.
________________________________________________________________________
________________________________________________________________________
________________________________________________________________________
________________________________________________________________________
27. Calculate the number of cubic meters of concrete that has to be ordered to lay a
sidewalk that is .75 meters wide, 50 meters long and 10 cm deep.
________________________________________________________________________
________________________________________________________________________
________________________________________________________________________
________________________________________________________________________
7.1.13 Volume of a Cube

A cube is a special type of rectangular solid where the three sides of the rectangle are all
the same size. Since l, w, and h of a cube are all the same, these sizes can be represented
by 's' (side), and the formula to determine the volume of a cube will be
V=sxsxs
= s3
For example, calculate the volume of a concrete block that has a measure of 1 m on each
side.
Solution: Volume = length x width x height (or s3)

= 1m x 1m x 1m
= 1 cubic meter (or 1 m3)
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Practice Example
Solve the following problem:
28. Determine the volume of acid that will fit into a square battery whose acid storage
cavity is 15 cm on each side.
________________________________________________________________________
________________________________________________________________________
________________________________________________________________________
________________________________________________________________________
7.1.14 Volume of a Sphere

The volume of a sphere (a solid round object) is determined by the formula:
V = 4/3  r3
The volume of a sphere is a measure in cubic units.
For example, calculate the volume of gas in a balloon that has a radius of 6 cm.
Solution: r = 6 cm
V = 4/3  r3
= 4/3 x 3.14 x 6 x 6 x 6
= 904.32 cc or cm3
Practice Examples
29. Find the volume of a spherical tank if the radius is 3.8 m.

________________________________________________________________________
________________________________________________________________________
________________________________________________________________________
________________________________________________________________________
30. Find the volume of the largest sphere that can be placed in a cube, if one side of the
cube measures 28.4 cm.
________________________________________________________________________
________________________________________________________________________
________________________________________________________________________
________________________________________________________________________
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7.1.15 Volume of a Cylinder

A cylinder is defined as a solid with a circle at either end. Hence, the volume of a
cylinder is determined by the formula:
V =  r2h
where  r2 is the area of the base and h is the height.
For example, a well is dug 28 m deep with a radius of 1.3 m. Calculate the volume of
earth removed.
Solution: h = 28 m
r = 1.3 m
V =  r2h
= 3.14 x 1.3 m x 1.3 m x 28 m
= 148.58 cu m, or m3
Practice Examples
31. Cement pillars that support bridges often are cylindrical. If the radius of a pillar is 0.5
m and it is 12.3 m high, what is the volume of the pillar?
________________________________________________________________________
________________________________________________________________________
________________________________________________________________________
________________________________________________________________________
32. Find the amount of concrete used to make a concrete pipe 4.65 m long, if the outside
radius is 0.63 m and the inside radius is 0.54 m.
________________________________________________________________________
________________________________________________________________________
________________________________________________________________________
________________________________________________________________________
7.2 BASIC DENSITY AND PRESSURE CALCULATIONS USED IN WELL

SERVICE OPERATIONS
The table below provides definitions of the calculations examined in this section. These
calculations relate to all operational areas and provide knowledge that you will use in the
field.
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WELL SERVICE OPERATIONAL CALCULATIONS

Term Definition
1. Density Closeness of matter in an object
2. Specific Gravity Density related to a reference material, usually water
3. Hydrostatic Pressure Weight of a column of fluid in a well
4. Hydrostatic Pressure Gradient Pressure exerted by a 1 meter column of fluid
5. A.P.I. Gravity American Petroleum Institute system for measuring
fluid densities
6. Differential Pressure Difference between two hydrostatic pressures
7. Bottom Hole Treating Pressure Pressure exerted on a formation at the bottom of a
well
8. Frac Gradient Pressure required to force fluid into a formation
9. Hydraulic Pumping Power Calculation for determining the output of a pump in
kilowatts
7.2.1 Density
When we say that one substance is heavier than another substance of an equal volume,
we are really comparing their densities. Mass refers to the amount of matter an object
contains. Unlike the weight of an object, an object's mass remains constant regardless of
where it is located.
For example, compare the mass of iron to the mass of an equal volume of wood. If we
have one cubic centimeter of iron having a mass of 7.9 grams and one cubic centimeter of
wood having a mass of 0.5 grams, we can say that iron has a greater density than the
wood.
We can express the densities of these substances as:

iron 7.9 g/cm3
wood 0.5 g/cm3
The table below shows the densities of some other common materials:
Substance g / cm3 kg / m3
water 1.0 1,000
aluminum 2.7 2,700
lead 11.3 11,300
gold 19,3 19,300
limestone 3.2 3,200
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ice 0.92 920

gasoline 0.70 700
sea water 1.03 1,030
mercury 13.6 13,600
But how can we calculate density? The calculation of the density of a substance is
possible if we know its mass and volume. In the middle column of the table, we can see
that all of the densities of the substances are expressed in grams per cubic centimeter
(g/cm3). That is, grams per cubic centimeter is another way of saying grams (the mass of
the substance) divided by cubic centimeters (the volume of the substance). In a more
general way, we can say that:
Density = Mass / Volume
In the metric system, water is used as the standard unit of density. This standard is
derived from the fact that 1000 cubic centimeters of water has a mass of 1000 grams. By
using the formula for density with the information we already know about water (that is,
1000 cubic centimeters of water has a mass of 1000 grams), we can calculate its density:
Density = Mass
Volume
= 1000 grams
1000 cubic centimeters
= 1.0 g / cm3
Knowing the formula for density as well as the mass and volume of a particular substance
enables you to calculate its density.
For example, if you know that the mass of 2 cubic meters of 15% HCl is 2.1498
kilograms, its density can be calculated as shown below:
Density = Mass
Volume
= 2.1498 kg
2 m3
= 1.0749 kg / m3
Note: The standard unit of density in the petroleum industry is kg/m3

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7.2.2 Specific Gravity (S.G.)

While perhaps not immediately apparent, Specific Gravity is a concept with practical
application in our daily lives. For example, when you test the antifreeze fluid in your car,
you are using the principle of Specific Gravity. Essentially, this test involves using an
instrument, called a hydrometer, to compare the density of the antifreeze fluid to the
density of a standard. The resulting comparison indicates whether or not the fluid needs
to be upgraded or changed. The table below lists the specific gravity of some substances
common to well service operations:
Substance Specific Gravity

water 1.0
crude oil .73890 to 1.0 +
15% HCl 1.0749
dry cement 3.15
iron 7.4
7.2.3 Calculating Specific Gravity

You will note from the table that no units (for example, grams, cubic centimeters, g/cm3)
are assigned to the values of specific gravity. This is because specific gravity (S.G.) is
the ratio of density of a material to the density of a known reference material (usually
water). The specific gravity of a substance is calculated by dividing the density of the
substance by the density of the reference material. Performing this calculation cancels
out the units, leaving only the numerical value for the specific gravity of a substance.
As an equation, specific gravity is expressed in the formula:

density of material in kg / m3
S.G. =
density of reference material in kg / m3
In the petroleum industry the reference material is water. From the previous section in
this module, we know that the density of water is 1000 kg/m3. Using this information
with the formula for specific gravity, we can calculate the S.G. for any substance, if we
know its density.
For example, we can calculate the specific gravity of 15% Hydrochloric Acid - a fluid
you use frequently in well servicing operations - using the formula outlined above. If we
know that the density of 15% Hydrochloric Acid is 1074.9 kg/m3, then we can calculate
its specific gravity as shown below:
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S.G = density of 15% hydrochloric acid

density of reference material (water)
= 1074.9 kg / m3
1000 kg / m3
= 1.0749
In summary, we can say that the specific gravity of 15% Hydrochloric Acid (HCl) is
equal to the weight of one cubic meter of HCl (1074.9 kg) divided by the weight of one
cubic meter of water (1000 kg). This gives us a value of 1.0749.
In another example, we can calculate the specific gravity of water itself:

S.G. of water = density of water
density of reference material
= 1000 kg / m3
1000 kg / m3
= 1.0
The specific gravity of a substance tells us the weight of a volume of that substance
relative to the weight of an equal volume of water. Therefore, specific gravity tells us
which substances are heavier than water and which ones are lighter. Substances that have
a specific gravity greater than 1.0 are heavier than water and those with a specific gravity
less than 1.0 are lighter than water.
7.2.4 Using Specific Gravity To Calculate Density

If the specific gravity of a material is known, we can calculate its density. This can be
achieved by manipulating the specific gravity formula:
S.G. = density of material
density of reference material
This new formula is shown below:

density of material = S.G. x density of water
Being able to derive this formula is important because there may be times when the only
piece of information you have is the specific gravity of a material, and from this you are
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required to calculate its density. For example, assume that you have been given a
Hydrochloric Acid solution (HCl) with a S.G. of 1.2. What is the density of this HCl?
We can calculate its density as follows:

density = S.G. x density of water
= 1.2 1000 kg/m3
= 1200 kg/m3
Note: Specific gravity of a fluid can be measured using a hydrometer, which is an

instrument that floats in the liquid being measured. A hydrometer sinks into the liquid
only to a depth the liquid’s density will permit, and the specific gravity is read from a
graduated scale on the instrument. For example, hydrometers are used to check the
quality of acid in batteries.
Practice Examples
33. A 15% HCl acid has a density of 1074.9 kg/m3. What is its specific gravity?
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34. A 3% KCl water solution has a density of 1017.4 kg/m3. What is its specific gravity?
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35. A 28% HCl acid has a density of 1142.2 kg/m3. What is its specific gravity?
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36. The specific gravity of a 10% HCl acid is 1.05. What is its density?
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37. The specific gravity of a 4% KCl water solution is 1.0239. What is its density?
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38. The specific gravity of a 10% calcium chloride solution is 1.0835. What is its
density?
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7.3 HYDROSTATICS
Hydrostatics is concerned with the study of fluids that are not in motion; that is, fluids
that are static. It is a part of science that is critical to BJ Canada’s operations. As a
Coiled Tubing Equipment Operator, you will be working with hydrostatics on a daily
basis in field operations and your work at the base. It provides the basis for much of the
information you read, the calculations you make, and the data you record. The key
concepts of hydrostatics are listed below.
7.3.1 Pressure
Pressure is defined as the force per unit area on a surface. At BJ Canada, the standard
unit of pressure is the Pascal. It will normally be expressed in either kPa, which is the
abbreviation for 1,000 Pascals; or MPa, which is the abbreviation for 1,000,000 Pascals.
7.3.2 Applied Pressure

Applied pressure is the pressure applied to the system by a pump or similar device.
Applied pressure is felt equally throughout a pumping system. For example, if 5,000 kPa
were applied to a pipe by a pump unit, we could measure at any point on that pipe and the
result would be a pressure of 5,000 kPa. In a well 4,000 meters deep, a pump pressure of
20,000 kPa at the surface will also be exerted at the bottom of the well.
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7.3.3 Hydrostatic Pressure (H.P.)

The other type of pressure we must deal with in well service operations is hydrostatic
pressure. This is pressure caused by the weight of the column of fluid in the well. A
hydrostatic pressure exists at every point in the column of fluid. The hydrostatic pressure
at any point in the well depends
on the height of the column of
fluid above that point.
The height of the column of fluid

refers to the true vertical height
of that column. To show that a
fluid column's height rather than
its overall volume is the
important factor, consider the
illustration of the irregularly
shaped vessel in Figure shown.
Each of the three parts of the

vessel shows the same height of
fluid even though their volumes
and shapes are different. This is
particularly important where
calculations of hydrostatic pressure involve columns of fluid which
are not vertical.
For example, in a deviated well (a well that has been drilled on a gradual curve or angle),
the depth of the well and the true vertical depth of the well are not the same. As
illustrated in Figure below, the measured depth of a deviated well may be 4,000 meters,
but the true vertical depth may be 2,500 meters. It is the true vertical depth that is used to
calculate hydrostatic pressure.
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There are only two ways that a hydrostatic pressure can be changed:
1. by changing the weight of
the fluid in the column
2. by changing the height of
the column
Therefore, when calculating basic

hydrostatic pressure exerted by a
column of fluid, equipment
operators require the depth (the
height of the fluid column in
meters) and the fluid weight
(indicated by hydrostatic pressure
gradient of the fluid).
7.3.4 Hydrostatic Pressure Gradients

The hydrostatic pressure gradient of a fluid is the pressure exerted by a one meter high
column. The unit that we use to measure this pressure is the kilopascal per meter, or
kPa/m. For example, the hydrostatic pressure gradient of water is 9.8 kPa/m. This means
that a column of water 1 meter high exerts a hydrostatic pressure of 9.8 kPa. From what
we have covered in the previous section, we know that the area covered by the column of
fluid is not important - it's the height of the column that determines the pressure exerted.
Figure below will help us develop a formula for calculating hydrostatic pressure using
two quantities:
1. the hydrostatic pressure gradient
2. the depth of a column of a fluid
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Figure 3
The illustration shows two columns of water. The dimensions of the column on the left
are 10 meters by 1 meter by 1 meter. The dimensions of the column on the right are 10
meters by 2 meters by 1 meter. As this illustration suggests, the column on the right
contains twice as much water as the one
the left. Yet in spite of this fact, they both
exert the same hydrostatic pressure: 98
kPa.
Perhaps a better way to explain this is to

imagine 10 individual square blocks of
water (the dimensions of each is 1 meter
by 1 meter by 1 meter). If you could
place them one on top of the other in a
single stack, then the weight of all ten
would press down on a surface area of
one square meter (see figure).
Remember, the hydrostatic pressure
gradient for water is 9.8 kPa/m. To
calculate the hydrostatic pressure exerted by our
stack on the surface on which it rests, we need to Figure 4
multiply its hydrostatic
pressure gradient (9.8 kPa/m) by its height (10 meters). The formula shown below can be
used to make this calculation.
Page 138
Hydrostatic Pressure = Hydrostatic Pressure Gradient x Depth

or
H.P. = H.G. x Depth
= 9.8 kPa/m x 10m
= 98 kPa
As in our previous example, the hydrostatic pressure is 98 kPa. Like our previous
example, the volume of water in the column is not considered in the calculation. Even if
the column of water is only one centimeter in diameter and 10 meters in height, the
hydrostatic pressure is still 98 kPa.
Using this formula we can calculate the hydrostatic pressure of any column of fluid. For
example, what would be the hydrostatic pressure of a column of water in a well 1500
meters deep.
Solution: H.P. = H.G. x Depth
= 9.8 kPa/m x 1500
= 14,700 kPa
Note: The equation for calculating hydrostatic pressure ( H.P. = H.G. x Depth) can be
manipulated to allow us to calculate hydrostatic pressure gradient (H.G.).
H.G. = H.P.
Depth
7.3.5 Calculating Hydrostatic Pressure Involving Other Fluids

As a Coiled Tubing Equipment Operator employee, you work with fluids other than
water. Some of these include hydrochloric acid, calcium chloride solution, sodium
chloride solution, and potassium chloride solution. A key part of well service operations
is to calculate the hydrostatic pressure these fluids exert in wells and other service
environments. To do this, you must first determine the appropriate hydrostatic pressure
gradient. This can be done in two ways: using a formula, or using tables found in the
Engineers Handbook.
Determining Hydrostatic Pressure Gradient Using A Formula

The hydrostatic pressure gradient (H.G.) of a fluid can be calculated using two pieces of
information. One is the specific gravity of the fluid itself, and the other is the hydrostatic
pressure gradient of water (9.8 kPa/m). These are used in the formula listed below:
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H.G. of a fluid = specific gravity of the fluid x H.G. of water (9.8 kPa/m)
Or, if the density of the fluid is known, you can substitute the formula for specific
gravity:
H.G. of a Fluid = density of material x H.G. of water (9.8 kPa/m)
density of water
For example, the specific gravity for a 14% Hydrochloric (HCl) Acid solution is 1.0702.
Using the formula above, we can calculate the hydrostatic pressure gradient (H.G.)
H.G. of 14% HCl = 1.0702 x 9.8 kPa/m

= 10.488 kPa/m
or, using the density of 14% HCl
H.G. of 14% HC = 1070 kg / m3 x 9.8 kPa/m

1000 kg / m3
= 10.488 kPa/m
Determining Hydrostatic Pressure Gradient Using Tables in the Engineers Handbook

The hydrostatic pressure gradient (H.G.) of a fluid can be determined using the tables in
the Engineers Handbook. Table 1 below shows the Hydrochloric Acid Table from the
handbook.
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Page 141
Using the same 14% HCl solution as an example, we can see from the table that:
Specific Gravity = 1.0702
Density = 1070.2 kg/m3
Hydrostatic Pressure Gradient = 10.495 kPa/m
Notice that the value for the H.G. for 14% HCl found in the table in the Engineers
Handbook differs slightly from the value calculated using the formula above. This
difference exists because the calculation uses a H.G. value for water rounded to one
decimal place (i.e., 9.8 kPa/m). The value in the tables (10.495 kPa/m) is calculated
using a H.G. value for water taken to three or four decimal places, and is more accurate
than the value calculated from the formula.
Practice Examples
39. Using the formulas covered in the preceding sections, answer the following
questions:
(a) What is the hydrostatic pressure gradient (H.G.) of a fluid having a density of 1550
kg/m3?
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(b). What is the hydrostatic pressure gradient (H.G.) of a fluid having a density of 1750
kg/m3?
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40. Using the appropriate formulas and tables, solve the following questions:
(a) What is the hydrostatic pressure (H.P.) at the bottom of a well 1500 meters deep
filled with 28% HCl acid?
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(b) What is the hydrostatic pressure (H.P.) at the 1,900 meter point of a 2,700 meter well
with both tubing and casing full of 3% KCl water?
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________________________________________________________________________
________________________________________________________________________
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7.4 A.P.I. GRAVITY

The American Petroleum Institute (A.P.I) has developed a system for measuring fluid
densities that is used extensively throughout the world. Basically, it is another means to
express the ratio of a material's density to a known reference density of another material.
While BJ Canada’s Equipment Operators are not required to be experts in the detailed
workings of the A.P.I. gravity system, you should know how to convert A.P.I. values to
those of the conventional specific gravity system.
Many of our customers use A.P.I. gravity values when they refer to hydrocarbon fluids
and the work they require on their wells; therefore, the required calculations require a
conversion to the system we use. You can make these conversions in two ways: by using
a formula, or by using the tables in the Engineers Handbook.
Converting A.P.I Gravity to Conventional S.G. Using A Formula

The formula to convert A.P.I. values to conventional specific gravity values is listed
below:
141.5 _
Specific Gravity = 131.5 + A.P.I. gravity
Sample Problem #1: What is the specific gravity of 350 A.P.I. oil?
Answer: S.G. =
141.5 _
131.5 + A.P.I. gravity
141.5 _
= 131.5 + 35
= .8498
There may be times when you have to calculate the A.P.I. gravity from the conventional
Specific Gravity. The formula shown below will enable you to do this.
141.5 _
A.P.I. Gravity = specific gravity - 131.5
Page 143
Sample Problem #2: What is the A.P.I. gravity of oil that has a specific gravity of .8448?
Answer: A.P.I. Gravity = 141.5 _ - - 131.5

specific gravity
141.5
= .8448 - 131.5
= 35.990 A.P.I.
Converting A.P.I. Gravity to Conventional S.G. Using the Engineers Handbook

Converting A.P.I. Gravity values to conventional specific gravity can be achieved using
the tables in the Engineers Handbook. Using 35° A.P.I. oil as an example, we can see
from the table (Table 2) that:
Specific Gravity = 0.8498

Density = 848.8 kg/m3
Hydrostatic Pressure Gradient = 8.334 kPa/m
Page 144
Page 145
Practice Examples
41. Using the formulas covered in the preceding sections of this module, answer the
following questions:
(a) What is the specific gravity of 59° A.P.I. oil?

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(b) What is the density of 59° A.P.I. oil?

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(c) What is the hydrostatic pressure gradient (H.G.) of 59° A.P.I. oil?
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________________________________________________________________________
________________________________________________________________________
42. Using the formulas covered in the preceding sections of this module, answer the
following questions:
(a) What is the A.P.I Gravity of oil that has a specific gravity of .8273?
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________________________________________________________________________
________________________________________________________________________
(b) What is the hydrostatic pressure gradient (H.G.) of oil that has a specific gravity of .
8273?
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(c) What is the density of oil that has a specific gravity of .8273?
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7.5 DIFFERENTIAL PRESSURE

Differential pressure is the difference between two separate hydrostatic pressures. In a
well, it occurs when two columns of fluid having different specific gravities are present
and linked in the well. The concept of differential pressure is illustrated in Figure below.
Figure 5
One column contains water and the other contains cement. The hydrostatic pressures
exerted by these two columns of fluid are unequal and because of this, we say that there
is a pressure differential at the fluid interface; that is, at the bottom of the columns.
The concept of pressure differential finds frequent application in the oil well servicing
industry. Figure below illustrates a side view of a typical oil well at a depth just above
the 1000 meter level. As in the example we examined above, this oil well is made up of
two columns of fluid: the tubing, which is filled with oil; and the annulus, which is filled
with water. For the purposes of this example, we will assume that these two
columns of fluid are connected at the 1000 meter level. At this level, the tubing ends, and
the oil and water are free to interact.
Page 147
The calculations that accompany Figure below indicate mathematically that there is a
differential pressure between the oil and the water in this well of 1,470 kPa.
The sample problems and solutions below are presented to give you an indication of the
calculations that you will be required to make on service operations in the field.
Figure 6
Page 148
Sample Problem #3
An oil well is 2000 meters deep (see figure below).
The annulus contains cement with a density of 1780 kg/m3. The tubing contains mud
with a density of 1200 kg/m3. What is the differential pressure at 2000 meters.
Answer:
(a) (i) Calculate the hydrostatic pressure gradient (H.G.) of the mud.
H.G. = density of material x H.G. of water (9.8 kPa / m)

density of water
= 1200 kg / m3 x 9.8 kPa / m

1000 kg / m3
= 11.76 kPa / m
Page 149
(ii) Calculate the hydrostatic pressure (H.P.) of the mud at 2000 meters.
H.P. = H.G. x depth
= 11.76 kPa / m x 2000 meters
= 23,520 kPa
(b) (i) Calculate the hydrostatic pressure gradient (H.G.) of the cement.

density of water
= 1780 kg / m3 x 9.8 kPa / m

1000 kg / m3
= 17.44 kPa / m
(ii) Calculate the hydrostatic pressure (H.P.) of the cement at 2000 meters.
H.P. = H.G. x depth
= 17.44 kPa / m x 2000 meters
= 34,880 kPa
(c) Calculate the differential pressure by subtracting the hydrostatic pressure for mud from
the hydrostatic pressure for cement.
Differential Pressure = cement H.P. - mud H.P.
= 34,880 kPa - 23,520 kPa
= 11,360 kPa
Page 150
Sample Problem #4
You are completing a cement plug job (see Figure below). The drill pipe is spotted
at 1200 meters. Using fresh water, you have displaced the cement (1901 kg/m3 density)
around the bottom and back up the annulus 200 meters (to the 1000 meter point). What is
the differential pressure?
Answer:
(a) (i) Calculate the hydrostatic pressure gradient (H.G.) of the cement.

density of water
= 1901 kg / m3 x 9.8 kPa / m

1000 kg / m3
= 18.629 kPa / m
(ii) Calculate the hydrostatic pressure (H.P.) of the cement at 1000 meters.
H.P. = H.G. x depth

= 18.629 kPa / m x 1000 meters
= 18,629 kPa
Page 151
(b) (i) We know that the hydrostatic pressure gradient (H.G.) for water is 9.8 kPa/m.
(ii) Calculate the hydrostatic pressure (H.P.) of the water at 1000 meters.
H.P. = H.G. x depth
= 9.8 kPa / m x 1000 meters
= 9,800 kPa
(c) Calculate the differential pressure by subtracting the hydrostatic pressure for water from
the hydrostatic pressure for the cement.
Differential Pressure = Cement H.P. - water H.P.
= 18,629 kPa - 9,800 kPa
= 8829 kPa
Note: There is an alternate way to solve these types of questions. Rather than
calculating the hydrostatic pressure for each of the fluids and then
subtracting these values to find the differential pressure, you can subtract
the two calculated hydrostatic pressure gradient (H.G.) values first.
Then, multiply the difference between the H.G. values by the depth of the
fluid column to determine the differential pressure. Sample Problem #3
is solved using this method.
Sample Problem #5
Sample Problem #4 is solved again using the alternative method outlined in the "Note"
above.
Answer:
(a) Calculate the hydrostatic pressure gradient (H.G.) of the cement.

density of water
= 1901 kg / m3 x 9.8 kPa / m

1000 kg / m3
= 18.629 kPa / m
Page 152
(b) We know that the hydrostatic pressure gradient (H.G.) for water is 9.8 kPa/m.
(c) The difference in H.G. values "a" and "b" equals

(18.629 kPa/m - 9.8 kPa/m) 8.829 kPa/m.
(d) Differential Pressure is found by multiplying the difference in H.G. values (8.829
kPa/m) by the depth of the columns of fluids.
Differential Pressure = Difference in H.G. values - Depth of Column
= 8.829 kPa/m - 1000 meters
= 8829 kPa
Practice Examples
44. You have a 3200 meter well with a tubing full of 28% HCl (density of 1142.2 kg/m3).
The annulus is full of fresh water. What is the differential pressure of the two columns?
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45. An oil well is 1700 meters deep. The tubing in it is filled with fresh water. The
annulus is filled with 3% KCl water (density of 1017.4 kg/m3). What is the differential
pressure?
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7.6 BOTTOM HOLE PRESSURE
7.6.1 Bottom Hole Treating Pressure

Bottom Hole Treating Pressure (B.H.T.P.) is the pressure exerted on a formation at the
bottom of a well. B.H.T.P. is the combined force of two pressures:
(a) the hydrostatic pressure (H.P.) caused by the column of fluid in the tubing
(b) the pressure exerted on the column of fluid by a pump.
In Figure (right), we are

pumping 15% HCl acid at 7000
kPa down in a well that is 3000
meters deep.
The B.H.T.P. is the sum of the

hydrostatic pressure of the HCl
and the pressure exerted by the
pump.
Figure 9
In this case the hydrostatic pressure is:
H.P. = H.G. x Depth

= (S.G. of 15% HCl x H.G. of water) x depth
= (1.0749 x 9.6 kPa/m) x 3000 meters
= 31,602 kPa
Page 155
The bottom hole treating pressure can then be calculated:
B.H.T.P. = H.P. + Pump Pressure

= 31,602 kPa + 7000 kPa
= 38,602 kPa
7.6.2 Bottom Hole Pressure
Breakdown
The "breakdown" point (see Figure below) is observed on the surface gauges as a
pressure peak.
This peak is reached when sufficient fluid pressure is built up to overcome the earth's
compressive forces tending to hold the rock material together. At "breakdown," the rock
fractures along a plane perpendicular to the minimum compressive stress in the
formation.
Fracture Extension
The horizontal line in Figure (above) to the right of the "breakdown" peak represents the
extension of the fracture. This means that as the pumping of fluid continues, the fracture
width continues to increase. Once sufficient width has been established, sand-laden
slurry is injected. The sand provides the support to keep the fractures of the rock
formation open.
Page 156
Wellhead Pressure
This pressure is registered at the surface, and includes pump pressure and friction
pressure while pumping, but does not include hydrostatic pressure.
Instantaneous Shut In Pressure

When pumping stops, the wellhead pressure falls to the Instantaneous Shut In Pressure
(I.S.I.P.). Essentially, I.S.I.P. is equal to the wellhead pressure registered at the surface
less friction down the tubulars. Friction pressure is not considered because the actual
flow of fluid through tubulars stops when pumping stops. It is for this reason that the
wellhead pressure falls instantly to the I.S.I.P. point when pumping stops. The downward
sloping line to the right of the I.S.I.P. point on the graph indicates a gradual loss of
pressure. This pressure loss is caused by fluid leak off into the formation matrix.
Bottom Hole Treating Pressure (B.H.T.P.)

Bottom Hole Treating Pressure is used to determine the pressure required in the
perforations of the casing to propagate a fracture. It is calculated in fracturing operations
by adding the Instantaneous Shut In Pressure to the Hydrostatic Pressure.
B.H.T.P. = H.P. + I.S.I.P.
Sample Problem #6
Calculate the B.H.T.P. on a job where the I.S.I.P. equals 13,000 kPa and the fluid in the
well has a density of 850 kg/m3. The depth of the zone being treated is 1000 meters.
Answer:
= 21,330
Page 157
Practice Examples
46. Calculate the bottom hole treating pressure (B.H.T.P.) for a well 3,800 meters deep.
We are pumping 28% HCl at 5,500 kPa.
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________________________________________________________________________
________________________________________________________________________
47. Calculate the B.H.T.P. for the case when the I.S.I.P. equals 11,000 kPa and the fluid in
the well has a specific gravity of 1.0550. The depth of the zone to be treated is 1450
meters.
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________________________________________________________________________
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48. What is Instantaneous Shut In Pressure?

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7.6.3 Frac Gradients

Frac gradient (F.G.) refers to the pressure that is required to force fluid into a formation.
It is simply the Bottom Hole Frac Pressure (B.H.F.P.) divided by the depth. Frac
Gradient is expressed as a gradient, in kPa/m, to enable:
1. the easy calculation of the anticipated wellhead treating pressure (W.H.T.P.) and
pumping power requirements
2. on site evaluation of problems encountered during pumping (eg: such problems
include higher than anticipated W.H..TP., which may be the result of the high F.G.
or a perforation or tubular problem)
The formula for calculating frac gradient (F.G.) is:

F.G. = I.S.I.P + H.P.
depth
Sample Problem #7
A well has an instantaneous shut in pressure of 14,000 kPa. The treatment zone in the
well is at a depth of 1,500 meters and the hole is full of 3% KCl water. We know from
the Engineers Handbook that the H.G. of 3% KCl is 9.98 kPa/m. What is the frac
gradient?
Answer: F.G. = I.S.I.P + H.P.

depth
= 14,000 kPa + (9.98 kPa / m x 1500m)

1500
= 19.3 kPa / m
F.G. = I.S.I.P + H.P.

The formula used for the calculation of frac gradients, that is,
depth
can be manipulated to give us a formula for calculating the pressure required to break
down the formation in a well. The formula for frac pressure is
I.S.I.P + H.P. = F.G. x Depth

or
Frac Pressure = F.G. x Depth
Page 159
Sample Problem #8
Calculate the pressure required to break down the formation in a well 1,800 meters deep
where the fracture gradient is 22.3 kPa/m.
Answer:
Frac Pressure = Frac Gradient x Depth
= 22.3 kPa/m x 1,800 meters
= 40,140 kPa
Practice Example
49. You are completing an acid wash on a well that is 2000 meters deep, and the
frac gradient is 17.9 kPa/m. What would be the maximum allowable treating
pressure that can be applied without fracturing the well?
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7.7 HYDRAULIC PUMPING POWER
Part of your responsibilities as an Equipment Operator requires you to calculate pumping

power on service operations. These calculations are important since they inform you
whether or not a particular pumper unit on a job has the power capability to deliver the
required pressures. The formula used to calculate pumping power is:
Power (KW) = Rate (m3 / minute) x pressure (kPa)
60
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Sample Problem #
The program for an acid job calls for a rate of .85 m3 / minute at a pressure of 16,000 kPa.
What is the pumping power required on this job?
Answer:
Use the formula for power listed above:
Power (KW) = Rate (m3 / minute) x pressure (kPa)

60
3
= .85 m / minute x 16,000
60
= 226.66 KW
Sample Problem # 10
An injection test is required on an injection well. The program calls for a step rate test to
start at .1 m3 / minute and then increase to 1.2 m3 / minute. The maximum pressure
allowed is 35,000 kPa. How much power is required to complete this test?
Answer:
Use the maximum rate in the formula used to calculate power:
Power (KW) = rate x pressure

60
= 1.2 m3 / minute x 35,000 kPa
60
= 700 KW
Note: A typical acid pumper will develop a maximum of 260 KW of power.

Metric Conversion: 1 hydraulic horse power (H.H.P.) = .746 KW
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Practice Examples
50. Calculate the pumping power (Kw) required to pump 3.2 m3/minute at 20,000
kPa.
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51. The program for an acid job calls for a rate of .90 m3/minute at a pressure of
18,000 kPa. What is the pumping power required on this job?
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8.0 APPENDIX 2: AUXILIARY EQUIPMENT
The purpose of this Appendix is to provide extra information relating to auxiliary

equipment used on a daily basis as part of well servicing operations. In many cases, the
information provided is not part of your job duties; for example, external repair vendors
perform the overhaul of swivel joints and check valves. Although you would not do these
tasks as part of your job, there is some value in understanding the procedures.
The advantage of understanding these procedures involves the goals of Corporate BJ,
which is to create consistent competency levels for their operators on a world-wide basis.
This means that regardless of the location in the world, all operators within the same level
are expected to know and perform similar types of operations and tasks with a similar
degree of competency.
In order to fulfill these requirements, this appendix discusses some of the more common
procedures that apply to BJ International expectations. You may also be asked questions
about on any of the topics on the tests you complete before you can progress to the next
level of Equipment Operator.
8.1 SWIVEL JOINTS (CHIKSANS)

Perform the following operations to prevent leakage, malfunctioning due to internal wear,
packing degradation, or ball race deterioration.
 Lubricate a swivel joint after about 15 jobs or when it is difficult to rotate,

whichever occurs first. Proper lubrication prevents leakage, malfunctions,
packing degradation, and ball race deterioration.
 Swivels are greased with a normal grease gun. The recommended grease to use is
Jet-Lube "Arctic" NLGI Grade 2. The procedures for greasing swivels are as
follows:
- one shot of grease per quarter turn of the swivel joint (grease should not be
coming out of the dust seal)
- should the swivel joint feel rough after greasing, pull it out service for
inspection
- swivel should be ready for use
 Replace packing whenever a leak occurs.
 After you have used a swivel joint for an acid or corrosive job, always flush it
thoroughly with water. This practice will prevent corrosion and deterioration
when the swivel joint is not in service.
 Document the repacking of a swivel joint as specified by the district policies.
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8.1.1 Disassembling the Swivel Joint

The parts of a swivel joint are shown in Figure below.
Removing the Ball Bearings

1. Mount the swivel joint on a proper rack or vice.
2. Remove the ball-plug snap rings on one of the races with snap ring pliers.
3. Remove the ball plugs.
4. Secure the female component in a vice or rack with the ball-plug hole facing
down. Rotate the swivel joint slowly. The bearings should drop out. If they do
not, use a magnet or small screwdriver to remove them.
5. Repeat steps 2 to 4 for the remainder of the races.
Figure: Swivel Joint Components
8.1.2 Disassembling Parts

1. Separate male and female parts. If they do not come apart, check to see if any
bearings are still in the race channels.
2. Remove the packing from the female packing chamber. Be very careful not to
damage the sealing surface.
3. Remove the o-ring from the female component.
4. Remove the grease retainer from the male component.
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8.1.3 Cleaning and Inspecting the Parts

1. Inspect all parts for excessive wear, corrosion, or other damage.
2. Inspect ball races for dints or grooves.
3. Clean all parts and smooth any rough spots with a fine emery cloth.
4. Check male and female components for excessive wear or corrosion.
5. Inspect the inside surface of the elbow of the swivel joint very carefully for
erosion or corrosion. Most wear usually occurs here. Refer to Figure below,
which shows high wash areas. Check the ball races for severe pitting or wear.
6. Smooth all parts carefully and clean all surfaces before assembling. Remove
minor scratches or pitting with a fine abrasive. All sealing surfaces should be
completely smooth before assembling.
8.1.4 Assembling the Swivel Joint

1. Apply a thin coat of lubricant to the ball races, sealing surfaces, and o-rings.
Apply lightweight oil to the ball bearings.
2. Install new packing and o-ring in the female component as required (refer to
Figure below). Apply a thin coat of lubricant. Note: The anti-extrusion ring
(brass ring) must face outward, toward ball races.
3. Place the grease retainer on the male component and position it at the extreme end
of machine surface so that it is clear of female end when the parts are initially
assembled. Note: The lip on the grease retainer must face away from the ball
races when it is installed.
Figure: High Wash Areas of Swivel Joints

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Note: The areas of high internal wash are shown above. Damage occurs from scouring
and fluid turbulence during pumping operations. Always check the inside of the
swivel joints for this kind of damage. Failure to do so can result in serious injury.
4. Secure the female component on a swivel joint rack or vice.

5. Secure the female component on the swivel joint rack so that the ball-plug holes
are in an upward position.
6. Insert the male component into the female component.
7. Look through ball holes and align the ball races with the holes.
8. Drop the balls through the holes into the races and rotate the male component
after you drop each ball. All balls must be put back into the ball races in the same
manner. Use a small screwdriver to push the balls out of the way. Continue the
process until all balls are in place. Note: Make sure you install the correct
number of balls. The total number of balls per race in a 2” (50.8 mm) swivel
joint is 23. In a 3” (76.2 mm) swivel joint, it is 33.
9. Lubricate the ball bearings with light oil.
10. Install a grease retainer into the groove of the female component. Use a small
screwdriver and take care not to tear the retainer. Make sure the lip of the retainer
faces outward.
11. Insert new ball plugs with the grooves properly aligned with the ball bearings.
12. Install the snap-ring.
8.1.5 Lubricating the Swivel joint

1. Remove the grease plug and install a proper grease nipple fitting.
2. Use a grease gun and inject a small amount of grease in each bearing race.
3. Rotate the male component 90 degrees (one-quarter turn) and add more grease.
As you grease, rotate the male end continuously. Note: Avoid injecting too much
grease. When grease is pushed out the swivel assembly you have over-greased.
Over greasing will make it difficult or impossible to rotate the swivel joint, or it
will cause distortion of the anti-extrusion ring.
4. Repeat step 3 twice.
5. Check that the swivel joint rotates smoothly. If it rotates roughly or not at all,
disassemble it and check for proper assembly or damaged parts.
6. If you notice lubricant on the inside of the primary packing or distortion of the
packing on the inner diameter, disassemble the joint and carefully inspect the
seals. Replace them when damaged.
7. Remove the grease fittings and replace the lube plug.
8. Document the repack in accordance with the district requirements.
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8.2 PLUG VALVES

You should service plug valves monthly. Every base should have a high pressure grease
gun with a gauge for injecting grease into plug valves. The recommended grease for plug
valves is Climax 800 XH. The procedures for greasing plug valves is as follows:
 the valve should be in the open position
 pump grease into the plug valve until you see the grease start coming into the
open valve (the pressure on the gauge would be approx. 9000 psi)
 work the plug valve
 plug valve should be ready for use
The components of a plug valve are shown in Figure below.
8.2.1 Disassembling the Plug Valves

1. Use a swivel joint rack or proper shop vice to hold the plug valve properly in
place.
2. Remove the grease fitting, lock nut, actuator cap, and felt gasket (Figure below).
3. Remove the body cap using a proper socket wrench. If a plug valve has a
threaded end on the cap, a larger washer or a plate with a hole drilled in it may be
fastened to it. Use the plug cap nut to hold the body cap wrench in place.
4. Remove the plug by pulling and twisting the plug in a circular motion with a
wrench. It may be necessary to hammer the plug out. Using a thick punch placed
through the hole in the bottom of the valve body may help; however, it may
damage the plug.
5. Remove the side segments by gently prying them from the sides of the cavity wall
with a screwdriver.
6. Remove the seal segments. If they must be pried loose, be careful not to damage
the body cavity.
7. Remove and replace any damaged button head grease fittings.
8. Clean the cavity surface with diesel or solvent and wipe it dry. Make sure the
surface is completely clean.
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Figure: Plug Valve

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8.2.2 Repairing the Plug Valves

1. After you have cleaned the parts, check them for wear and corrosion. The portion
of the body that contacts the segment seal, the plug and body, and the body
surfaces that contact the lower and upper stem seals must be completely smooth.
2. Use a file to remove dents and rust from the side segments that may damage the
seal segments.
3. Use a file to remove rust and deposits from the center portion of the seal segment
that contacts the body.
4. Use 400-grit sandpaper to clean all other seal surfaces.
5. Replace any parts with sealing surfaces that cannot be smoothed with 400-grit
sandpaper.
8.2.3 Assembling the Plug Valves

1. Inspect all new and used parts and remove small burrs, dirt, or rust. Remove
grease from the passageway in the plug (if the valve is greased through the plug).
2. Apply a very thin coat of plug-valve grease to the surface of seal segments that
will contact the valve body.
3. Install the seal segments in the seal-segment grooves and install both seal
segments in the valve body.
4. Apply a liberal amount of plug-valve grease to the exposed surface of the seal
segments and to the exposed portion of the body cavity that will contact side
segments.
5. On valves designed with grease fittings in the plug, install grease fitting into the
plug and pump grease until clean grease emerges from the grease passage.
Tighten 3/8” (10 mm) NTP fittings to 50-60 ft-lbs (67.8 to 81.4 N.m), and ½” (13
mm) NPT fittings to 80-90 ft-lbs (108.6 to 122.1 N.m).
6. Apply a liberal amount of plug-valve grease to the outside area of the plug.
7. Place the plug stem, seals, and nylon packing on the top and bottom of plug.
8. Apply a liberal amount of plug-valve grease to the side segments and install
them in the body so that about one half of their height remains above the top
of the body cavity.
9. Install the plug using the segments as a guide. Apply firm pressure to the plug
after aligning the chamfers on the plug and seal segments. After the plug is
partially installed by hand, use a soft face mallet or a block of wood (available
in the shop) between a hammer and the plug to firmly seat the plug in the
body.
10. Inspect the segment seals to ensure that they are still in the seal segment
groove. If the seal has popped out, then you have used too much grease
between the seal segment and the body. If that is the case, remove the plug
and remove some of the grease from the seal segments. Then, reinstall the
segments and the plug.
11. Install a new o-ring on the body cap. The ring should fit firmly in the groove of
the body cap.
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12. Remove excess grease from the body cap shoulder area. This area should be
completely free from foreign debris.
13. Apply anti-seize compound to the body cap threads and install the body cap into
the body. When using hammer wrenches, hit the wrench with a heavy hammer
(at least 5 lbs (2.3 kg)) or a heavy mallet a few times after the body cap reaches
the bottom.
14. Replace the plug cap in the open position by aligning it with the valve body and
turning it. Tighten the stop nut until the handle is firmly in place.
15. If the valve is equipped with an actuator or operator, bolt it back on the valve and
check if the valve opens and closes completely. Adjust limit stops, if necessary.
16. Install the grease nipple and grease valve in an open position until grease flows
into the through bore.
8.3 CHECK VALVES

You should service your check valves each month or after approximately 15 jobs. A
drawing of a check valve is shown in Figure below. Follow the maintenance procedure
below.
Check valve
flapper
Check valve cap, remove in a clockwise
direction, remove cap and replace “O” if
needed. Install new flapper, replace and
ttighten cap
Flow
direction
Dart style check valve

normally used in nitrogen
services
Figure: Check Valves

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Note: All check valves have the proper flow direction indicated on their valve body,
usually with an arrow. When assembling them, ensure that the arrow points in the same
direction as the fluid flow.
8.3.1 Disassembling Check Valves

1. Attach the valve to a proper workbench or place it in a vise capable of properly
holding it.
2. When repairing the valve in the field, leave it attached to the main line.
3. Use a proper box-end hammer wrench and in a counter clockwise direction,
pound the cap off the top. You will see a large snap ring on the inside body of the
valve.
4. Use a pair of snap ring pliers or a large screwdriver to pull the snap ring from the
body of the valve.
5. Lift the flapper from the body.
6. Remove the O-ring.
8.3.2 Assembling Check Valves

1. Clean the threads on the valve cap and internal threads on the valve body.
2. Clean the o-ring groove and insert a new o-ring.
3. Insert a new flapper with new bushings on the lugs.
4. Replace the snap ring.
5. Grease the threads on the cap and grease the top surface of the check valve
(where the cap meets the body).
6. Screw the cap back in place, taking care not to cross thread the cap.
7. Tighten the cap with a proper wrench and hammer
8.4 IRON TRUCK

BJ Services uses Iron Trucks in its land-based oil and gas well servicing operations.
These trucks are built and equipped to serve one primary purpose: to move heavy
connections and assist in picking up and laying the surface treating line on the well site.
Properly trained and knowledgeable Equipment Operators are better able to prevent
needless accidents and damage to the equipment.
You should note that BJ Services uses different manufacturers for its vehicles. In
addition, it is often necessary to modify and update equipment as new trucks are
produced. For this reason, some of the procedures that we will cover in this section may
not apply to your particular vehicle. Your supervisor or the maintenance department will
explain anything special about your particular unit.
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All normal procedures for driving and operating units, as discussed earlier in this manual,
apply to the operation of iron trucks. The purpose of this section is to highlight the
additional considerations that apply to iron trucks.
8.4.1 Operation and Maintenance

There are several things that require your attention if you are operating an iron truck with
a crane or boom. Although you will receive additional training to operate any crane or
boom, the purpose of this section is to highlight the basic safety and operational
procedures. Consult the HSE Resource Book for more information about operating
cranes and booms.
8.4.2 Hydraulic Booms

Check the operation of the boom before you leave for the job site. If it is hydraulically
operated, engage the P.T.O and set the engine idle at no more than 800 rpm. This is the
proper engine speed to use for safe, smooth operation of the boom. Higher engine speeds
cause the boom to operate with a jerky, uneven motion, and may injure you or other
personnel.
Safety Guides
1. ensure there are no overhead obstructions or power lines which might be struck
by the boom as it is moved
2. ensure anyone who might be assisting you is not in a position where they could be
struck by the boom
3. make certain the boom is not anchored or chained to anything on the deck of the
iron truck
Cable Winch
Check the cable winch operation by operating the control levers in both directions. The
cable should move in accordance with the operation of the controls.
Emergency Kill Control
The road engine’s emergency kill control lever (or toggle switch) is also considered to be
part of the boom’s controls. In the event that the boom cannot be controlled, the
emergency engine kill switch stops the boom’s movement. Throwing this switch to the
emergency position will do one of two things, depending on how your unit is equipped.
It will either kill the engine, thereby stopping the hydraulic power supplied by the engine;
or, it will relieve the hydraulic pressure from the system and leave the engine running.
Your supervisor will explain which system your truck has.
Note: Pull the lever or move the switch only if there is an actual emergency.
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After you are satisfied that all of the controls are working properly, make certain you
replace the boom securely in its cradle. This should be done in order to avoid any strain
on the system’s hydraulics. Do NOT forget to disengage the P.T.O. when you are
finished using it. Driving the unit to location with the P.T.O. engaged will severely
damage the unit.
Safety Guides for Operating
1. where possible, use the boom should be used to unload all connections and lines
2. watch for overhead obstructions and other people anytime you are operating the
boom
3. use caution when swinging the boom when it is loaded, especially when you have
a load at the end of the boom
4. use caution when moving a load at the end of the boom, since the load continues
to swing in the direction of the movement after you let go of the boom’s control
lever
5. keep the load close to the ground whenever possible and observe the boom
capacity at all times
8.5 WINCH TRACTOR OPERATIONS

As with iron trucks, all BJ Canada policies and procedures for driving and operating
heavy units apply to winch tractors. These are discussed earlier in the manual. The
purpose of this section is to outline extra safety precautions and procedures that are
specific to winching operations.
Before operating a power winch, you must visually check all of the various parts of the
power winch and wireline cable to assure that they are in safe operating condition. If you
discover that the power winch is in need of repair, report it to your district’s maintenance
personnel before you leave for the job site.
Safety Guides
1. ensure all personnel are well away from the unit and load before operating the
power winch
2. if there is a chance that the load may slide or roll off during unloading operations,
do not remove the tie down devices until the lifting slings and hoist line are
attached and the slack in the hoist line is taken up
3. no worker shall remain or ride on any load or part of a load being raised or
lowered
4. do not work, stand or pass under a suspended load
5. do not work, stand or pass between the winch mechanism and the load being
winched
6. always wear appropriate PPE, which at the minimum includes coveralls, safety
glasses, hard had, gloves, and proper foot ware
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7. always lower loads with the winch clutch engaged, and never loads by free
spooling the winch
8. all guards or safety devices shall remain in place on any power winch equipment
(the guards will only be removed when necessary for immediate repairs)
9. no less than three windings of wireline cable shall be on the power winch drum
10. when lifting a load, all personnel shall stand outside the radius of the winch line in
case of breakage
11. be especially careful of ”pinch points” when operating winches
12. ensure the winch truck is properly lined up with a load before hoisting begins
13. empty storage tanks or field bins of any materials before hoisting to minimize the
weight
14. never splice wireline cable that is directly connected to a winch drum onto
another length of cable using wire rope clips or splices
15. discarded or defective cable must be marked so that it will not be used again for
hoisting
16. spool wireline onto the winch drum in a level fashion to avoid the cable from
being pinched or flattened against other loops
8.6 WIRE ROPE AND CABLE

The information in this section shows you how to correctly handle, maintain, store, and
use wire rope for the best performance and safety.
Description
A wire rope is a piece of flexible, multi-wired, stranded machinery made of many
precision parts. It usually consists of a core member around which a number of multi-
wired strands are ”laid” or bent. There are two general types of cores for wire rope: fiber
cores and wire cores. The fiber core may be made from natural or synthetic fibers. The
wire core can be an independent Wire Rope Core (IWRC), a Strand Core (SC), or a
patented TUF-FLEX Core.
The purpose of the core is to provide support and maintain the position of the outer rope
strands during operation. Any number of multi-wired strands may be laid around the
core. The most popular arrangement is six (6) strands around the core.
Handling Wire Cable
Even though wire rope is made with steel for increased strength, proper care is required if
the cable we use will be able to give us the full service life for which it was designed.
Unwinding New Wire Cable
A wire rope can be damaged permanently even before it goes into service. Unwinding
from a wire spool the wrong way can put destructive ”kinks” and ”dog legs” in the rope.
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For this reason, it is important that wire rope be unwound from wire spools in the proper
manner.
Set the spool up on jacks so that the rope comes from the underside of the spool.
Once unwinding has started, the spool may begin to turn faster than the rope is being
pulled off; however, no damage is done to the rope. This is because the rope, in coming
from the underside of the spool, will simply loosen without forming loops, kinks, or dog
legs.
Short lengths of wire rope frequently come in ”coils.” Uncoil these lengths by rolling the
coil slowly like a wheel, leaving behind a straight rope. Uncoiling by laying the coil flat
and pulling off the top gives you a hard- to handle, ”kinky” rope. This is not only
incorrect, it is time wasting, frustrating, and often damaging to the wire rope.
Winding Wire Rope onto a Drum
When unwinding wire rope from a spool, the best procedure to use is to first lay the rope
out straight on the ground prior to winching it onto the drum. If the rope is to be pulled
directly from a spool onto the winch tractor’s drum, apply tension to the wire rope spool
to eliminate the possibility of reverse bends, kinks and/or other rope damage.
Wire Rope Break-In
A new wire rope should have a short ”break- in” period before it is put into full operation.
During this time, the wire rope should be run with a light load. The break-in process
results in the adjustment of the core wires and strands into a more efficient rope. A
proper break-in period will result in a longer and safer wire rope life.
Cutting Wire Cable
Wireline cable may be cut in only one of three ways:
1. cable cutters
2. commercial cutter
3. cutting torch
A cutting torch is the recommended procedure because this process fuses the frayed ends
and prohibits them from fraying. Never use a hacksaw for cutting any wireline cable.
Abuses of Wire Cable
More damage is done to wire rope by improper use than anything else. Even though wire
rope is one of the most uniform mechanical products made, a certain number of ropes do
fail prematurely. In most cases, these failures are caused by abuse. The following chart
highlights the more common reasons why cable fails due to abuse.
When Installing Wire Rope
Effect Cause
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Doglegs and kinks Pulling or dragging the wire rope around a post or other
sharp corner; using the improper procedure when removing
the wire rope from either reels or coils.
Excessive abrasion Improper threading of the wire rope through a block or
when fastened to a drum causing the rope to rub against
itself.
High strands Improper socketing, splicing, or binding; driving nails or
other objects between the strands.
When Using Wire Rope
Effect Cause
Crushed or bruised Poor drum winding practices; crossover on drums;
pinching of the wire rope; being flattened against
equipment; running over the rope with tractor or trailer;
over-sized sheave or pulley.
Doglegs and kinks Jumping sheaves; operating over small diameter sheaves;
pulling out loops in the wire rope when the rope is slack,
causing either open or tight kinks; lifting sharp cornered
objects without comer protection; bad drum winding;
dividers on drums.
Corrosion and rust Lack of lubrication; corrosive fluid; atmosphere.
Popped core Momentary compressive force on the wire rope which
pushes the rope’s strands apart; hitting the fluid in a well at
high speed; bending over small sheaves; crushing on the
drum.
Excessive abrasion Improper threading of the wire rope through a block or
when fastened to a drum causing the rope to rub against
itself; pinching grooves; improper alignment of sheaves;
presence of abrasive material.
Broken wires Fatigue from excessive bending over small sheaves or

reverse bends; Martensite developed from sliding or
striking of the wire rope against some object which causes
sparking; surface wear (creep); collapse of the core due to
overloading; small sheaves; restriction of movement of
the strands due to pinching grooves; excessive vibration;
broken sheaves or drums; excessive rope speeds;
corrugated sheaves.
Bird caged Too sudden release of a load.
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Effect Cause
High strands This condition starts at some localized area such as a
dogleg, crushed section, or improperly attached end
fittings.
Failure at the socket Poor socket design; wrong size wedge used or the socket
was already deformed from consistent overloading.
Reduction in diameter Excessive abrasion; external or internal corrosion;
overloading; vibration fatigue.
Cut or sheared wires Mechanical abuse caused by agents outside the installation,
or by something abnormal or accidental on the installation
itself.
Side wear worn out The wire rope has been operated on the rope on sheaves or
drums that are either or out of alignment.
Over-stressing A sudden application of a load to a slack rope; too rapid an

acceleration of the load; jerking a load; the impact from the
sudden stopping of the load.
Whipping of the Rope Jerking or running with a wire rope that is too loose.
Wire Rope Lubrication
It is very important to lubricate wire rope, since all of the wires have to move freely in
relation to each other. When a rust-bound rope is suddenly jerked, it cannot absorb the
load shock throughout its length. Instead the brunt of the shock is concentrated in one
area and this results in the breaking of wires, strands, and on some occasions the entire
rope.
There are two phases of wire rope lubrication:

1. during manufacture
2. during actual use
During Manufacture
Wire rope manufacturers consider the lubricant that they use as part of the rope itself.
They control the type and quantity of lubricant that is applied to the rope when it is
manufactured. Their application of this lubricant is usually made ”hot” and covers both
the internal and the external parts of the rope.
During Use
Prior to re-lubricating a wire rope, any accumulation of dirt or abrasive material should
be steamed off of the wire rope. This will allow better penetration of the lubricant and
help cut down on the rope’s wear. Only an external application of lubricant is possible in
the field. The lubricant must penetrate to the inside of the wire rope to get coverage
within the strands and the core.
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Manual spray and brush-on methods are generally best accomplished at a sheave where
strands are opened up. This allows the lubricant to penetrate to the core of the rope.
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9.0 APPENDIX 3: GLOSSARY OF TERMS

Accumulator: A pressure vessel charged with nitrogen gas and used to store hydraulic
fluid under pressure for operation of pressure control equipment.
Accumulator Precharge: An initial nitrogen charge in an accumulator which is further
compressed when the hydraulic fluid is pumped into the accumulator storing potential
energy.
API: American Petroleum Institute
AW Rod Thread: A parallel thread with three threads per inch (3 TPI) similar to the BW
THREAD. The thread is square cut and is used in applications of 1.75” OD thread or less.
Balance Point: Footage of coiled tubing in the hole where the buoyed weight of the
tubing is equal to the well pressure acting against the cross-sectional area. Note, this is a
static condition with the pipe full of fluid and does not include frictional forces of the
stripper assembly and/or pipe rams, if engaged.
Ballooning: The increase in diameter and decrease in length of tubing due to the effects
of temperature change, cycling or high internal pressure.
Banana Blade: A design of under reamer blade that enables reaming in both RIH and
POOH mode. The name reflects the shape and the design minimizes the risk of
becoming stuck due to overlying debris.
Bending Cycle: The act of straightening or bending coiled tubing. One bending cycle for
the purpose of CYCLE actually includes six such bends, off, and then back onto the work
reel.
Blowout: An uncontrolled flow of pressurized wellbore fluids and/or formation fluids
from the wellbore or into lower pressured subsurface zones (underground blowout).
Blind Rams: Rams whose ends are not intended to seal against any coiled tubing. The
seal against each other to effectively close the hole.
Boot: The boot provides a solid connection from bare wires to the KEMLON PIN in the
SWBPV bulkhead. It consists of a gold plated pin crimped to the wire. A Teflon sleeve
to protect the pin and a rubber boot to cover and seal the connection.
B.O.S.S. Tool: Ball Operated Shear Sub, a ball operated hydraulic release tool. This tool
is used to release the coiled tubing from the bottom hole assembly if it was to become
stuck.
Bullhead: Any pumping procedure in which fluid is pumped into the well against
pressure.
Page 181
BW Rod Thread: A parallel thread with three threads per inch (3 TPI) similar to the AW
THREAD. The thread is square cut and is used in applications of 1.75” OD thread or
greater.
Check Valve: A valve that allows flow through it in one direction only. This device is
installed at the coiled tubing connector and allows fluid to be circulated down the string
but prevents backflow. This device may be a ball-and -seat type or flapper type.
Choke: A device with either a fixed or a variable aperture used to control the rate of flow
of liquids and/or gas.
Choke Line Valve: The valve(s) connected to the end part of the well control stack
which controls the flow to the choke.
Christmas Tree: A term applied to the combination of valves and fittings assembled
above the top of the tubing spool on a completed well to contain well pressure and
control the flow of hydrocarbons and other fluids.
Circulation: The movement of fluid or gas, from a vessel on surface, down a tubular
string, returning up the annulus and back to a vessel or pit on surface.
Closing Ratio: The ratio of the wellhead pressure to the hydraulic actuation pressure
required to close the well control component.
Collapse: The flattening of the coiled tubing due to external pressure or external
pressure combined with either tension or bending.
Collapse Pressure: The amount of pressure required to flatten the sides of pipe.
Collector: The means of transferring electrical signals from the rotating coiled tubing
reel to a stationary plug and so onwards to remote surface instrumentation.
Concentric Operations: Well operations conducted using small diameter coiled tubing
inside of conventional tubing or tubingless completion’s. This is normally performed
with the Christmas tree in place using a small rig or hoisting unit.
Control Panel: An enclosure displaying an array of switches, push buttons, lights,
valves, various pressure gauges, and/or meters to control or monitor coiled tubing
operating functions.
Core Diameter: The diameter of the core of the work reel onto which the coiled tubing
is spooled.
CYCLE: The name for the BJ SERVICES CT life monitoring system. All bases have
access to it and updates are based upon information written on specific sheets by the job
supervisor. For more information contact the Operations Engineering Department.
Data Key: The security control for CIRCA. To access CIRCA a key has to be used.
Each issue of CIRCA has a unique key which is not interchangeable.
Page 182
Diametrical Growth: Change in the diameter of the tubing.

Diamond Matrix: A term used to describe a particular type of bit.
Dimple Connector: A tubing connector using grub screws to secure BHA’s to the coiled
tubing.
Defect: A defect is an imperfection of sufficient magnitude to warrant rejection of the
product.
DMUR: Drilling, Milling and Under-Reaming
Dongle: A computing term for a Data Key. See above.
Drag: Friction between a moving device (such as coiled tubing) and another moving or
non moving part (such as tubing or formation walls).
E-Line: Electric line, a small-diameter conductive line used in electric wireline
operations.
Elongation: The increase in gage length of a tensile test specimen, expressed as a
percent of the original gage length.
Emergency Shut-down Device (ESD): System to shut-down a well or series of wells in
the event of an emergency
Fatigue: The process of progressive localized permanent structural change occurring in a
material subjected to conditions which produce fluctuating stresses which culminate in
cracks or complete failure after a sufficient number of fluctuations.
Fish: A universal description for a downhole obstruction not intended to be there.
Normally used to describe an item of equipment left in the well as a consequence of a
previous workover operation.
Flow Tee: A piece of iron in the shape of a “T” allowing gas and fluids to be circulated
out of the side to a tank or pit.
Friction Coefficient: A dimensionless figure utilized in CIRCA to define the condition of
the well. The higher the coefficient the 'rougher' the well is assumed to be.
Friction Lock: A term used to describe the situation whereby further entry into the well
with the coiled tubing is not possible. The situation occurs due to formation of a Helical
Spiral and so the driving force from the injector is not transmitted to the BHA thereby
preventing further progress into the well.
Gate Valve: A valve which employs a sliding gate to open or close the flow passage.
The valve may or may not be full-opening.
Page 183
Grapple Connector: A tubing connector using grapples to connect BHA’s to the bottom
of a coiled tubing string.
Gravity Stabilized: The CT is lying straight within the hole, however, it is beyond the
Neutral Point and therefore, if conditions change, it is possible for the CT to form a
Helical Spiral.
Hardness: A measure of the hardness of a metal as determined by pressing a hard steel
bar or diamond penetrator into a smooth surface under standard conditions.
Hardness (Testing): Testing of the hardness of a material.
Helical Spiral: This term describes the manner in which the coiled tubing is lying in the
well i.e. similar to a spring. The situation occurs as a result of forces opposing the
direction of RIH such that the rigidity of the coiled tubing is not sufficient to overcome
them and the coiled tubing conforms to the shape of the completion with 3600 wall
contact.
Hipp Tripper: See percussion hammer
Hydril: Registered trademark of a prominent manufacturer of oilfield, equipment
especially annular blowout preventers.
Hydrostatic Head: The pressure which exists at any point in the wellbore due to the
weight of the column of fluid above that point.
Injector Head: A piece of equipment with one or more motors driving one or more
chains equipped with gripping blocks to inject or withdraw coiled tubing from a wellbore.
Usually equipped with a stuffing box to allow this to be accomplished with pressure in
the wellbore.
Jar: A percussion tool operated manually or hydraulically to deliver a heavy downward
or upward blow to an item in the borehole.
Kick: Intrusion of formation liquids or gas that results in an increase in pit volume or an
increase in observed wellhead pressure.
Kill Line: A high-pressure line between the pumps and some point below a well control
component. This line allows fluids to be pumped into the well or annulus with the well
control component closed.
Lift Frame: A frame used to connect the injector head to a wellhead or test tree on a
floating rig.
Lobe Pattern: In a PDM motor the Stator consists of a series of internal spiral grooves in
a rubber molding. The Rotor consists of a series of external spiral grooves on a coated
steel shaft. The ratio of the rotor grooves to stator grooves is the Lobe Pattern. The
higher the ratio, the better the motor (usually).
Page 184
Lubricator: A specially fabricated length of casing or tubing usually placed temporarily

above a valve on the casing head or tubing head. It is used to run tools into a producing
well and provides a method for sealing off pressure and thus should be rated for the
highest anticipated pressure.
Manifold: An assemblage of pipe, valves, and fittings by which fluid from one or more
sources is selectively directed to various system or components.
Maximum Anticipated Surface Pressure: The highest pressure predicted to be
encountered at the surface of a well. This pressure prediction is based upon a wellbore
filled with gas from the surface to the completion interval.
Mill: A downhole tool with rough, sharp, extremely hard cutting surfaces for removing
metal by grinding or cutting.
Milling: The act of operating a mill to remove metal from the wellbore.
Moineau Principal: The name given to the operating method of PDM motors due to the
inventor Rene Moineau. He was the first to patent such devices between 1930 and 1948.
Mud Motor: See PDM
NC Thread: Originally a mining thread, tapered with 12 threads per inch with the threads
having a conical shape. Similar in appearance to a Regular Thread.
Neutral Point: The transition zone between the Stable region (no helical buckling
possible) and the Unstable region (helical buckling may occur).
Opening Ratio: The ratio of the well pressure to the hydraulic actuation pressure
required to open the well control component.
Ovality: The difference between the largest and smallest outside diameter on a cross-
section.
Overbalance: The extent to which the hydrostatic pressure of the fluid column exceeds
the formation pressure.
P.D.C.: Polycrystalline Diamond bit is a recent advance in bit design. Discs of
polycrystalline man-made diamond are fixed to a tungsten carbide insert. The
manufactured insert combines the hardness of diamond with the impact resistance of
tungsten carbide.
P.D.M.: Positive Displacement Motor is the term to describe a motor which operates on
the Moineau Principal. It is the most common design of motor used on CT DMUR
operations. A metal Rotor is forced to turn inside a rubber Stator due to the force of fluid
passing through it.
Percussion Hammer: A drilling tool that delivers high frequency blows to the bit.
Page 185
Permanent Installation: Installation of coiled tubing left in place for the purpose of
injection or production.
Pipe Rams: The rams in a well control device which are designed to seal around coiled
tubing to close and isolate pressure in the annular space below the rams.
Pipe/Slip Rams: Combination rams which provide the function of a pipe ram and slip
ram in one ram body.
P.L.T.: The abbreviated term for a Production Logging Tool. Irrespective of the tools run
all flow analysis operations are defined as a 'PLT'.
Pin: The pin or Kemlon Pin, to give it its manufacturers name, provides a solid electrical
connection from a high pressure zone to a low pressure zone. The pin is rated to 20,000
psi and consists of gold pins set in ceramic and surrounded by a metal housing complete
with o-rings to provide the pressure seal across the bulkhead.
Plug Back TD: the bottom of the well.
Plug Valve: A valve whose mechanism consists of a plug with a hole through it on the
same axis as the direction of fluid flow. Turning the plug. 90o opens or closes the valve.
The valve may or may not be full-opening.
Polished Rod Clamp: Fastening device to connect the polished rod to the bridle of a
beam pumping unit.
Power Fluid: Pressurized hydraulic fluid dedicated to the direct operation of functions.
Precharge: See “Accumulator Precharge”
Pressure Test, Well Control Component: The process of pressure testing internally the
well control component or well control stack.
Radiographic Inspection: Inspection carried out through the use of X-ray.
Reel: Device to hold hoses or coiled tubing usually equipped with a rotary joint allowing
for the pumping of gas and fluids through the hose or tubing.
Regular Thread: A tapered thread with a high number of threads per inch with the
threads having a conical section. Similar to the NC Thread.
Regulator (Pressure): A hydraulic device that reduces upstream supply pressure to a
desired (regulated) pressure. It may be manual or remotely operated and, once set, will
automatically maintain the regulated output pressure unless reset to a different pressure.
Reservoir: A storage tank for control fluids used to operate the well control components
and other hydraulically-actuated devices.
Page 186
Rheology: The term to collectively describe fluid properties. The definition of fluids is
important for CIRCA analysis and covers density, viscosity etc.
Rig: The derrick or mast, drawwoks, and attendant surface equipment of a drilling or
workover unit.
Riser: A pipe through which liquid travels upwards.
Roll-on-connector: A connector where the tubing is compressed into ridges machined
into the tool. Used to attach BHA’s to the bottom of coiled tubing.
R.O.P.: An abbreviation for Rate Of Penetration, a measure of the efficiency of the
DMUR process. As high a rate as possible is the goal, however, this must be achieved
without excessive bit wear and/or Stall conditions or overloading of the well surface
handling facilities.
Roto-Jet: Patented BJ Services tool used for high pressure jetting of scale and solids in
the wellbore.
Rotor: An internal component of the PDM motor. A polished metal spiral, it enables the
force of fluid to be transferred into rotary motion to turn the bit. The performance of the
motor is determined by the Lobe configuration of the rotor.
Runaway: Uncontrolled ascent or descent of coiled tubing in a wellbore.
Shear Rams: The rams in a well control device which are designed to shear the coiled
tubing located directly across the ram position.
Shear/Seal Ram: Combination ram which provides function of a shear ram and blind
ram in one ram body.
Shore’s Hardness: This is a rating system to define the applicability of rubber to a
pressure environment. Thus the higher the number the greater the hardness and therefore
the applicability for higher pressures is assured. The rating applies to o-rings and stripper
rubbers.
Shut-off Valve: A valve that closes a hydraulic or pneumatic supply line.
Slip Rams: The rams in a well control device which are equipped with coiled tubing
slips that, when engaged, prevent movement of the coiled tubing but do not isolate
pressure or control flow.
Slip Ring: A term for the Collector. See above.
Snubbing: Condition for working coiled tubing though a pressurized stripper, where
wellbore pressure applied against the cross-sectional area of the tube creates an upward
acting force greater than the weight of the tubing in the wellbore. In this condition,
mechanical assistance is required to apply thrust to the tubing while injecting or to
maintain control of the tubing when extracting. This condition is commonly called “light
pipe operations”.
Page 187
Spinner, Fullbore: This tool is supplied by the logging company and measures flow
contribution from the formation. The impeller is protected by a centralizer and requires
only simple calibration runs. It is susceptible to failure due to foreign matter clogging the
impeller.
Spinner, Inline: Unlike the Fullbore Spinner this tool requires more passes for
calibration and is generally not as reliable as the full bore version, however it is a lot
more fragile.
Spool: See reel
Stable: A CIRCA term to define the CT. When a section is described as stable it is
impossible to have helical buckling in that particular section given the conditions. The
stable section ends at the Neutral Point with the section below to TD being classed as the
Unstable section.
Stable Spiral: Describes the section of CT which is beyond the Neutral Point and is
therefore in the Unstable region. By definition the CT has formed a helical spiral all
sections of which are in contact with the completion tubulars.
Stabilizer: A sub utilized in the BHA to prevent excessive lateral movement of the CT
during DMUR operation.
Stall: A situation during DMUR operations when the applied WOB results in the Torque
required to turn the bit is greater than the Torque supplied from the motor. A sharp CT
circulating pressure rise will be seen upon this occurring.
Stator: The stationary rubber element of the PDM motor. The Rotor is held in place by
the stator which until the application of fluid pressure, prevents the Rotor from turning.
The stator provides the internal seal to enable pressure build-up.
Stiff Wireline: BJ Services name for wireline installed into coiled tubing.
Stored Hydraulic Fluid Volume: The fluid volume recoverable from the accumulator
system between the maximum designed accumulator operating pressure and the
precharge pressure.
Strain Gauge: The term used to describe an electronic load cell. The strain gauge
measures weight by calibrating the changes in resistance as a result of the load, either
positive or negative, applied to it.
String: An entire length of coiled tubing.
Stripper: A device with a resilient elastomeric element used to effect a seal in the
annulus. This device is used primarily to isolate well pressure from the atmosphere when
injection or extracting the coiled tubing in live wellbores.
Page 188
Stripper Rubber: Inserts made of rubber compounds run inside stuffing boxes to seal
well pressure in the well bore as the coiled tubing is being run into or being withdrawn
from the well.
Stripping: Condition for working coiled tubing through a pressurized stripper, where
wellbore pressure applied against the cross-sectional area of the tube creates an upward
acting force less than the weight of the tubing in the wellbore. In this condition,
mechanical assistance is required to apply thrust to the tubing while injecting or to
maintain control of the tubing when extracting. This condition is commonly called “light
pipe operations”.
Stuffing Box: A device that prevents leakage around the coiled tubing as it is being run
into and out of the wellbore.
Stub Acme Thread: A parallel thread form with 10 threads per inch with square sided
threads. A fine version of the AW and BW Threads.
Swab Valve: The top most valve on the tree installed above the flow “T” so that tools
may be lubricated out of the well with the well flowing.
Swabbing: The lowering of the hydrostatic pressure in the wellbore due to upward
movement of pipe and/or tools.
SWBPV: An abbreviation for the Stiff Wireline Back Pressure Valve. The valve is used
exclusively on Stiff Wireline operations.
TC (Tungsten Carbide) Matrix: The form a particular type of bit or mill can take.
More coarse than diamond bits and therefore for softer materials.
T.R.T.: Tension Release Tool.
Tapered Mill: A particular bit type either TC or Diamond Matrix. Used for enlarging
holes in blockages of debris or for dressing fish. Two types exist either concave or
convex depending upon external or internal drilling of the obstruction being required.
Total Depth (TD): See plug back T.D.
Tensile Strength: The greatest longitudinal stress that a metal can bear without tearing
apart. A metal’s tensile strength is greater than it’s yield strength.
Transition Point: The Point on the tapered coiled tubing string where tubing segments
of different wall thickness are welded together.
Trip: The event which involves deployment of the coiled tubing string from the reel into
the wellbore and the subsequent retrieval of the coiled tubing back onto the reel.
Torque: The shear force produced when the rotation, from the motor, (an axial force) is
resisted due to the friction between the fill and the Bit. The greater the torque the greater
the shear force.
Page 189
Triaxial Stress: The total equivalent stress acting on the CT as a combination of the axial
stresses (due to tension or compression), radial stress (due to pressure) and hoop stresses
(due to any applied torque).
Ultrasonic Inspection: Testing through the use of ultrasonic waves to detect
discontinuities or corrosion in metal structures.
Underbalance: Relating to a condition in which the pressure in the wellbore is less than
the pressure in the formation.
Underreamer: A device used to underream. Usually to enlarge the wellbore below the
casing.
Unstable Spiral: Describes the section of CT which is beyond the Neutral Point and is
therefore in the Unstable region. By definition the CT has formed a helical spiral.
However, sections of the CT are not in contact with the completion tubulars, e.g., due to a
diameter change or a nipple. This will be the most likely place for a failure to occur.
Useable Hydraulic Pressure: The hydraulic fluid volume recoverable from the
accumulator system between the maximum designed accumulator operating pressure and
the minimum operating pressure.
Weak Link: A description of the shear sub utilized to pull off the tool string when stuck
downhole. Two types are utilized in Stiff Wireline, either the shear pin type in the
SWBPV or the collet release used in the TRT. See above.
Weight Bar: A heavy weight or bar placed near the BHA. The bar provides weight so
that the tools will lower properly into the well. Also called sinker bars or stem.
Well Control Component, Annular Type: A device which can form a seal in the
annular space around any object in the wellbore or upon itself. Compression of a
reinforced elastomer packing element by hydraulic pressure effects the seal.
Well Control Component, Ram Type: A device designed to form a seal on the well
bore with or without coiled tubing in the well. The equipment can use one set of blind
rams, shear rams, slip rams or pipe rams to effect the required seal arrangement of the
equipment, an/or existing well conditions. Combination shear/seal and pipe/slip rams are
available.
Well Control Stack: An integral body or an assembly of well control components
including ram-type BOPs, annular type BOPs, spools, valves, and nipples connected to
the top of the wellbore to control well fluids.
Well Control Equipment Drill: A training procedure to ensure that coiled tubing
personnel are familiar with correct operating practices to be followed in the use of well
control equipment for blowout prevention.
Page 190
Wellhead: An assemblage of valves and spools located below the Christmas tree and
above the casing strings for the purpose of hanging and isolating the various tubular
strings.
WOB: An abbreviation for Weight On Bit, i.e., the force transmitted to the bit through the
CT weight and the injector head. Too little WOB leads to excessive bit wear per foot of
penetration and excessive WOB will cause a Stall and/or cleaning problems. The
optimum WOB is one that enables DMUR to take place keeping the CT pressure below
the Stall pressure.
Yield Strength: A measure of the force required to deform tubular goods to the extent
that they are permanently distorted.
Page 191
Page 192
10.0 APPENDIX 4: MANUAL EVALUATION FORM
Please evaluate this manual by answering the questions below, and return the form to
your district trainer. Your participation and comments will be used to improve the quality
of training at BJ Services Canada.
Section One
Please circle the number that best
Name of Manual describes the extent to which you agree
EO Coiled Tubing Manual with the following statements.
Strongly Agree Strongly Disagree

1. The manual objectives are clear. 1 2 3 4 5
2. I am able to achieve the stated objectives. 1 2 3 4 5
3. The content is relevant to my job. 1 2 3 4 5
4. The content is challenging. 1 2 3 4 5
5. The information provides enough detail. 1 2 3 4 5
6. The manual is clear and concise. 1 2 3 4 5
7. The information is organized in a logical 1 2 3 4 5
manner.
8. The language is clear and understandable. 1 2 3 4 5
9. In the future, I will use this manual as a 1 2 3 4 5
resource of information.
10. I am comfortable with my level of 1 2 3 4 5
understanding of this manual.
Approximate time spent with this manual: __________________
Length of time with BJ Services Canada: __________________
Section Two
1. Please list suggestions that you feel might improve the quality of this manual.
Page 193
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2. Please list topics you think should have been included in this manual.
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Coiled Tubing

1.0 MANUAL INTRODUCTION................................................................1

2.0 HEALTH, SAFETY, AND ENVIRONMENT......................................7

EO Coiled Tubing Training Manual

2.6.6 Environmental Spills and Releases.......................................................32

3.0 EQUIPMENT USED IN COILED TUBING OPERATIONS..........37

4.0 DOWNHOLE TOOLS..........................................................................59

5.0 OPERATIONAL PROCEDURES FOR COILED TUBING............67

EO Coiled Tubing Training Manual

5.2 Pre-Job Considerations.......................................................................................67

6.0 INTERPERSONAL SKILLS.............................................................105

EO Coiled Tubing Training Manual

7.0 APPENDIX 1: BASIC MATH AND WELL SERVICING

8.0 APPENDIX 2: AUXILIARY EQUIPMENT.....................................163

EO Coiled Tubing Training Manual

8.1 Swivel Joints (Chiksans)..................................................................................163

9.0 APPENDIX 3: GLOSSARY OF TERMS..........................................179

10.0 APPENDIX 4: MANUAL EVALUATION FORM.........................191

EO Coiled Tubing Training Manual

EO Coiled Tubing Training Manual

1.0 MANUAL INTRODUCTION

1.1 MANUAL DESCRIPTION

The manual is organized into 6 sections, including:

EO Coiled Tubing Training Manual

 Appendix 4: Manual Evaluation Form

1.2 MANUAL OBJECTIVES

General Manual Objectives

EO Coiled Tubing Training Manual

1.3 COMPANY MISSION STATEMENT

We are committed to operate our business as a valued neighbour in the communities in

1.3.1 BJ Canada Values

Our service attitude is represented by hard work, a positive attitude, a willingness to

EO Coiled Tubing Training Manual

1.4 COILED TUBING EQUIPMENT OPERATOR RESPONSIBILITIES

1.5 COMPETENCY ASSESSMENT

EO Coiled Tubing Training Manual

EO Coiled Tubing Training Manual

 Section 4: Pre-Job Procedures

Applied Skills Evaluations

EO Coiled Tubing Training Manual

2.0 HEALTH, SAFETY, AND ENVIRONMENT

2.1 GENERAL SAFETY

2.1.1 Safety: Measures of Success

EO Coiled Tubing Training Manual

2.1.2 Personal Responsibilities for Safety

EO Coiled Tubing Training Manual

2.1.3 Sources of Safety Information

BJ Canada Health, Safety, and Environment (HSE) Resource Book

Safety Standards Manual

Radiation Safety Manual for Operators

Material Safety Data Sheet (MSDS)

EO Coiled Tubing Training Manual

and reactivity, toxicological properties, preventative measures, first aid measures,

2.1.4 Hazard Analysis and Identification

EO Coiled Tubing Training Manual

2.2 MAIN HAZARDS OF COILED TUBING OPERATIONS

EO Coiled Tubing Training Manual

2.2.1 Pressurized Contents of Piping and Related Equipment

2.3 PERSONAL PROTECTIVE EQUIPMENT (PPE) REQUIREMENTS CHART

EO Coiled Tubing Training Manual

(X) Denotes required PPE

Coiled Tubing Drilling

Pipeline Inspection Services