J-76-1 IKS Wellhead Installation and Operation Manual

J-76-1

IKS WELLHEAD INSTALLATION AND OPERATION MANUAL

TIX-IKS CORPORATION

IKS 20"X13.3/8"X9.5/8"X7.5/8"X4.1 20"X13.3/8"X9.5/8"X7.5/8"X4.1/2"-10000#W.P. /2"-10000#W.P. WELLHEAD INSTALLATION AND OPERATION MANUAL FOR VIETSOVPETRO

CONTENTS Page 1. Introduction --------------------------------------------------------------------------------------------

3

2. Unpacking --------------------------------------------------------------------------------------------------

3

3. Wellhead Installation Procedure ----------------------------

3

○ Installation of 20.3/4"-3000 Type "H" "H" Casing Housing -------

5

○ Installation and and Testing of 20.3/4"-3000 20.3/4"-3000 BOP BOP Stack ------

7

○ Installation and and Removal of 20.3/4" 20.3/4" Wear Bushing ---------------

9

○ Installation of 20.3/4" x 13.3/8" Type "CHU" Unitized Casing Hanger ------------------------------------------------------------------------------------ 11 ○ Installation of 20.3/4" x 13.3/8" Type "PO" Packoff ----- 16 ○ Installation of 20.3/4"-3000 x 13.5/8"-5000 Type "S" Casing Spool -------------------------------------------------------------------------------------- 18 ○ Installation and Testing of 13.5/8"-5000 BOP Stack ------ 23 ○ Installation and Removal of 13.5/8" Wear Bushing -------- 25 ○ Installation of 13.5/8" x 9.5/8" Type "CHU" Unitized Casing Hanger ------------------------------------------------------------------------------------ 27 ○ Installation of 13.5/8" x 9.5/8" Type "PO" Packoff ------ 32 ○ Installation of 13.5/8"-5000 x 11"-10000 Type "S" Casing Spool -------------------------------------------------------------------------------------- 34 ○ Installation and Testing of 11"-10000 BOP Stack --------- 39 ○ Installation and Removal of 11" Wear Bushing ------------ 41

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○ Installation Installation of 11" x 7.5/8" Type "CHU" Unitized Casing Hanger ------------------------------------------------------------------------------------ 43 ○ Installation of 11" x 7.5/8" Type "PO" Packoff ---------- 48 ○ Installation of 11" x 11"-10000 Type "TD" Tubing Spool -------------------------------------------------------------------------------------- 50 ○ Installation and Testing of 11"-10000 BOP Stack --------- 55 ○ Installation and Removal of 11" Wear Bushing ------------ 57 ○ Installation and Testing of 11" x 4.1/2" Type "DCL2/SPCL" Tubing Hanger and X'mas Tree ----------- 59

Appendix A:

Operating Instructions for Lubricator Lubricator ----------------------- 66

Appendix B:

Operating Instructions Instructions for Valve Removal Tool ---- 67

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1. INTRODUCTION IKS wellhead assemblies you have chosen are the products whose reliability will be fully assured with a minimum of control and maintenance. This manual describes the matters required in installation, use and maintenance of IKS wellhead. When some matters not described in the manual or assistance is required, or if there are any questions on maintenance operations, please contact us. As for the details of parts and apparatus used, please refer to catalogues.

2. UNPACKING All IKS wellheads are shipped per stage, that is, wellhead is separated into casing housing assembly, casing spool assembly, tubing spool assembly and X'mas tree assembly, and shipped from our plant with each assembly firmly placed on a skid or in a wooden box. API gate valves assembled in the wellhead are shipped from plant with their gate in full open position to protect gate sealing surfaces. When wellhead arrived at your place, please check if there is a specified number of dismantled parts or any damaged area. In case such

an accident accident occurred, occurred, please request an accident accident certificate certificate

from the shipping agent.

3. WELLHEAD INSTALLATION PROCEDURE The general drawing of 20" x 13.3/8" x 9.5/8" x 7.5/8" x 4.1/2"-10,000# W.P. wellhead is shown in Fig.1. The installation procedure of this wellhead will be described in sequence.

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20"X13.3/8"X9.5/8"X7.5/8"X4.1/2"TBG-10,000#W.P. 20"X13.3/8"X9.5/8"X7.5/8"X4.1/2"T BG-10,000#W.P. WELLHEAD ASSEMBLY FIG.1

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INSTALLATION OF 20.3/4"-3000#W.P. TYPE "H" CASING HOUSING

1. The casing housing is installed after the installation of the surface casing. A pocket has been machined in the lower part of the casing housing to allow a slip-on fit on the casing. 2. Remove test port plug before preheating and welding. 3. To achieve a good sound weld, the casing housing and casing in the slip-on area should be preheated to 177℃ minimum (API 6A 14 t h  Edition Appendix B recommended pre-heat pre-heat range is 121℃-204℃ ). 4. Use a 3.2mm or 4.0mm moisture free low hydrogen rod (AWS E-7018) to obtain a good sound weld and h elp to prevent cracking. 5. The inside weld should be made first then the outside fillet. (see FIG.1) 6. The welded areas also should be post heated to 399℃ - 427℃ after welding. 7. The test port in the SOW area has been provided to test the integrity of the two welds after they have been air cooled(Do not force cool). The test pressure should be no more than 80% of the c asing collapse pressure.

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INSTALLATION OF 20.3/4"-3000#W.P. TYPE "H" CASING HOUSING

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INSTALLATION AND TESTING OF 20.3/4"-3000#W.P. BOP STACK

1. Install 20.3/4"-3000#W.P. BOP stack and support flange on casing housing. Note 1: Make sure that all rams are fully retracted. Note 2: Make sure that all holddown screws of support flange are fully retracted. 2. Clean and inspect tool joint threads. 3. Clean and inspect test plug threads. 4. Lubricate threads with API modified thread compound or similar compound. 5. Install test plug to drill pipe. 6. Lower test plug through BOP stack until properly located in casing housing. Note 1: Make sure that tool joint is not located where BOP's rams are. Note 2: Side outlet valve on casing housing should be opened during test. 7. Close BOP rams and test BOP system. 8. After completion of test, bleed pressure to zero and open BOP rams. 9. Retrieve BOP test plug and apply grease and provide safekeeping for test plug until it is used again.

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INSTALLATION AND TEST OF 20.3/4"-3000#W.P. BOP TEST PLUG

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INSTALLATION AND REMOVAL OF 20.3/4" WEAR BUSHING

1. Clean and inspect running tool threads. 2. Lubricate threads with API modified thread compound or similar compound. 3. Install running tool to drill pipe. 4. Install wear bushing to running tool. 5. Slowly lower wear bushing through BOP stack until properly located in casing housing. 6. Run in all holddown screws located in support flange. Tighten all holddown screws. 7. Remove running tool from wear bushing and retrieve. 8. Prepare to drill out for next casing. 9. Retrieve wear bushing by reversing order of above-mentioned procedure.

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INSTALLATION OF 20.3/4" WEAR BUSHING

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INSTALLATION OF 20.3/4" X 13.3/8" TYPE "CHU" UNITIZED CASING HANGER

1. INSTALLATION OF CASING HANGER AT WELLHEAD (1) Open side outlet valve of casing housing and discharge water from BOP stack. Keep side outlet valve open until casing hanger is installed. (2) Nipple down BOP stack and raise it about 2 feet(60cm) from top of casing housing. (3) Wash out casing housing bowl. (4) Make sure that casing is centered in casing housing. (5) Place two boards of equal thickness on casing housing flange, straddling casing, to support casing hanger. (6) Remove two socket head cap screws painted yellow from casing hanger, using Allen wrench provided with casing h anger and separate it into two parts. Do not loosen other cap screws. (7) Wrap casing hanger around casing and place it on boards. (8) Close casing hanger around casing and screw socket head cap screws into their original hole to assemble casing hanger. Do not clamp seal. Leave all socket head cap screws 1/16"(1.6mm) loose. (9) With proper tension on casing, remove boards and install casing hanger in casing housing. (10) Make sure that casing is level. (11) Slack off casing load to zero. Make note of total amount of casing load put on casing hanger(slips). Note: Minimum casing load required to m ake slips properly function is about 10 ton. (12) Remove slip handles or eye-bolts from casing hanger. (13) Tighten all socket head cap screws with Allen wrench provided with casing hanger. Tightening of socket head cap screws will seal void around casing.

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Seal may be tested by use of BOP or after next spool is installed. (1 4) Close side outlet valve of casing housing. (15) Drain water from casing, and make rough cut on casing so that it will protrude about 12" to 14"(300mm to 350mm) from top face of casing housing flange. (16) Remove cut casing stub.

2. INSTALLATION OF CASING HANGER THROUGH BOP STACK (1) Drain water from BOP stack through side outlet of casing housing. Leave this valve open until casing hanger is installed. (2) Measure distance from top face of casing housing flange to top face of Kelly bushing. (3) Make certain that casing joint is not in BOP stack nor in casing housing. (4) Wash out casing housing bowl. (5) Center casing in casing housing. (6) Place two boards of equal thickness on rotary table, straddling casing, or use a metal slip plate to support the casing hanger. (7) Remove two socket head cap screws painted yellow from casing hanger with Allen wrench provided with casing hanger, and separate casing hanger into two parts. Do not loosen other cap screws. (8) Wrap casing hanger around casing and place it on boards. (9) Close casing hanger, and screw socket head cap screws into their original hole to assemble casing hanger. Leave socket head cap screws 1/16"(1.6mm) loose to avoid clamping seal. (10) Tie sash cord or similar soft line to handles fixed to casing

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hanger. Measure distance obtained in Step (2) o n sash cord or soft line and mark measurement with knot. (11) With proper tension on casing, firmly support casing hanger with soft line and remove boards. (12) Slowly lower casing hanger through BOP stack until properly set in casing housing. Check measurement marked in Step (10). Note: Do not let casing hanger free fall through BOP stack. (13) Make sure that casing hanger is level. Slack off casing load to zero. Record total amount of casing l oad put on casing hanger (slips). (14) Nipple down BOP stack, and raise it about 2 feet(60cm). (15) Remove slip handles or eye-bolts from casing hanger. (16) Be certain casing is centered in casing housing and tighten all socket head cap screws with Allen wrench provided with casing hanger. Void around casing will be sealed by tightening of socket head cap screws. Seal may be tested through BOP or after next spool is installed. (17) Close side outlet valve of casing housing. (18) Drain water from casing, and make rough cut on casing so that it will protrude about 12" to 14"(300mm to 350mm) from top face of casing housing flange. (19) Remove cut casing stub.

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20.3/4" X 13.3/8" TYPE "CHU" UNITIZED CASING HANGER

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INSTALLATION OF 20.3/4" X 13.3/8" TYPE "CHU" UNITIZED CASING HANGER

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INSTALLATION OF 20.3/4" X 13.3/8" TYPE "PO" PACKOFF

1. Make final cut on casing 5.3/4"(146mm) above top face of casing housing flange. Level and smooth cut-off end of casing. Chamfer or round outside and inside corner of casing. Clean its circumference and make sure that there is no damage in external surface. 2. Cleanly wipe and apply grease to recess in top of casing housing. Lubricate circumference of casing also. 3. Install type "PO" packoff in recess of casing housing in following manner: Use eye-bolts to lift lower adapter (thicker one) and set it in recess. Next, place seal ring on lower adapter. There is no distinction between upper and lower sides of seal ring. Lift upper adapter (thinner one) using eye-bolts and install it on seal ring. Note: Get rid of air trapped in recess as much as possible when installing packoff seal ring.

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INSTALLATION OF 20.3/4" X 13.3/8" TYPE "PO" P ACKOFF

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INSTALLATION OF 20.3/4"-3000#W.P. X 13.5/8"-5000#W.P. TYPE "S" CASING SPOOL

1. Cleanly wipe flange faces of casing housing and casing spool, and inspect ring grooves. 2. Install ring gasket and flange protector on housing positioned below. 3. Pick up and suspend casing spool so that it will be level. 4. Install 4 studs directly underneath side outlets of casing spool. 5. Confirm that double "P" seals are installed in grooves provided in bottom of casing spool, and slowly lower casing spool over casing stub until properly located on ring gasket. Note 1 : In case of "P" seals will be installed in grooves, before installing "P" seals in grooves, put it in hot water heated to about about 80 ﾟ C for 5 to 10 10 minutes minutes and make make it soft soft first. first. Crimp seal into heart shape and grasp crimped end on inside diameter with one hand and start by inserting side opposite from crimp into groove. Be sure to soften "P" seal in hot water because crack may develop in "P" seal when being deformed. 6. Tighten all studs and nuts, making sure that casing spool is correctly set without any place being strained. Be sure to tighten nuts evenly

and careful not cock casing casing spool. spool.

Tightening torque shall be as recommended in A PI Specification. As for space between flanges, tighten nuts until it will be as specified in API specification.

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7. Inject IKS "P-15" plastic packing into where double "P" seals are installed. Two injection ports and two bleed ports(vent) are provided for each "P"seal in 20.3/4"-3000#w.p. flange (as shown in Fig.) in which double "P"seals for 13.3/8" casing are installed. Plastic packing shall be injected in following manner : (1) Firstly, remove 3/8NPT plug from bleed port to provide outlet for air to escape from and circulate plastic packing around seal. (2) Next, remove 3/4NPT plug from injection p ort, and then remove 7/8"-9UNC x 1" long set screw with Allen wrench. Check valve is installed in innermost part of injection port to prevent back flow of injected plastic packing. (3) Insert plastic packing and screw set screw into injection port, and continue to screw it until it touches check valve. (4) Check if plastic packing is issuing from bleed port. (5) In case plastic packing can not yet be seen, inject another stick of plastic packing or sticks u ntil packing comes out, and then install 3/8NPT plug into bleed port. Note 1: When using manual injection gun to inject plastic packing, packing injection operation will become difficult when seal is energized. Note 2: When using hydraulic injection gun to inject plastic packing, pressure will be stabilized when seal is energized. Note 3: "P" seal shall not be pressurized higher than 80% of design casing collapse pressure or rated working pressure of flange, whichever is least. 8. Install test pump to 1/2NPT test port fitting. 9. Test annulus space by injecting pressure corresponding to 80% of

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design casing collapse pressure, or rated working pressure of flange, whichever is least. Hold pressure for 15 minutes. Note : This method will test integrity of double "P" seals, ring joint connection and/or lower pack-off. Higher pressure testing will cause deformation of casing I.D. and collapse of casing and such damage will not be known until downhole equipment is lowered through casing. 10. When seals hold pressure, install 3/4NPT plug in injection port. Remove test pump, and install pressure releasing tool to where test pump has been installed to release pressure. Remove pressure releasing tool after pressure has been bled, and install safety cap on 1/2" test port fitting.

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INSTALLATION OF 20.3/4"-3000#W.P. X 13.5/8"-5000#W.P. TYPE "S" CASING SPOOL

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LOCATION OF INJECTION, VENT AND TEST PORT IN BOTTOM FLANGE OF 20.3/4"-3000#W.P. X 13.5/8"-5000#W.P. TYPE "S" CASING SPOOL

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INSTALLATION AND TESTING OF 13.5/8"-5000#W.P. BOP STACK

1. Install 13.5/8"-5000#W.P. BOP stack and support flange on casing spool. Note 1: Make sure that all rams are fully retracted. Note 2: Make sure that all holddown screws of support flange are fully retracted. 2. Clean and inspect tool joint threads. 3. Clean and inspect test plug threads. 4. Lubricate threads with API modified thread compound or similar compound. 5. Install test plug to drill pipe. 6. Lower test plug through BOP stack until properly located in casing housing. Note 1: Make sure that tool joint is not located where BOP's rams are. Note 2: Side outlet valve on casing spool should be opened during test. 7. Close BOP rams and test BOP system. 8. After completion of test, bleed pressure to zero and open BOP rams. 9. Retrieve BOP test plug and apply grease and provide safekeeping for test plug until it is used again.

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INSTALLATION AND TEST OF 13.5/8"-5000#W.P. BOP TEST PLUG

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INSTALLATION AND REMOVAL OF 13.5/8" WEAR BUSHING

1. Clean and inspect running tool threads. 2. Lubricate threads with API modified thread compound or similar compound. 3. Install running tool to drill pipe. 4. Install wear bushing to running tool. 5. Slowly lower wear bushing through BOP stack until properly located in casing spool. 6. Run in all holddown screws located in support flange. Tighten all holddown screws. 7. Remove running tool from wear bushing and retrieve. 8. Prepare to drill out for next casing. 9. Retrieve wear bushing by reversing order of above-mentioned procedure.

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INSTALLATION OF 13.5/8" WEAR BUSHING

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INSTALLATION OF OF 13.5/8" X 9.5/8" TYPE "CHU" UNITIZED CASING HANGER

1. INSTALLATION OF CASING HANGER AT WELLHEAD (1) Open side outlet valve of casing spool and discharge water from BOP stack. Keep side outlet valve open until casing hanger is installed. (2) Nipple down BOP stack and raise it about 2 feet(60cm) from top of casing spool. (3) Wash out casing spool bowl. (4) Make sure that casing is centered in casing spool. (5) Place two boards of equal thickness on casing spool flange, straddling casing, to support casing hanger. (6) Loosen 3 socket head screws painted yellow with Allen wrench provided with casing hanger, and pull t hem up 1.1/2"(38mm) to open casing hanger. Do not loosen other bolts. (7) Wrap casing hanger around casing and place it on boards. (8) Close casing hanger around casing and replace 3 yellow painted socket head cap screws to assemble casing hanger. Do not clamp seal. Leave all socket head cap screws 1/16"(1.6mm) loose. (9) With proper tension on casing, remove boards and install casing hanger in casing spool. (10) Make sure that casing is level. (11) Slack off casing load to zero. Make note of total amount of casing load put on casing hanger(slips). (12) Remove slip handles or eye-bolts from casing hanger. (13) Tighten all socket head cap screws with Allen wrench provided with casing hanger. Tightening of socket head cap screws will seal void around casing. Seal may be tested by use of BOP or after next spool is installed.

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 (14) Close side outlet valve of casing spool. (15) Drain water from casing, and make rough cut on casing so that it will protrude about 12" to 14"(300mm to 350mm) from top face of casing spool flange. (16) Remove cut casing stub.

2. INSTALLATION OF CASING HANGER THROUGH BOP STACK (1) Drain water from BOP stack through side outlet of casing spool. Leave this valve open until casing hanger is installed. (2) Measure distance from top face of casing spool flange to top face of Kelly bushing. (3) Make certain that casing joint is not in BOP stack nor in casing spool. (4) Wash out casing spool bowl. (5) Center casing in casing spool. (6) Place two boards of equal thickness on rotary table, straddling casing, or use a metal slip plate to support the casing hanger. (7) Loosen 3 socket head screws painted yellow with Allen wrench provided with casing hanger, and pull t hem up 1.1/2"(38mm) to open casing hanger. Do not loosen other bolts. (8) Wrap casing hanger around casing and place it on boards. (9) Close casing hanger around casing and replace 3 yellow painted socket head cap screws to assemble casing hanger. Do not clamp seal. Leave all socket head cap screws 1/16"(1.6mm) loose. (10) Tie sash cord or similar soft line to handles fixed to casing hanger. Measure distance obtained in Step (2) o n sash cord or soft line and mark measurement with knot. (11) With proper tension on casing, firmly support casing hanger with

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soft line and remove boards. (12) Slowly lower casing hanger through BOP stack until properly set in casing spool. Check measurement marked in Step (10). Note: Do not let casing hanger free fall through BOP stack. (13) Make sure that casing hanger is level. Slack off casing load to zero. Record total amount of casing l oad put on casing hanger (slips). (14) Nipple down BOP stack, and raise it about 2 feet(60cm). (15) Remove slip handles or eye-bolts from casing hanger. (16) Be certain casing is centered in casing spool and tighten all socket head cap screws with Allen wrench provided with casing hanger. Void around casing will be sealed by tightening of socket head cap screws. Seal may be tested through BOP or after next spool is installed. (17) Close side outlet valve of casing spool. (18) Drain water from casing, and make rough cut on casing so that it will protrude about 12" to 14"(300mm to 350mm) from top face of casing spool flange. (19) Remove cut casing stub.

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13.5/8" X 9.5/8" TYPE "CHU" UNITIZED C ASING HANGER

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INSTALLATION OF 13.5/8" X 9.5/8" TYPE "CHU" UNITIZED CASING HANGER

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INSTALLATION OF 13.5/8" X 9.5/8" TYPE "PO" PACKOFF

1. Make final cut on casing 5.3/4"(146mm) above top face of casing spool flange. Level and smooth cut-off end of casing. Chamfer or round outside and inside corner of casing. Clean its circumference and make sure that there is no damage in external surface. 2. Cleanly wipe and apply grease to recess in top of casing spool. Lubricate circumference of casing also. 3. Install type "PO" packoff in recess of casing spool in following manner: Use eye-bolts to lift lower adapter (thicker one) and set it in recess. Next, place seal ring on lower adapter. There is no distinction between upper and lower sides of seal ring. Lift upper adapter (thinner one) using eye-bolts and install it on seal ring.

Note: Get rid of air trapped in recess as much as possible when installing packoff seal ring.

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INSTALLATION OF 13.5/8" X 9.5/8" TYPE "PO" P ACKOFF

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 INSTALLATION OF 13.5/8"-5000#W.P. X 11"-10000#W.P. TYPE "S" CASING SPOOL

1. Cleanly wipe flange faces of casing spools, and inspect ring grooves. 2. Install ring gasket and flange protector on spool positioned below. 3. Pick up and suspend casing spool so that it will be level. 4. Install 4 studs directly underneath side outlets of casing spool. 5. Confirm that double "P" seals are installed in grooves provided in bottom of casing spool, and slowly lower casing spool over casing stub until properly located on ring gasket.

Note 1 : In case of "P" seals will be installed in grooves, before installing "P" seals in grooves, put it in hot water heated to about about 80 ﾟ C for 5 to 10 10 minutes minutes and make make it soft soft first. first. Crimp seal into heart shape and grasp crimped end on inside diameter with one hand and start by inserting side opposite from crimp into groove. Be sure to soften "P" seal in hot water because crack may develop in "P" seal when being deformed.

6. Tighten all studs and nuts, making sure that casing spool is correctly set without any space being strained. Be sure to tighten nuts evenly. and careful not cock casing spool. Tightening torque shall be as recommended in A PI specification. As for space between flanges, tighten nuts until it will be as specified in API specification. 7. Inject IKS "P-15" plastic packing into w here double "P" seals are installed.

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One injection port and one bleed port (vent) are provided for each "P"seal in 13.5/8"-5000#w.p. flange (as shown in Fig.) in which double "P"seals for 9.5/8" casing are installed. Plastic packing shall be injected in following manner : (1) Firstly, remove 3/8NPT plug from bleed port to provide outlet for air to escape from and circulate plastic packing around seal. (2) Next, remove 3/4NPT plug from injection p ort, and then remove 7/8"-9UNC x 1" long set screw with Allen wrench. Check valve is installed in innermost part of injection port to prevent back flow of injected plastic packing. (3) Insert plastic packing and screw set screw into injection port, and continue to screw it until it touches check valve. (4) Check if plastic packing is issuing from bleed port. (5) In case plastic packing can not yet be seen, inject another stick of plastic packing or sticks u ntil packing comes out, and then install 3/8NPT plug into bleed port.

Note 1: When using manual injection gun to inject plastic packing, packing injection operation will become difficult when seal is energized. Note 2: When using hydraulic injection gun to inject plastic packing, pressure will be stabilized when seal is energized. Note 3: "P" seal shall not be pressurized higher than 80% of design casing collapse pressure or rated working pressure of flange, whichever is least. 8. Install test pump to 1/2NPT test port fitting. 9. Test annulus space by injecting pressure corresponding to 80% of design casing collapse pressure, or rated working pressure of flange, whichever is least. Hold pressure for 15 minutes.

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Note : This method will test integrity of double "P" seals, ring joint connection and/or lower pack-off. Higher pressure testing will cause deformation of casing I.D. and collapse of casing and such damage will not be known until downhole equipment is lowered through casing. 10. When seals hold pressure, install 3/4NPT plug in injection port. Remove test pump, and install pressure releasing tool where test pump has been installed to release pressure. Remove pressure releasing tool after pressure has been bled, and install safety cap on 1/2" test port fitting.

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INSTALLATION OF 13.5/8"-5000#W.P. X 11"-10000#W.P. TYPE "S" CASING SPOOL

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LOCATION OF INJECTION, VENT AND TEST PORT IN BOTTOM FLANGE OF 13.5/8"-5000#W.P. X 11"-10000#W.P. TYPE "S" CASING SPOOL

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INSTALLATION AND TESTING OF 11"-10000#W.P. BOP STACK

1. Install 11"-10000#W.P. BOP stack and support f lange on casing spool. Note 1: Make sure that all rams are fully retracted. Note 2: Make sure that all holddown screws of support flange are fully retracted. 2. Clean and inspect tool joint threads. 3. Clean and inspect test plug threads. 4. Lubricate threads with API modified thread compound or similar compound. 5. Install test plug to drill pipe. 6. Lower test plug through BOP stack until properly located in casing housing. Note 1: Make sure that tool joint is not located where BOP's rams are. Note 2: Side outlet valve on casing spool should be opened during test. 7. Close BOP rams and test BOP system. 8. After completion of test, bleed pressure to zero and open BOP rams. 9. Retrieve BOP test plug and apply grease and provide safekeeping for test plug until it is used again.

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INSTALLATION AND TEST OF 11"-10000#W.P. BOP TEST PLUG

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INSTALLATION AND REMOVAL OF 11" WEAR BUSHING

1. Clean and inspect running tool threads. 2. Lubricate threads with API modified thread compound or similar compound. 3. Install running tool to drill pipe. 4. Install wear bushing to running tool. 5. Slowly lower wear bushing through BOP stack until properly located in casing spool. 6. Run in all holddown screws located in support flange. Tighten all holddown screws. 7. Remove running tool from wear bushing and retrieve. 8. Prepare to drill out for next casing. 9. Retrieve wear bushing by reversing order of above-mentioned procedure.

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INSTALLATION OF 11" WEAR BUSHING

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INSTALLATION OF 11" X 7.5/8" TYPE "CHU" UNITIZED CASING HANGER

1. INSTALLATION OF CASING HANGER AT WELLHEAD (1) Open side outlet valve of casing spool and discharge water from BOP stack. Keep side outlet valve open until casing hanger is installed. (2) Nipple down BOP stack and raise it about 2 feet(60cm) from top of casing spool. (3) Wash out casing spool bowl. (4) Make sure that casing is centered in casing spool. (5) Place two boards of equal thickness on casing spool flange, straddling casing, to support casing hanger. (6) Loosen 3 socket head screws painted yellow with Allen wrench provided with casing hanger, and pull t hem up 1.1/2"(38mm) to open casing hanger. Do not loosen other bolts. (7) Wrap casing hanger around casing and place it on boards. (8) Close casing hanger around casing and replace 3 yellow painted socket head cap screws to assemble casing hanger. Do not clamp seal. Leave all socket head cap screws 1/16"(1.6mm) loose (9) With proper tension on casing, remove boards and install casing hanger in casing spool. (10) Make sure that casing is level. (11) Slack off casing load to zero. Make note of total amount of casing load put on casing hanger(slips). (12) Remove slip handles or eye-bolts from casing hanger. (13) Tighten all socket head cap screws with Allen wrench provided with casing hanger. Tightening of socket head cap screws will seal void around casing. Seal may be tested by use of BOP or after next spool is installed.

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 (14) Close side outlet valve of casing spool. (15) Drain water from casing, and make rough cut on casing so that it will protrude about 10" to 12"(250mm to 300mm) from top face of casing spool flange. (16) Remove cut casing stub.

2. INSTALLATION OF CASING HANGER THROUGH BOP STACK (1) Drain water from BOP stack through side outlet of casing spool. Leave this valve open until casing hanger is installed. (2) Measure distance from top face of casing spool flange to top face of Kelly bushing. (3) Make certain that casing joint is not in BOP stack nor in casing spool. (4) Wash out casing spool bowl. (5) Center casing in casing spool. (6) Place two boards of equal thickness on rotary table, straddling casing, or use a metal slip plate to support the casing hanger. (7) Loosen 3 socket head screws painted yellow with Allen wrench provided with casing hanger, and pull t hem up 1.1/2"(38mm) to open casing hanger. Do not loosen other bolts. (8) Wrap casing hanger around casing and place it on boards. (9) Close casing hanger around casing and replace 3 yellow painted socket head cap screws to assemble casing hanger. Do not clamp seal. Leave all socket head cap screws 1/16"(1.6mm) loose. (10) Tie sash cord or similar soft line to handles fixed to casing hanger. Measure distance obtained in Step (2) o n sash cord or soft line and mark measurement with knot. (11) With proper tension on casing, firmly support casing hanger with

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soft line and remove boards. (12) Slowly lower casing hanger through BOP stack until properly set in casing spool. Check measurement marked in Step (10). Note: Do not let casing hanger free fall through BOP stack. (13) Make sure that casing hanger is level. Slack off casing load to zero. Record total amount of casing l oad put on casing hanger (slips). (14) Nipple down BOP stack, and raise it about 2 feet(60cm). (15) Remove slip handles or eye-bolts from casing hanger. (16) Be certain casing is centered in casing spool and tighten all socket head cap screws with Allen wrench provided with casing hanger. Void around casing will be sealed by tightening of socket head cap screws. Seal may be tested through BOP or after next spool is installed. (17) Close side outlet valve of casing spool (18) Drain water from casing, and make rough cut on casing so that it will protrude about 10" to 12"(250mm to 300mm) from top face of casing spool flange. (19) Remove cut casing stub.

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11" X 7.5/8" TYPE "CHU" UNITIZED CASING HANGER

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INSTALLATION OF 11" X 7.5/8" TYPE "CHU" UNITIZED CASING HANGER

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INSTALLATION OF 11" X 7.5/8" TYPE "PO" PACKOFF

1. Make final cut on casing 5.1/2"(140mm) above top face of casing spool flange. Level and smooth cut-off end of casing. Chamfer or round outside and inside corner of casing. Clean its circumference and make sure that there is no damage in external surface. 2. Cleanly wipe and apply grease to recess in top of casing spool. Lubricate circumference of casing also. 3. Install type "PO" packoff in recess of casing spool in following manner: Use eye-bolts to lift lower adapter (thicker one) and set it in recess. Next, place seal ring on lower adapter. There is no distinction between upper and lower sides of seal ring. Lift upper adapter (thinner one) using eye-bolts and install it on seal ring. Note:

Get rid of air trapped trapped in recess recess as much much as possible possible when installing packoff seal ring.

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INSTALLATION OF 11" X 7.5/8" TYPE "PO" PACKOFF

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INSTALLATION OF 11" X 11"-10000#W.P. TYPE "TD" TUBING SPOOL

1. Cleanly wipe flange faces of tubing spools, and inspect ring grooves. 2. Install ring gasket and flange protector on spool positioned below. 3. Pick up and suspend tubing spool so that it will be level. 4. Install 4 studs directly underneath side outlets of tubing spool. 5. Confirm that double "P" seals are installed in grooves provided in bottom of tubing spool, and slowly lower tubing spool over casing stub until properly located on ring gasket.

Note 1 : In case of "P" seals will be installed in grooves, before installing "P" seals in grooves, put it in hot water heated to about about 80 ﾟ C for 5 to 10 10 minutes minutes and make make it soft soft first. first. Crimp seal into heart shape and grasp crimped end on inside diameter with one hand and start by inserting side opposite from crimp into groove. Be sure to soften "P" seal in hot water because crack may develop in "P" seal when being deformed.

6. Tighten all studs and nuts, making sure that tubing spool is correctly set without any space being strained. Be sure to tighten nuts evenly. and careful not cock tubing spool. Tightening torque shall be as recommended in A PI specification. As for space between flanges, tighten nuts until it will be as specified in API specification. 7. Inject IKS "P-15" plastic packing into w here double "P" seals are installed.

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One injection port and one bleed port (vent) are provided for each "P"seal in 11"-10000#w.p. flange (as shown in Fig.) in which double "P"seals for 7.5/8" casing are installed. Plastic packing shall be injected in following manner : (1) Firstly, remove 3/8NPT plug from bleed port to provide outlet for air to escape from and circulate plastic packing around seal. (2) Next, remove 3/4NPT plug from injection p ort, and then remove 7/8"-9UNC x 1" long set screw with Allen wrench. Check valve is installed in innermost part of injection port to prevent back flow of injected plastic packing. (3) Insert plastic packing and screw set screw into injection port, and continue to screw it until it touches check valve. (4) Check if plastic packing is issuing from bleed port. (5) In case plastic packing can not yet be seen, inject another stick of plastic packing or sticks u ntil packing comes out, and then install 3/8NPT plug into bleed port.

Note 1: When using manual injection gun to inject plastic packing, packing injection operation will become difficult when seal is energized. Note 2: When using hydraulic injection gun to inject plastic packing, pressure will be stabilized when seal is energized. Note 3: "P" seal shall not be pressurized higher than 80% of design casing collapse pressure or rated working pressure of flange, whichever is least. 8. Install test pump to 1/2NPT test port fitting. 9. Test annulus space by injecting pressure corresponding to 80% of design casing collapse pressure, or rated working pressure of flange, whichever is least. Hold pressure for 15 minutes.

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Note : This method will test integrity of double "P" seals, ring joint connection and/or lower pack-off. Higher pressure testing will cause deformation of casing I.D. and collapse of casing and such damage will not be known until downhole equipment is lowered through casing. 10. When seals hold pressure, install 3/4NPT plug in injection port. Remove test pump, and install pressure releasing tool where test pump has been installed to release pressure. Remove pressure releasing tool after pressure has been bled, and install safety cap on 1/2" test port fitting.

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INSTALLATION OF 11" X 11"-10000#W.P. TYPE "TD" TUBING SPOOL

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LOCATION OF INJECTION, VENT AND TEST PORT IN BOTTOM FLANGE OF 11" X 11"-10000#W.P. TYPE "TD" TUBING SPOOL

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INSTALLATION AND TESTING OF 11"-10000#W.P. BOP STACK

1. Install 11"-10000#W.P. BOP stack on tubing spool. Note 1: Make sure that all rams are fully retracted. Note 2: Make sure that all holddown screws of tubing spool are fully retracted. 2. Clean and inspect tool joint threads. 3. Clean and inspect test plug threads. 4. Lubricate threads with API modified thread compound or similar compound. 5. Install test plug to drill pipe. 6. Lower test plug through BOP stack until properly located in tubing spool. Note 1: Lower test plug so that recesses of test plug will be at 90 degrees from side outlets of tubing spool. Note 2: Make sure that tool joint is not located where BOP's rams are. Note 3: Side outlet valve on tubing spool should be opened during test. 7. Close BOP rams and test BOP system. 8. After completion of test, bleed pressure to zero and open BOP rams. 9. Retrieve BOP test plug and apply grease and provide safekeeping for test plug until it is used again.

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INSTALLATION AND TEST OF 11"-10000#W.P. BOP TEST PLUG

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INSTALLATION AND REMOVAL OF 11" WEAR BUSHING

1. Clean and inspect running tool threads. 2. Lubricate threads with API modified thread compound or similar compound. 3. Install running tool to drill pipe. 4. Install wear bushing to running tool. 5. Slowly lower wear bushing through BOP stack until properly located in tubing spool. Note : Lower wear bushing into tubing spool so that cut-off opening of wear bushing will be at 90 degrees from side outlets of tubing spool. 6. Run in all holddown screws located in top flange of tubing spool. Tighten all holddown screws. 7. Remove running tool from wear bushing and retrieve. 8. Prepare to install production tubing. 9. Retrieve wear bushing by reversing order of above-mentioned procedure.

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INSTALLATION OF 9" WEAR BUSHING

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INSTALLATION AND TESTING OF TYPE "DCL2/SPCL" TUBING HANGER AND X'MAS TREE

1. Clean and inspect tubing threads of tubing hanger and tubing string. 2. Make up tubing hanger in tubing string and tighten to recommended tubing connection torque. Note : Assure that sealing area of hanger neck is not damaged. 3. Wrap 5-6 turns of 1/4" control line around tubing approximately 4 feet (120 Cm) below tubing hanger and secure control line in place with control line clamp. 4. Cut 1/4" control line approximately 12 - 15 feet (360 - 450 Cm) above clamp. 5. Wrap control line around tubing 2 complete spiral turns above clamp and feed control line through control line port in tubing hanger. 6. Slide Swagelok fitting over control line. NPT thread first and screw this NPT thread into tubing hanger. 7. Pull 1/4" control line upward through Swagelok fitting and make spiral turns of control line below tubing hanger firmly attach to tubing. 8. Push 3" of control line down through Swagelok fitting and tighten Swagelok. 9. Using pipe bender, form 90 degree bend above Swagelok and wrap surplus 1/4" control line around tubing hanger neck. Secure control line in place with binding wire and duct tape. 10. Install back pressure valve into tubing h anger. 11. Make up running/landing joint to tubing h anger and slowly lower tubing hanger through BOP stack until properly set on guide wedges in tubing spool. Note : Lower tubing hanger so that recesses of tubing hanger will be at 90 degrees from side outlets of tubing spool.

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12. Run in holddown screws sequentially until tight. 13. Remove landing string, nipple down BOP stack and riser. 14. Clean and inspect seal pocket and ring groove in bottom of X'mas tree. 15. Pick up X'mas tree and suspend it vertically. 16. Clean and inspect tubing hanger neck. 17. Unwind 6 - 8 feet (180 - 240 Cm) of 1/4" control line from around neck of tubing hanger. 18. The procedure to be followed for safe installation of continuous control line to tubing head adapter of X'mas tree shall be performed in following sequence. (1) Following parts provided for this operation shall be prepared beforehand: Two 1.3/4"-8UN x 310 mm long stud bolts. Two 1.3/4"-8UN x 88 mm high special height nuts. (2) Remove all nuts screwed on 16 stud bolts studded in bottom of tubing head adapter. (3) Screw special height nuts prepared in Item (1) as far as one half of their depth on two (180 degrees apart, diametrically located) of these 16 stud bolts of tubing head adapter. (4) Screw two 310 mm long stud bolts prepared in Item (1) into special height nuts. Make sure that t wo bolts have been screwed in to midpoint of depth of special height nut and are properly connected. (5) Screw nuts removed from tubing head adapter stud bolts on free end of these 310 mm long stud bolts connected by special height nuts. Nut should be screwed up to point at which stud bolt will protrude downward about 150 mm from n ut. 19. Lubricate“DX”-Ring lightly, install “DX”-Ring in tubing hanger.

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20. Install ring gasket and flange protector on upper flange of tubing spool. 21. Slowly lower suspended X'mas tree onto tubing spool, and insert 150 mm protruding part (mentioned in Item (5) of Step 18) of 310 mm long stud bolts into holes in tubing spool flange. Screw and tighten nuts previously removed from tubing head adapter stud bolts on lower end of these studs protruding from underneath of f lange to secure proper space between tubing spool and X'mas tree for control line installation. Keep X'mas tree suspended until control line installation related operations are completed. 22. Remove control line needle valve block and Swagelok fitting, and feed 1/4" control line through outlet in tubing head adapter. 23. After 1/4" control line has been fed through outlet in tubing head adapter, remove nuts screwed on two stud bolts fastened to tubing spool and raise X'mas tree to remove two 310 mm long stud bolts. Remove special height nuts. Note: Keep these two 310 mm long stud bolts and two special height nuts for installation of other X'mas tree. 24. Again slowly lower X'mas tree over extended neck of tubing hanger until properly located on ring gasket. Caution : Do not nip control line in flange make up. Keep tension on 1/4" control line. 25. Properly set X'mas tree and tighten nuts. 26. Inject oil through test port to discharge air through outlet of 1/4" control line and fill space around neck portion of tubing hanger with oil. 27. When space has been filled with oil, slide Swagelok fitting over free end of 1/4" control line, and screw it into tubing head adapter tight. Make up ferrule nut of Swagelok fitting. 28. Cut off control line approximately 1/2" ( 12.7 mm) above ferrule nut

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of Swagelok fitting. 29. Apply pressure pressure from test port port to space area to 10000 psi (703 kgf/c ㎡) and hold for 15 minutes. A vent port is opening. 30. After successful testing, insert small diameter tube through test port and send compressed air available at rig through this tube to exhaust oil test fluid. Repeat this operation until at least one half of space is filled with air. 31. Clean BX 151 ring groove and install ring gasket in t ubing head adapter. Install control line needle valve block on control line exit. 32. Remove cap and 1"NPT plug from 1/4" control line needle valve block. 33. Connect control line to 1"NPT threads, open needle valve and inject oil into control line. Apply 10000 psi (703 kgf/c ㎡ ) test pressure and hold for 15 minutes. Note : This pressure will also be applied to down hole tools. 34. Remove back pressure valve. (See appendix A) 35. Close wing valves and swab valve. 36. Prepare to clean up and test well. Note : Hydraulic actuated surface safety valves should be locked open during wire line operations and installation.

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ＣＯＮＴＲＯＬ

ＬＩＮＥ

ＣＬＡＭＰ

TYPE "DCL2/SPCL" TUBING HANGER ASSEMBLY MADE UP TO TUBING

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ＤＸ－ＲＩＮＧ

ＳＰＥＣＩＡＬ

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ＬＯＮＧ

ＮＵＴ

ＳＴＵＤ

INSTALLATION OF DHSV CONTROL LINE TO T UBING HEAD ADAPTER

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ＢＯＬＴ

ＶＥＮＴ

ＣＯＮＴＲＯＬ

ＬＩＮＥ

ＣＯＮＴＲＯＬ

ＮＥＥＤＬＥ ＶＡＬＶＥ

ＰＯＲＴ

ＬＩＮＥ

ＮＥＥＤＬＥ

ＢＬＯＣＫ

ＶＡＬＶＥ

ＢＬＯＣＫ

ＴＥＳＴ

ＰＯＲＴ

INSTALLATION OF TYPE "DCL2/SPCL" TUBING HANGER WITH CONTINUOUS CONTROL LINE TO X'MAS TREE

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