Irp 3.3 Completions & Well Servicing

IRP 3.
3 COMPLETIONS & WELL SERVICING

MAY 2012 DRAFT
REV 04MAY2012
Note to Reviewers:
This is third chapter of six in IRP 3.
This is the second industry review for this chapter. Modifications based on comments from
the first industry review have been incorporated in consultation with the original
Completions and Well Servicing Working Group.
Modifications are noted as follows:
New content is green
Deleted content has a strikethrough
Appendix A and B drawings have been modified for clarification in accordance

with regulation.
IRP 3: IN SITU HEAVY OIL OPERATIONS
3.3 COMPLETIONS & WELL SERVICING
TABLE OF CONTENTS
3.3. Completions & Well Servicing ................................................... 5
3.3.1
Introduction ......................................................................5
3.3.2
3.3.3
Completions Design ...........................................................7

Primary Well Servicing .......................................................7
3.3.4
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3.3.1.1 Definitions ........................................................................ 5
3.3.3.1
3.3.3.2
3.3.3.3
3.3.3.4
3.3.3.5
Offset production .............................................................. 7

Primary Completions Planning .......................................... 8
Primary Well Completions and Workovers ........................ 9
Primary BOP and Well Control Requirements.................. 10
Primary Well Stimulation ................................................ 11
a. Spacing ....................................................................... 11
b. Stimulus Operations ...................................................... 12
c. Foaming ....................................................................... 12
d. Swabbing ..................................................................... 12
3.3.3.6 Primary Wellbore Integrity ............................................. 12
a. Wellbore Condition ........................................................ 12
b. Primary Wellbore Remediation ........................................ 13
c. Remedial Cementing ...................................................... 13
Secondary Well Servicing ................................................. 13

3.3.4.1 Offset Production ............................................................ 14
3.3.4.2 Secondary Completions Planning .................................... 15
a. Welding ....................................................................... 16
b. Temperature ................................................................ 16
c. Wellbore Access ............................................................ 16
d. Liners .......................................................................... 17
e. Packers ........................................................................ 17
f. Seals and Connections ................................................... 17
g. Observation Wells ......................................................... 17
3.3.4.3 Secondary Well Completions and Workovers .................. 18
3.3.4.4 Secondary BOP and Well Control Requirements .............. 19
a. Temperature ................................................................ 20
b. Auxiliary Tubing External Attachments ............................. 20
c. Offset Spool ................................................................. 21
d. Observation Well .......................................................... 21
e. Slant Wells ................................................................... 21
3.3.4.5 Secondary Well Stimulation ............................................ 21
a. Spacing ....................................................................... 21
b. Temperatures ............................................................... 22
c. Stimulus Operations ...................................................... 22
d. Foaming ...................................................................... 22
3.3.4.6 Secondary Wellbore Integrity ......................................... 22
a. Wellbore Condition ........................................................ 22
b. Deformation Classifications ............................................ 23
c. Wall Loss Class ............................................................. 25
d. Secondary Wellbore Casing Remediation .......................... 25
e. Casing Breaks/Parted Casing/Collapsed Casing ................. 25
f. Sulphide Stress Corrosion Cracking .................................. 26
g. Remedial Cementing ..................................................... 26
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3.3.5
3.3.6
Well Servicing Equipment Spacing ................................... 26

Well Abandonment........................................................... 27
Appendix A: Well Servicing Equipment Minimum Spacing: Class

IIA
28
Appendix B: Associated Well Servicing Equipment Minimum
Spacing: Class IIA ................................................................... 29
Appendix C: Well Servicing Spacing Matrix ...................................... 30
LIST OF TABLES
Table 1. Deformation Classifications ................................................................. 24
Table 2. Wall Loss Classes ............................................................................... 25
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3.3.
COMPLETIONS & WELL SERVICING
3.3.1 INTRODUCTION
Completions and well servicing reviews concerns specific to in situ heavy oil
operations and includes those situations common to the heavy oil industry with a
primary focus on worker safety.
The content presented here is intended for production engineers, completions
superintendents, wellsite supervisors, and those in planning from an integrated
approach.
This chapter emphasizes key regulations in several REG statements. IRP statements
are phrased with both shall and should throughout the chapter. Appendices A
and B illustrate spacing diagrams that are also provided in a larger format for
reproduction in the Doghouse package available on the IRP 3 landing page.
Central topics covered in completions and well servicing include:
Service rig operations for primary and secondary wells
Continuous rod rigs
Coiled tubing
Wireline
Snubbing units
Flush-by units
3.3.1.1
Definitions
Following are a collection of key definitions relevant to completions and well

servicing. A complete glossary with terms used across the entire IRP is available in
the Glossary at the back of this document.
Heavy Kill
Heavy kill occurs when the volume of kill fluid has sufficient density and composition
to successfully kill the well.
Keyseat
Keyseat refers to a small diameter channel worn into the side of tubing or casing
string.
Ovality
The degree of ovality refers to the difference in the ratio of minimum ID to
maximum ID.
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Primary Recovery Well (Class IIA)

According to ID 91-3, a primary recovery well has a reservoir sandface pressure
equal to or less than the hydrostatic pressure that would be exerted at the sandface
if the well were filled with formation fluids.
Secondary Recovery Well (Class IIA)
According to ID 91-3, a secondary recovery well has a reservoir sandface pressure
greater than the hydrostatic pressure that would be exerted at the sandface if the
well were filled with formation fluids. It occurs by virtue of injection into the
formation of fluid(s) other than water at ambient temperatures. This includes all
wells that are part of an active Enhanced Oil Recovery (EOR) project, approved by
the ERCB and any offset wells within 1000 m of an EOR well.
Sandface
The sandface refers to the physical interface between the formation and the
wellbore. The diameter of the wellbore at the sandface is one of the dimensions used
in production models to assess potential productivity.
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3.3.2 COMPLETIONS DESIGN

Completions design needs to consider the production scheme intended for the well.
Equally, production operations need to assess the completions design if
modifications to the original production scheme occur at any time through the life
cycle of the well (see 3.5 Production Operations).
IRP
Completions design should consider the intended production scheme in

the final design and Operators shall document the final completions
design.
IRP
An engineering assessment should be completed when modifications to

the original completion design are required.
3.3.3 PRIMARY WELL SERVICING

Primary well servicing refers to well servicing that does not involve enhanced oil
recovery (EOR) or secondary recovery.
3.3.3.1
Offset production
It is important to review offset production data and history to identify potential

problems during well servicing operations. From the perspective of in situ heavy oil
operations, wells can become sour after a short time on production (see 3.1.2.3
Surface Casing Vent Flow and Gas Migration and 3.5.5 Surface Casing Vent and Gas
Migration Monitoring).
To reduce potential problems consider the following data sources:
IRP
area zonal communication,
cumulative production of offset wells,
BHP,
H2S content, and
use of EOR techniques or stimulation methods.

Any well within a 1000 m of a high pressure CSS well, or within
300 m of a SAGD well, shall follow thermal procedures described
in 3.3.4 Secondary Well Servicing below.
Note. If after two years no steaming has been carried out within 1000
m of a well, the well may be considered primary with regulatory
approval. Approval may be granted on the basis of a current reservoir
pressure and temperature survey.
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A thorough individual well history is important to assess the potential for well
servicing problems. Well history data gathering should consider, but not be limited
to, the following:
data on cumulative and current offset well production
data on BHP, temperature, H2S content, casing failures, surface casing

vent flow (SCVF), gas migration (GM), sand issues
data on EOR techniques (e.g., steam, fireflood, O2 injections, CO2

injection, propane floods, polymer floods)
3.3.3.2
Primary Completions Planning
The following planning considerations are pertinent to primary completions.
Review BHP casing, wellhead, sand content, fluid viscosity, fluid density,
and regulatory requirements.
Ensure wellhead design includes full bore access and tool access to casing
weights.
Prior to completion, ensure surface casing isolation from production casing

and install a surface casing vent assembly.
(see REG statement below and 3.5.5 Surface Casing Vent and Gas
Migration Monitoring)
Install valves on all standing cased wells.
Establish baseline gas migration data prior to completion (see 3.5.5

Surface Casing Vent and Gas Migration Monitoring).
Ensure communication and synergy with drilling for conditions and final
design of the well (e.g., cement, deviations, doglegs, trouble spots, etc.)
Refer to 3.1.2 Operational Integrity.
Design well pads and patterns to maximize service and completion work.
Design well pads and patterns that efficiently accommodate service and
completion work (see 3.1.1.2 Multi-Operational Pad Planning).
REG
Well completion design must accommodate a surface casing

vent (SCV) assembly in accordance with jurisdictional
regulations.
REG
In Saskatchewan, surface casing bowls can only be removed

(without prior approval) in Township 44-54 inclusive, and only if
the production casing is cemented to surface with no fallback
and the gas migration and SCVF tests are negative.
Note. All horizontal wells and any wells outside the area described
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above require written approval from the Ministry of Energy & Resources
Regional office to have surface casing bowls removed.
To prepare a well for primary production, it is important to follow established
procedures during wellhead installation. For in situ heavy oil operations, conduct
wellhead installation procedures with particular attention to:
back welding,
pressure testing,
availability of mill certifications, and
corresponding heat numbers.
It is equally important to ensure equipment is properly rated for pressure,

temperature, and the possibility of future H2S (see 3.1.2.3 Surface Casing Vent Flow
and Gas Migration).
For detailed guidance on installation procedures refer to IRP 5.2.3 Wellhead
Installation.
REG
In Saskatchewan, surface casing bowls can only be removed in

Township 44-54 inclusive, and only if the production casing is
cemented to surface with no fallback and the gas migration and
SCVF tests are negative.
IRP
Wellhead designs should accommodate existing and anticipated future

operating parameters (e.g., workover, stimulation, EOR).
Refer to IRP 5: Minimum Wellhead Requirements and in this document
3.4.3 Wellhead Design.
It is important to prepare completions plans that include considerations for

abandonment such as:
Ensure the wellhead design accommodates future abandonment.
Evaluate lower cased zones for abandonment prior to completion.
Consider cased hole abandoning lower zones on initial completion, if sump

is excessive below the target zone.
3.3.3.3
REG
Primary Well Completions and Workovers

All in situ heavy oil primary well completions and workovers
must comply with relevant jurisdictional regulations.
Following is a list of the key regulatory documents:
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Directive 033: Well Servicing and Completions Operations - Interim

Requirement Regarding the Potential for Explosive Mixtures and Ignition in
Wells
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Directive 037: Service Rig Inspection Manual
ID 91-3: Heavy Oil/Oil Sands Operations
IRP Volume 7: Standards for Wellsite Supervision of Drilling, Completion

and Workovers.
Saskatchewans Oil and Gas Conservation Regulations, 1985
Saskatchewan Upstream Industry Storage Standards
Additionally, completions and workovers should consider the following:
spacing limitations due to existing production facilities (see Appendix A:

Well Servicing Equipment Minimum Spacing and Appendix B: Associated
Well Servicing Equipment Minimum Spacing: Class IIA. For a combined
diagram of spacing requirements for service rigs, drilling rigs and existing
wells see: 3.1 Integrated Planning, Appendix A: Minimum Spacing
Requirements for Multi-Operational Pads);
accommodations for well type (e.g., horizontal, directional, slant, vertical,

and well service classification);
if applicable, ensure an Emergency Response Plan (ERP) is in place and in

accordance with jurisdictional regulations;
if applicable, ensure procedures are in place to address venting of odorous

compounds and to control noise during well servicing operations in
accordance with jurisdictional regulations; and
waste management in accordance with jurisdictional regulations

(see 3.1.1.6 Waste Management).
3.3.3.4
Primary BOP and Well Control Requirements
All primary BOP configurations are considered Class IIA in accordance with ID 91-3
Heavy Oil/Oil Sands Operations. 1 Class IIA Primary refers to a well having a
sandface reservoir pressure equal to or less than the hydrostatic pressure that would
be exerted at the sandface if the well were filled with formation fluids.
REG
BOP components on a Class IIA primary well must be tested to

the pressures specified in Section 8.147 of the Oil and Gas
Conservation Regulations. A 10-minute test must be conducted
prior to servicing the first well of a program (i.e., change of
Operator), and thereafter, within 30 calendar days.
Note. A kill line is not required on a Class IIA BOP.
Since ID 91-03 was originally published in 1991, it refers to Class IIA. All current ERCB documentation
now has dropped the A and refers to Class II only.
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REG
In Saskatchewan BOP components must comply with the

Saskatchewan Oil and Gas Conservation Regulations (1985).
General primary well control considerations follow.
Determine if servicing BOPs requires full bore access to production casing.

When moving tubing, full access to the wellbore is recommended at all
times.
Consider anticipated BHP.
Be aware of the type and volume of kill fluid required.
Follow established kill procedures.
Determine operations to be carried out (e.g., coil tubing [see IRP Vol. 21 Coiled Tubing Operations], wireline, continuous rod, flush-by operations,
etc.).
Determine tools to be used that would affect BOP configuration/regulation.
Ensure appropriate cutters are on the floor for capillary tubes and Electric
Submersible Pump (ESP) power cables.
Tubing strings too small for the existing pipe ram size(s) may be pulled
either with an annular BOP and variable type ram, or alternatively an
annular BOP and rod ratigans.
3.3.3.5
Primary Well Stimulation
Primary well stimulation includes four key considerations: spacing, stimulus

operations, foaming, and swabbing.
a. Spacing
The density of fluid being pumped may affect equipment spacing requirements.
Refer to Appendix A: Well Servicing Equipment Minimum Spacing: Class IIA and
Appendix B: Associated Well Servicing Equipment Minimum Spacing: Class IIA for
spacing specifications.
Note.
Density under 920 kg/m3 changes well treatment considerations and

spacing requirements.
For solvent injection operations, refer to IRP Volume 8: Pumping of Flammable

Fluids.
REG
All stabilized foam cleanout operations must comply to ERCB

Class IIA equipment spacing regulations.
REG
In Saskatchewan all stabilized foam cleanout operations must

comply to Saskatchewan Oil and Gas Conservation Regulations
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(1985) and the PDB ENV 13 S-01 Saskatchewan Upstream

Petroleum Industry Storage Standards. Additionally, discussion
with Saskatchewan OHS may also be required.
b. Stimulus Operations
REG
All stimulus operations must follow established OHS procedures.
REG
Stimulus operations (e.g., acidizing, fracturing, foam cleanout)

must be in accordance with Directive 033: Well Servicing and
Completions Operations - Interim Requirement Regarding the
Potential for Explosive Mixtures and Ignition in Wells.
REG
In Saskatchewan all stimulus operations must comply to

Saskatchewan Oil and Gas Conservation Regulations (1985) and
the PDB ENV 13 S-01 Saskatchewan Upstream Petroleum
Industry Storage Standards. Discussion with Saskatchewan OHS
may also be required.
c. Foaming
Operators may choose to foam for cleanout. The IRP 3 Committee acknowledges
there are other cleanout methods as effective as foaming. The IRP 3 Committee
does NOT endorse, or recommend, any single method of cleanout. Cleanout
methods are selected at the Operators discretion.
If an Operator does choose to foam, it is recommended to foam with a Regulator
approved stable foam blend and follow Operator approved procedures. For
information regarding foaming considerations see the supporting document Foam
Cleanouts for guidelines pertaining to foaming.
d. Swabbing
Always swab as directed in Operator approved procedures.
REG
In Alberta, space the swabbing return tank 15 m from the

wellhead according to ID 91-3.
REG
In Saskatchewan, space the swabbing return tank 45 m from

the wellhead according to OHS requirements.
3.3.3.6
Primary Wellbore Integrity
Primary production can cause casing damage or failures to occur in the region of the
producing zone. A casing inspection program should be developed as required.
The following topics are relevant to in situ heavy oil wellbore inspections.
a. Wellbore Condition
The wellbore or casing condition inspections may seek to identify issues with
corrosion, ovality, wear, etc. Inspections may include, but not be limited to, the
following:
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mechanical inspections (e.g. gauge ring / scraper runs)
pressure tests
casing inspection logs (e.g., multi-finger caliper, magnetic flux leakage,

ultrasonic inspection, etc.)
cement bond quality
b. Primary Wellbore Remediation

In instances where primary wellbore remediation is required, jurisdictional
regulations apply.
REG
In Alberta regulatory approval must be obtained for non-routine

repairs according to Bulletin 2009-07: Revisions to the Digital
Data Submission System Regarding Interim Directive 2003-01.
REG
In Saskatchewan, the appropriate regional office must be

contacted to obtain approval for non-routine repairs.
c. Remedial Cementing
Efforts should be made at the planning stages to avoid the necessity of remedial
cementing (see 3.1.2.1.1 Cement Integrity). Remedial cementing may be required:
depending on gas migration and/or vent flow test results and jurisdiction,
to repair casing damage,
to ensure zonal isolation,

(as per Directive 020: Well Abandonment in Alberta and according to area
specific guidelines in Saskatchewan)
to establish cement top on initial completion, and

(per Directive 009: Casing Cementing Minimum Requirements)
to ensure ground water protection (per Directive 020).

Note. If discovered in initial completion that groundwater aquifers are not
covered by cement, then remedial cement squeeze may be necessary.
REG
In Alberta, any remediation must comply with Directive 009:

Casing Cementing Minimum Requirements.
REG
In Saskatchewan, contact the appropriate regional office for

program approval if remedial cementing is required.
3.3.4 SECONDARY WELL SERVICING

Secondary well servicing refers to well servicing that involves enhanced oil recovery
(EOR), and is also known as secondary recovery. It includes both cold secondary
recovery methods (e.g., solvent injection, water / polymer, etc.) and thermal
recovery methods (e.g. SAGD, CSS, fireflood, etc.)
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3.3.4.1
Offset Production
It is important to review offset production data and history to identify potential

problems during well servicing operations. From the perspective of in situ heavy oil
operations, wells can become sour after a short time on production. (see 3.1.2.3
Surface Casing Vent Flow and Gas Migration and 3.5.5 Surface Casing Vent and Gas
Migration Monitoring).
To reduce potential problems consider the following data sources:
area zonal communication;
cumulative production of offset wells;
BHP, H2S content, NORM 2; and
use of EOR techniques, stimulation methods.
Additionally the DRAFT Guidelines for Drilling Proximal to a SAGD Steam Chamber 3
is an excellent resource.
A thorough individual well history is important to assess the potential for well
servicing problems. Well history data gathering should consider, but not be limited
to, the items listed below.
drilling history of the well, noting any problems encountered while drilling
(particularly cementing problems)
data on current cycle performance with regards to steam injection

volumes versus cumulative or current production volumes (particularly
producing temperature for anticipated BHT and BHP)
data on previous workovers to identify any previously document casing

problems
produced fluid, gas analysis, and presence of NORM
Secondary well servicing should consider additional offset data including, but not
limited to, the following items listed below.
drilling history of offset wells, noting any problems encountered while

drilling
data on cumulative and/or current production levels
data on producing temperature, BHP, H2S content, gas to oil ratios, casing
problems, and sand issues
Naturally Occurring Radioactive Materials
This document is available on the IRP 3 landing page:

http://enform.ca/publications/irps/heavyoilandoilsandsoperations.aspx
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current status of wells (e.g., producing, steaming, or shut in) and possible
effects that change of status could have on individual wells
Communication with other wells can cause significant impact is especially important
for secondary recovery (see 3.1.1.2.2 Offset Wells and Proximal Operations and
3.5.3.10 Managing Proximal Operations). Secondary well servicing should consider,
but not be limited to the following:
data on well-to-well communication problems encountered while steaming

or producing
communication with other wells in area

Note. Communication between wells can change during the workover
potentially impacting BHP and/or temperature.
3.3.4.2
Secondary Completions Planning
The following planning considerations are pertinent to secondary completions.
REG
Identify intervention and abandonment needs.
Review NACE specifications for corrosion control.

(see 3.2.1.3.3 Thermal Production Casing Material Selection, b) Corrosion
Considerations and c) Corrosion Mitigations)
Define potential H2S and CO2 concentrations (see 3.1.2.3 Surface Casing
Vent Flow and Gas Migration).
Ensure equipment is properly rated for pressure, temperature, and

possibility of future H2S.
Establish baseline gas migration data prior to completion

(see 3.5.5 Surface Casing Vent and Gas Migration Monitoring).
Ensure communication and synergy with drilling for conditions and final
design of the well (e.g., cement, deviations, doglegs, trouble spots, etc.).
(see 3.1.2 Operational Integrity)
Design well pads and patterns that efficiently accommodate service and
completion work (see 3.1.1.2 Multi-Operational Pad Planning).
Well completion design must accommodate a surface casing
vent (SCV) assembly in accordance with jurisdictional
regulations.
To prepare a well for secondary production, it is important to follow established

procedures during wellhead installation. For detailed guidance on installation
procedures refer to IRP 5.2.3 Wellhead Installation.
IRP
Wellhead designs should accommodate existing and anticipated future

operating parameters (e.g., workover, stimulation, EOR).
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Refer to IRP 5: Minimum Wellhead Requirements and 3.4.3 Wellhead

Design.
a. Welding
Welding procedures may include, but not be limited to, the following considerations.
back welding
stress-relieving
non-destructive testing
pressure testing
availability of mill certifications
corresponding heat numbers
IRP
Operators shall have a welding procedure for severe service

tubing head installations. See 3.2.3.8.6 Welding Requirements
for details.
REG
In Alberta a cement bond log is required in accordance with

Directive 051 to test the quality of a cement bond.
REG
In Saskatchewan, a cement bond log may be required on a caseby-case basis. Contact the appropriate regional office.
b. Temperature
Temperature cycling in secondary recovery requires special consideration during
secondary planning.
High temperatures may de-rate materials.

(Refer to 3.2.1.3.1 Thermal Production Casing Loading)
Note. Cyclic loads and thermal stresses reduce the life of steel.
Special maintenance of the wellhead may be required during heating and

cooling cycles (e.g., re-torquing wellhead studs, maintenance or
inspection of steam gate valves).
IRP
All components shall be rated for the highest potential

temperature of the well.
IRP
Downhole equipment configuration shall allow for contraction

and expansion.
c. Wellbore Access
It is important to design the wellhead with the ability to accommodate access to any
production or working string being serviced for the purpose of well control.
Offset access for tubular and workover strings is important for workers to effectively
and safely complete the well. Wellbore access should:
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accommodate wellhead height and any auxiliary equipment installed; and
accommodate access necessary to install required BOPs and workover

equipment.
d. Liners
It is recommended to design liner hangers to allow easy entry to RIH (run in hole)
with tools and downhole equipment (see 3.2.1.3.6 Thermal Liner). If required,
pressure test liner hanger during initial completion. During completion/workover
ensure pressure and weight does not exceed hanger specifications.
e. Packers
During completion design, consider expansion and contraction caused by BHT
change that may occur during operations and which may impact packers.
Additionally, consider placing debris seals over packers to keep slip and setting
action free of materials that could cause packers to become stuck.
f.
Seals and Connections
High temperatures can change the characteristics of seals and connections. To

minimize the impact consider the following:
selecting high temperature materials for seals, polymer, and steel;
minimizing the number of instrumentation lines exiting the wellhead;

(see 3.2.3.8.4 Instrument String Configurations)
using premium thread for production string tubular connections; and

(see 3.2.1.3.4 Thermal Production Casing Connection Selection)
using slip seal assemblies/mandrel hang-off to terminate instrumentation

coil tubing at surface.
g. Observation Wells
Install wellheads suitable to reservoir conditions on observation wellbores. In
addition consider the following:
Note.
Evaluate risk as downhole conditions change.
Avoid threaded wellheads except for low pressure, non-perforated

observation wells.
Treat perforated observation wells the same as producing wells.

Some observation well designs make it difficult or impossible to test
casing bowl flange connections to wellhead or BOPs. This may require
custom equipment design and manufacture.
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3.3.4.3
Secondary Well Completions and Workovers
Due to the thermal nature of secondary recovery, it is important to be aware of the

maximum well temperature where workover operations can be conducted safely.
REG
All in situ heavy oil secondary well completions and workovers

must comply with relevant jurisdictional regulations.
Directive 033: Well Servicing and Completions Operations - Interim

Requirement Regarding the Potential for Explosive Mixtures and Ignition in
Wells
Directive 037: Service Rig Inspection Manual
ID 91-3: Heavy Oil/Oil Sands Operations
IRP Volume 7: Standards for Wellsite Supervision of Drilling, Completion

and Workovers.
Saskatchewans Oil and Gas Conservation Regulations, 1985
Saskatchewan Upstream Industry Storage Standards
Additionally, completions and workovers should consider the following:
spacing limitations due to existing production facilities (see Appendix A:

Well Servicing Equipment Minimum Spacing: Class IIA and Appendix B:
Associated Well Servicing Equipment Minimum Spacing: Class IIA. For a
combined diagram of spacing requirements for service rigs, drilling rigs
and existing wells see: 3.1 Integrated Planning, Appendix A: Minimum
Spacing Requirements for Multi-Operational Pads);
accommodation for well type (e.g., horizontal, directional, slant, vertical,

and well service classification);
if applicable, ensure an ERP is in place and in accordance with

jurisdictional regulations;
if applicable, ensure procedures are in place to address venting of odorous

compounds and to control noise during well servicing operations in
accordance with jurisdictional regulations;
evaluate the need for heavy kill procedures and develop procedures as
required; and
waste management in accordance with jurisdictional regulations (see

3.1.1.6 Waste Management).
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3.3.4.4
Secondary BOP and Well Control Requirements
All secondary BOP configurations are considered Class IIA in accordance with ID 913: Heavy Oil/Oil Sands Operations. Class IIA secondary wells have the following
characteristics due to fluid(s) injection (other than water) into the formation at
ambient temperatures:
sandface reservoir pressure greater than a Class IIA primary well or with a
bottomhole or injection pressure less than or equal to 21 MPa,
H2S release rate less than 0.001 m3/sec (see 3.1.2.3 Surface Casing Vent
Flow and Gas Migration),
includes all wells that are classified by the respective regulatory body as
an active EOR scheme and
any offset wells within 1000 m of a high pressure CSS well or within
300 m from any SAGD, fireflood, or solvent injection wellbore.
REG
BOP components on a Class IIA secondary well must be tested

to the pressures specified in Section 8.147 of the Oil and Gas
Conservation Regulations. A 10-minute test must be conducted
prior to servicing the first well of a program (i.e., change of
Operator), and thereafter, within 7 calendar days. If the BOPs
are moved to a new well within 7 calendar days of the original
10-minute test, BOP component pressure testing must be a
minimum of 2 minutes.
Note. A 15 m kill line is required.
REG
In Saskatchewan BOP components must comply with the

Refer to the following general secondary well control considerations:
Determine if servicing BOPs requires full bore access to production casing.

When moving tubing or removing tubing hanger, full access to wellbore is
recommended.
Review anticipated BHP and BHT.
Review the type and volume of kill fluid required.
Follow established kill procedures.
Be aware of any special concerns resulting from pumping water into a

thermal well during well kill. Consider temperature differences before
pumping fluid down the well.
Ensure kill procedures and fluids consider the effects of thermal downhole
temperatures (see 3.2.2.7 Well Control Practices in Thermal Areas and
3.2.3.6 Drilling Proximal to a Steam Chamber).
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Non-routine well control procedures may be required, but not limited to,
the following circumstances:
o
if a well will not hold a column of fluid (i.e., will not circulate under
normal conditions)
if a well swabs while tripping tubing, etc.
if wells are over-pressured (refer to Operators heavy kill

procedures)
Determine operations to be carried out (e.g., coil tubing [IRP Volume 21:
Coiled Tubing Operations], wireline, continuous rod, flush by operations,
etc.).
Determine tools to be used that could affect BOP configuration/regulation.
Strings too small for the existing pipe ram size may be pulled either with
an annular BOP that includes rams to accommodate each tubing string, or
a variable type ram.
a. Temperature
IRP
All BOP components shall be temperature rated at, or above, the

anticipated surface working temperature of the well being
serviced.
Note. If a rod string needs to be pulled from a thermal well, do not
exceed the maximum working temperature of the BOP elements.
For non-emergency conditions, 85C is the maximum recommended wellhead

temperature for servicing as recommended by the manufacturers. Temperatures
above 85C risk the integrity of well control elastomers unless appropriately risk
assessed.
If there is potential for exposure to hot fluids during well servicing, then proper PPE
needs to be available.
b. Auxiliary Tubing External Attachments
REG
According to D037 an annular preventer must be installed

whenever electrical cables, small diameter tubing control, or
circulating strings are being tripped. Other proposed
modifications must be approved by the appropriate regional
regulatory authority.
IRP
A means to cut auxiliary items (e.g., capillary tubes, ESP cables,

instrument cables) shall be available on the rig floor for tubing
strings with auxiliary external attached lines, tubes, or cables,
using Class II BOP (supplemented with an annular BOP) may be
used..
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c. Offset Spool
The use of offset rams is generally discouraged for tripping offset tubing strings.
An offset spool is recommended below a thermally suitable, dimensionally standard
BOP.
If multiple strings are to be handled, a back pressure valve should be available for
reconfiguring the BOP stack.
REG
While pulling tubing strings, each tubing string must be

equipped with its appropriate ram and/or a variable ram to
ensure well control (D037). Occasionally, with small tubing
strings appropriately sized rams are not available. In these
situations, modified designs must receive local regulatory
approval.
d. Observation Well
Non-perforated observation wells do not require BOPs if the wellbore has been
pressure tested.
If BOPs are used, they should be installed as required for the offsetting production
wells.
e. Slant Wells
For wells slanted at surface, design consideration should ensure that loads induced
due to the moment arm and weight of the BOP will not cause a structural failure of
the near surface casing string(s) or leakage at the BOP or wellhead flanges. Support
brackets or other means of supporting the BOP stack should be designed by a
professional engineer.
3.3.4.5
Secondary Well Stimulation
Secondary well stimulation includes four key considerations: spacing, stimulus

operations, foaming, and swabbing.
a. Spacing
The density of fluid being pumped may affect equipment spacing requirements.
Refer to Appendix A: Well Servicing Equipment Minimum Spacing: Class IIA and
Appendix B: Associated Well Servicing Equipment Minimum Spacing: Class IIA for
spacing specifications.
For solvent injection operations, refer to IRP Volume 8: Pumping of Flammable
Fluids.
Note.
Density under 920 kg/m3 changes well treatment considerations and

the well service classification.
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Note.
Stabilized foam cleanout operations do not change spacing from a Class

IIA.
b. Temperatures
IRP
Appropriate products shall be used for stimulations in situations

with elevated wellbore temperatures (e.g., using N2 rather than
air for foam generation).
c. Stimulus Operations
REG
All stimulus operations must follow established OHS procedures.
REG
Ensure stimulus operations (e.g., acidizing, fracturing, foam

cleanout) are compliant with Directive 033: Well Servicing and
Completions Operations - Interim Requirement Regarding the
Potential for Explosive Mixtures and Ignition in Wells.
REG
In Saskatchewan all stimulus operations must comply with the

d. Foaming
Operators may choose to foam for cleanout. The IRP 3 Committee acknowledges
there are other cleanout methods as effective as foaming. The IRP 3 Committee
does NOT endorse, or recommend, any single method of cleanout. Cleanout
methods are selected at the Operators discretion.
If an Operator does choose to foam, it is recommended to foam with a Regulator
approved stable foam blend and follow Operator approved procedures. For
information regarding foaming considerations see supporting document Foam
Cleanouts for guidelines pertaining to foaming.
3.3.4.6
Secondary Wellbore Integrity
Secondary production techniques can increase the risk of casing damage and failure
due to thermally-induced stresses. A casing inspection program should be developed
as required.
The following topics describe wellbore inspection considerations.
a. Wellbore Condition
The wellbore or casing condition inspections may seek to identify issues with
corrosion, ovality, casing body and connections, wear, etc. Inspections may include,
but not be limited to the following
mechanical inspections (e.g. gauge ring / scraper runs)
pressure tests
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casing inspection logs (e.g., multi-finger calliper, magnetic flux leakage,

ultrasonic inspection, etc.)
cement bond quality (as per Directive 051: Injection and Disposal Wells
Well Classifications, Completions, Logging, and Testing Requirements)
follow-up cement bond quality as required
temperature logs
Results of the casing inspection can identify wellbore conditions which may result in
one, or all, of the following constraints:
designate as POW (producer-only well),
operating pressure and temperature restrictions,
repair wellbore damage, and
wellbore shut-in and/or abandonment.
b. Deformation Classifications
Consider developing generic deformation classifications based on reduced ID.
Table 1 below is a guideline to develop deformation classifications.
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Table 1. Deformation Classifications
Deformation
Severity
Class
Amount of
Deformation
in
Connection
(mm)
Amount of
Deformation
in Pipe Body
(mm)
><3
<5
Ok to steam.
3-4
5-7
Ok to steam.
5-6
8-9
Requires pressure test before

steaming.
7-8
10-12
May or may not Cannot be

steamed dependent on location
of deformation and regulatory
reviewWell may be is
classified as POW and can be
purged and monitored or
plugged while steaming around
it.
>8
>12
May or may not Cannot be

steamed dependent on location
of deformation and regulatory
reviewWell may be shall be
plugged or repaired before
steaming operations in the
area. Should Cannot be POW
until patched or repaired.
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c. Wall Loss Class

Consider developing generic classes based on wall loss as illustrated in Table 2.
Table 2. Wall Loss Classes
Wall Loss
Class
% Wall
Loss
Standard
0-40
OK to steam.
41-50
Requires a pressure test before steaming.
51-70
Cannot be steamed. Well is classified as POW and can

be purged and monitored or plugged while steaming
around it.
71+
Cannot be steamed. Well shall be plugged or repaired

before steaming operations in the area. Cannot be
POW until patched or repaired.
d. Secondary Wellbore Casing Remediation

In instances where secondary wellbore remediation is required, jurisdictional
regulations apply.
REG
In Alberta regulatory approval must be obtained for non-routine

repairs according to Bulletin 2009-07: Revisions to the Digital
Data Submission System Regarding Interim Directive 2003-01.
REG
In Saskatchewan, the appropriate regional office must be

contacted to obtain approval for non-routine repairs.
REG
Discussions must be initiated with the Regulator if wellbore

integrity is jeopardized before proceeding with the repair.
e. Casing Breaks/Parted Casing/Collapsed Casing

If a complete casing break of the casing is suspected, avoid pulling tubing out; a
shift may result and dramatically escalate the complexity of abandonment.
After well servicing, sufficient tubing should be left in the well to facilitate future
access to the depth of the payzone entire wellbore.
If a serious casing anomaly is encountered, consider installing a casing patch or liner
tie-back, removable shear liners, or a permanent slim hole.
Consider downhole abandonment (per Directive 020) prior to conducting uphole
casing repairs as access to the lower wellbore can sometimes be lost.
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f.
Sulphide Stress Corrosion Cracking
The potential for sulphide stress corrosion cracking and subsequent casing failure
due to the increase of H2S during production may occur. Refer to 3.2.1.3.3 Thermal
Production Casing Material Selection, b) Corrosion Considerations and c) Corrosion
Mitigations along with 3.5.3.3 Corrosion Mitigations and 3.5.3.4 Sand Management
and Erosion for more information.
g. Remedial Cementing
Remedial cementing in secondary applications is similar to primary applications in
the following circumstances:
gas migration and/or vent flow test results and jurisdiction,
to ensure zonal isolation (per Directive 020),
to establish cement top on initial completion (per Directive 009), and
to ensure ground water protection (per Directive 020).

Note. If discovered in initial completion that groundwater aquifers are not
covered by cement, then remedial cement squeeze may be required.
REG
In Alberta, any remediation must comply with Directive 009:

Casing Cementing Minimum Requirements.
REG
In Saskatchewan, contact the appropriate regional office for

program approval if remedial cementing is required.
Consider the following special circumstances for secondary applications:
Avoid water pockets to prevent flashing and pipe collapse.

(see 3.2.1.3.1 Thermal Production Casing Loads (c) Collapse)
Use LCM if necessary.
Determine and control free water content.
3.3.5 WELL SERVICING EQUIPMENT SPACING

Well servicing equipment spacing requirements are summarized in Appendix A and
Appendix B. A detailed spacing matrix is available in Appendix C. It is recommended
to reproduce Appendices A, B, and C and post them in a visible area inside the
doghouse.
Appendix A: Well Servicing Equipment Minimum Spacing: Class IIA Service Rig
Appendix B: Associated Well Servicing Equipment Minimum Spacing: Class IIA
Appendix C: Well Servicing Spacing Matrix
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A larger version designed for 11x17 printing are available on the IRP 3 landing page
at:
http://enform.ca/publications/irps/heavyoilandoilsandsoperations.aspx
Note. Locate production POP tanks no closer than 7 m from well. Tanks must be
empty at all times and disconnected or locked out during well servicing operations.
3.3.6 WELL ABANDONMENT

REG
Routine abandonment must be conducted as per Directive 020 in

Alberta. Non-routine abandonments, as defined by Directive
020, require approval before work is started.
REG
All abandonments in Saskatchewan require approval.
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APPENDIX A: WELL SERVICING EQUIPMENT MINIMUM SPACING:

CLASS IIA
28 | Page
5/6/2012 11:06 AM
HEAVY OIL AND OIL SANDS OPERATIONS
APPENDIX B: ASSOCIATED WELL SERVICING EQUIPMENT

MINIMUM SPACING: CLASS IIA
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APPENDIX C: WELL SERVICING SPACING MATRIX
30 | Page
5/6/2012 11:06 AM

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IRP 3.

3 COMPLETIONS & WELL SERVICING

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Appendix A and B drawings have been modified for clarification in accordance

IRP 3: IN SITU HEAVY OIL OPERATIONS

3.3 COMPLETIONS & WELL SERVICING

Completions Design ...........................................................7

3.3.1.1 Definitions ........................................................................ 5

Offset production .............................................................. 7

Secondary Well Servicing ................................................. 13

IRP 3: IN SITU HEAVY OIL OPERATIONS

3.3 COMPLETIONS & WELL SERVICING

Well Servicing Equipment Spacing ................................... 26

Appendix A: Well Servicing Equipment Minimum Spacing: Class

IRP 3: IN SITU HEAVY OIL OPERATIONS

3.3 COMPLETIONS & WELL SERVICING

COMPLETIONS & WELL SERVICING

Service rig operations for primary and secondary wells

Continuous rod rigs

Following are a collection of key definitions relevant to completions and well

IRP 3: IN SITU HEAVY OIL OPERATIONS

3.3 COMPLETIONS & WELL SERVICING

Primary Recovery Well (Class IIA)

IRP 3: IN SITU HEAVY OIL OPERATIONS

3.3 COMPLETIONS & WELL SERVICING

3.3.2 COMPLETIONS DESIGN

Completions design should consider the intended production scheme in

An engineering assessment should be completed when modifications to

3.3.3 PRIMARY WELL SERVICING

It is important to review offset production data and history to identify potential

area zonal communication,

cumulative production of offset wells,

H2S content, and

use of EOR techniques or stimulation methods.

IRP 3: IN SITU HEAVY OIL OPERATIONS

3.3 COMPLETIONS & WELL SERVICING

data on cumulative and current offset well production

data on BHP, temperature, H2S content, casing failures, surface casing

data on EOR techniques (e.g., steam, fireflood, O2 injections, CO2

Primary Completions Planning

The following planning considerations are pertinent to primary completions.

Prior to completion, ensure surface casing isolation from production casing

Install valves on all standing cased wells.

Establish baseline gas migration data prior to completion (see 3.5.5

Well completion design must accommodate a surface casing

In Saskatchewan, surface casing bowls can only be removed

IRP 3: IN SITU HEAVY OIL OPERATIONS

3.3 COMPLETIONS & WELL SERVICING

availability of mill certifications, and

corresponding heat numbers.

It is equally important to ensure equipment is properly rated for pressure,

In Saskatchewan, surface casing bowls can only be removed in

Wellhead designs should accommodate existing and anticipated future

It is important to prepare completions plans that include considerations for

Ensure the wellhead design accommodates future abandonment.

Evaluate lower cased zones for abandonment prior to completion.

Consider cased hole abandoning lower zones on initial completion, if sump

Primary Well Completions and Workovers