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CD-4000-P15-006 CASINO 5 COMPLETION PROGRAMME REV0

1. LMRP CONNECTOR A lt lon cD P o 2 y D 1 lt HE o m E D l3 Ee 3 BH 5 5 o lt lt YES 2 bs vi E N E 2 B Sul 64 o u c EE E ME un ou C m p e LN No DATUM 0 0 OFHXT Y CONNECTOR Ft m DEPTH OF RAMS RIG INFORMATION UPPER ANNULAR UPPER PIPE RAM END USER SANTOS mo omo LOWER ANNULAR MIDDLE PIPE RAM NSTALLATOM OOOO SHEAR RAM LOWER PIPE RAM w T4 o DO NOT SCALE IF IN DOUBT ASK 3 Drawn by Date Drawn Responsible Engineer SEA LIMITED This documen S Fong 09 06 2004 M A Burns and all the information if THE Tile SANTOS CASINO m tai fidential LLL SEA LIMITED and is not to be EXPRO reproduced communicated to a third party or used in any OCEAN PATRIOT CAMERON THRT SPACEOUT TC MODE Drawing No 117538 P Ey manner whatsoever withou the prior written consent o GROUP EXPRO NORTH SEA LIMITED 3 l CASINO 5 COMPLETION PROGRAMME Santos APPENDIX J RIG FLOOR COMPLETION VALVE STATUS SCHEMATIC PRIVATE AND CONFIDENTIAL Page 68 of 83 Rev 0 Santos
2. S Casino 5 Lower Completion Assembly S 5 5 SUB ASSEMBLY RECORD EXPANDABLE BOTTOM CONNECTOR EBC ASSEMBLY SUB ASSEMBLY NO LC 01 01 ACTUAL ACTUAL TORQUE ft SIZE WEIGHT THREAD 7 LENGTH m MODULE DIAGRAM Ib DESCRIPTION In p p f GRADE I D in O D in DRIFT in SUPPLIER UP DOWN 1 5 5 Mk II 5 625 Stub 5 5 Expandable 5 5 n a 316L SS ESS ACME 4 830 6 063 4 705 Weatherford Bottom Connector Part 571 5501 000 012 Serial 8531 01 2 981m Y Made up with memac 2 x grub A screws made up with loctite 13 Lj 5 625 Stub 0 4 Bull Nose 5 5 n a 80 ACME n a n a 6 065 n a Weatherford Part 573 5500 021 020 Serial PO233536 1 1 3 381m TOTAL ASSEMBLY LENGTH m RECOMMENDED TORQUE DATA MINIMUM OPTIMUM MAXIMUM SIZE WT TREAD TYPE ft Ib ft Ib ft Ib SPECIFIC SUB ASSEMBLY FUNCTION PRESSURES 7 HYDROSTATIC PRESSURE TEST N A TEST FLUID N A TEST dba SERIAL NO SET INDICATION FULL BODY TEST N A DATE TEST NO FRICTION FACTOR 1 0 COMMENTS THREAD COMPOUND Bestolife 72733 COMMENTS TITLE NAME SIGNATURE DATE Weatherford PROJECT ENGINEER Eamonn Arandiga Halliburton SERVICES SUPERVISOR James Bochel Santos COMPLETION SUPERVISOR John Cooper Santos SENIOR COMPLETION ENGINEER Mike Andronov Advanced Wel
3. 2 UA YU CASINO 5 COMPLETION PROGRAMME Santos APPENDIX K FLOWHEAD AND SLICKLINE PRESSURE CONTROL SCHEMATIC PRIVATE AND CONFIDENTIAL Page 69 of 83 Rev 0 THE EXPRO SCOPE AND DIMENSIONS EXPRO SANTOS CASINO GROUP Stackup drawing 08 3 05 Top of Swab Valve Gate Maximum Toolstring Swallow Swab Valve to Stuffing Box 44 Ft Door Elevators Wford Expro 7 3 8 10K Flowhead Q Kill side outlet 3 1502 Thread DESCRIPTION LENGTH 2 Top Drive Sub N A w I 3 o 5 Tonne Air Hoist 3f N A Drive Sub 3ft clearance Lubricator Clamp Sling 5 5 Ft N A Y Tonne en 5 34 Otis Stuffing Box N A 5 34 Lubricator Section 8 Ft 3 l 5 34 Lubricator Section 8 Ft 3 Crossover 8 7 8 Bowen P C x 5 1 Ft 3 34 Otis Box 8 7 8 Bowen Lubricator Section 8 Ft 5 5 8 7 8 Bowen Dual Ram BOP 4 Ft 5 ti gt H gt a 3 5 E 11 12 Otis P C x 8 7 8 Bowen 4 Ft S top Box In Situ Test Sub Yellow 7 btm a Tool Break out Collar Lm 11 1 2 Otis Pump In Tee c w 2 4 Ft 7 1502 Thread gt CA a E 13 Bowen P C x 11 Otis Box 2 Ft T e n 3 A 10 Stub Acme Thread x 13 1 Ft 7 375 Bowen Box 10 3 4 x 350Ton Side of Flowhead Saver Sub to 7 375 c w Check Valve Flow side outlet 3 1502 Win
4. 216 1000 LT METHANOL TANK 1 7 SURFACE TREE 2 METHANOL INJECTION PUMP WATER UNE PSE2 194PSI O 10degC HEAT EXCHANGER VESSEL 1000 1 METHANOL TANK VL VENT LINE 1380 PSI PRESSURE SENSOR LINE TO MSRV VL HEAT EXCHANGER VESSEL STEAM LINE 2 OIL LINE SURGE TANK GASLINE 7 LUBRICATOR VALVE FLUID LINE PSV2 1440 PSI SEPARATOR Wisa w w ee COFLEXIP PSI MSRV ACTIVATED BY PSE1 6 AR LINE UPSTREAM OF CHOKE MANIFOLD B HOSES HARD PIPING 150 PSI HARD PIPING MSRV_ACTIVATION PRESSURE 7 SUBSEA TREE FLUID ID PSH2 DOWNSTREAM HEAT EXCHANGER 120 PSI HEATER VESSEL FSV FLOW SAFETY VALVE 40 PSI SURGE TANK MARK DESCRIPTION FRI SURGE TANK INLET FLOW RESTRICTOR 3 FL A B SAFETY SYSTEM SETTINGS This document and GAS MANIFOLD gt lt OIL gt lt MANIFOLD RIG WATER MANIFOLD 4 GL A SUPERGREEN 3 OL A GAS EINE BURNER OIL LINE TX1222 007 AIR LINE WATER LINE PROPANE IGNITION DIESEL IGNITION 3 WL B YI HORIZONTAL e Y SEPARATOR TX1 31 mus 1 gt Q 0 gt lt DKI IR FSV1 STEAM BOILER DIESEL FIRED DOWN RELIEF AS PER LAYOUT DRAWING 1440 psi FLAME OUT SENSOR PSH 1000 KPa RAN REMOTE MANUAL LOW LEVEL SENSOR NEsp2 Q ESD2 GENERATOR CR1004 003 TO OVERBOARD STEAM T HEAT EXCHANGER LJ STEAM TR
5. Upper Completion above the BOP s Close the BOP shear rams Running 7 tubing with no SSSV control line Pick up crossover 7 KSBEAR x 4 IF and well control valve Make up 5 Drill Pipe Close BOP variable pipe rams or annular around the 7 tubing Monitor pressures and prepare for kill Running 7 tubing with SSSV control line Either Or Pick up crossover 7 KSBEAR x 4 IF and well control valve Make up 5 Drill Pipe Pull the SSSV above the BOP s if necessary Close BOP variable pipe rams or annular around the 7 tubing Monitor pressures and prepare for kill Close the BOP shear rams 4 Section 10 0 Tubing Hanger at Rotary Table e Ensure well control valve made up to THHTT during SSSV make up e The THHTT is rated to 500 000lbs only with Opsi The Tubing hanger must be landed off in the split landing bowls rotary table with the THHTT installed during a well control situation Situation Actions if Well Flows Tubing Hanger at Rotary Table Blank end of SSSV control line If time permits Install the Tubing Hanger split bowls on the tubing hanger and land off in the Rotary Table Make up 5 drill pipe to top of THHTT Check space out of the completion at the BOP and close the annular around the 7 tubing and SSSV control line If annular does not seal close the BOP shear rams PRIVATE AND CONFIDENTIAL Page
6. 14 3 12 14 3 13 14 3 14 14 3 15 14 3 16 POOH with slickline Close MV Open KWV Bleed off pressure via the welltest choke manifold When pressure is Opsi drain lubricator using DV s Close SV Close DV s e Bleed hose downstream of DV s is only rated to 500psi e Monitor volumes to ensure MV not leaking Breakout lubricator inspect and make up the standing valve retrieval toolstring as per toolstring d in Appendix L Pressure test the Cromar sub to 5 000psi Open MV Confirm control line opening pressure on SIV line is maintained at 6500psi at least 2 000 psi above the maximum tubing head pressure Line up to pressure test the tubing via cement unit Open annulus to atmosphere and monitor returns Pressure up to 1 200psi above locked in THP approx 2 100 psi at surface and test tubing integrity for 10 mins e Confirm with Halliburton Technician that the differential used for tubing test will not set the packer e packer setting process commences at 1860psi 8 is completed at 2500 psi differential pressure at the packer setting depth e Drain hose downstream of DV s is only rated to 500psi DV s must be closed and welltest surge tank isolation valve must be tagged open If the tubing integrity test is good increase the pressure to 4 000psi surface pressure as per the Halliburton Technician instructions and set packer and hold for 10 minutes Chart record this test e SSSV control line pressure must be maintained at
7. 16 3 7 Rig down slickline pressure control equipment and the welltest surface lines from the flowhead PRIVATE AND CONFIDENTIAL Page 53 of 83 Rev 0 CASINO 5 COMPLETION PROGRAMME Santos 16 3 8 Perform JSA break out and lay down flowhead 16 3 9 Break out the Flowhead below saver pup Break out but do not remove saver pup from the flowhead landing joint Lay out flowhead assembly e Use extreme caution when breaking out the flowhead 16 3 10 Layout the 45ft bails slickline winch and top drive sub e The 22ft bails can be replaced with the 15ft bails at this point or later offline 16 3 11 POOH THRT SSTT to surface laying down 9 5 8 joints landing string Install THRT protective cap and rack back THRT SSTT in derrick e Ensure all 9 5 8 landing string is doped on POOH and thread protectors are installed e THRT SSTT will be needed for ITC running e Report any missing rope or tape from the landing string 16 4 Running ITC a Verify the 7 0 wireline plug has been installed and pressure tested in ITC before running b The BOP space out with relation to the THRT SSTT and ITC is detailed in Appendix 12 16 4 1 Apply 600psi above Open with the ROV flush from IWOCS Do not vent the line after flushing 16 4 2 RIH Cameron Internal Jetting Tool on drill pipe Forward circulate with seawater to jet ITC profile above Tubing Hanger as per the Cameron OMM Flush through the TCT at the same time
8. 1 75 60 Expro QRJ lt 4 Spring Jar 1 875 1 75 60 Open Expro QRJ dl lt 5 Spang Jars 1 875 1 75 84 Open Expro QRJ lt 6 X Over 1 875 1 75 4 Expro QRJ 1 1 16 Box lt 7 7 3 4 GS 6 94 3 125 20 25 Cameron 1 1 16 pin 8 Short Bore Protector 7 26 6 25 19 2 Cameron TOTAL LENGTH 26 63feet ho d Breakout Point is Black 13 Bowen Collar above Flowhead Appen Casino 5 Slickline Runs lrev2primary2 Page 5 of 6 E THE EXPRO Santo GROUP Proposed Toolstrings an S Santos Casino Toolstring f Run 6 Set 6 70 TH Plug With Shear Up Release Facility ITEM OUTSIDE FISHING CONNECTION DESCRIPTION DIAMETER NECK LENGTH SUPPLY TYPE 1 Rope Socket 125 1 875 1 75 12 Expro QRJ 2 Stem 1 875 1 75 60 Expro QRJ 3 Stem 1 875 1 75 36 Expro QRJ 4 Spring Jar 1 875 1 75 60 Open Expro QRJ 5 Spang Jar 1 875 1 75 84 Open Expro QRJ 6 Crossover 1 875 1 75 4 Expro QRJ 1 1 16 Box 7 3 UPT Shear Up 2 8 1 75 21 Expro 1 1 16 pin 8 2 1 2 Dummy Rope 2 1 2 2 313 12 Expro 1 9 16 pin x Socket c w Crossover 1 1 16 box 9 6 7 Lower TH Plug c w 6 7 2 313 on 21 Cameron 1 1 16 pin Running Tool Running Tool TOTAL LENGTH 25 83 FT Tool Breakout Point is Yellow
9. 16 1 10 Open XOV and PMV Confirm with ROV 16 2 Install Lower Tubing Hanger Plug 16 2 1 Make 6 7 wireline plug toolstring as per Toolstring f in Appendix L Open the SV and pressure test above MV to 5 000psi for 10 minutes e The 6 7 wireline plug is not able to drift the slickline 5 BOP s e Do not add dummy spacer 16 2 2 RIH the 6 7 wireline plug to the TH Pressure up to 3000psi and set the plug as per the Cameron OMM Release the running tool from the 6 7 wireline plug Bleed off pressure to Opsi Leave the welltest choke manifold open 16 2 3 POOH with slickline Close MV Close SV Open DV s Break out lubricator at Cromar sub remove and inspect toolstring Close DV s e Confirm to Completions Supervisor that the Tell Tail is functioned 16 2 4 Open MV Pressure test plug to 5 000 psi for 10 mins from above Bleed off to Opsi PRIVATE AND CONFIDENTIAL Page 52 of 83 Rev 0 CASINO 5 COMPLETION PROGRAMME Santos 16 2 5 Pressure tubing below 6 7 wireline plug from choke kill lines via AAV XOV and PMV to 1000psi for 10 minutes using the cement unit Record on chart recorder e Completions Supervisor to verify test pressure upon confirmation of SSSV set depth e Combined test and pumping pressure to be maintained safely below shut in wellhead pressure to avoid opening SSSV e Monitor tubing pressure from the welltest choke manifold 16 2 6 Close the PMV and XOV Confirm with the ROV 16 2 7 Open AMV Bleed of
10. 285 Coupling 29 13Cr 80ksi KS Bear Box KS Bear Box 6 184 7 698 6 059 MI 13 305 3 144m PUP Joint 29 13Cr 80ksi KS Bear Pin KS Bear Pin 6 184 7 039 6 059 Santos Y 9 968m TOTAL ASSEMBLY LENGTH m RECOMMENDED TORQUE DATA MINIMUM OPTIMUM MAXIMUM SIZE WT THREAD TYPE ft Ib ft Ib ft Ib SPECIFIC SUB ASSEMBLY FUNCTION PRESSURES 29ppf KS Bear 12 770 13 215 13 660 HYDROSTATIC i SIZE INCH PRESSURE TEST 5000 PSI TEST FLUID Inhibited Water TEST FIXTURE SERIAL NO FULL BODY TEST amp BELOW FLAPPER 5000 PSI DATE 1 amp 2 FRICTION FACTOR 1 0 aa di N A SETTING PLUG THREAD COMPOUND Bestolife 72733 CONTROL LINE PRESSURE TEST 15 MINS 7500 PSI COMMENTS FUNCTION PRESSURE psi avg 5 Cycles FLUID RETURN AVERAGE 5k psi 73 5m START TO OPEN 1 100 psi FULLY OPEN 1 550 psi START TO CLOSE 1 400 psi FULLY CLOSED 1 100 psi TITLE NAME SIGNATURE DATE Halliburton Workshop SUPERVISOR Peter Berge Halliburton SERVICES SUPERVISOR James Bochel Santos COMPLETION SUPERVISOR John Cooper Santos SENIOR COMPLETION ENGINEER Mike Andronov Advanced Well Technologies 5 05 2005 S Casino 5 Completion antos e e Santos TUBING HANGER SUB ASSEMBLY NO UC06 02 ACTUAL ACTUAL Sub Assembly DIAGRAM TORQUE DESCRIPTION s ze m
11. 4 3 Increase choke gradually under instruction from the Santos Completion Supervisor 15 4 4 Divert flow to the burner when conditions permit consult with Expro Well Test Supervisor Continue burning as long as there is no fall out of diesel Redirect flow to the surge tank if necessary e Change to the gas flare once the produced fluid is mainly gas This must be carried out in consultation with the Santos Completion Supervisor and the Expro Well Test Supervisor 15 4 5 Continue to increase the choke size gradually under the direction of the Santos Completions Supervisor allowing the well to stabilise after each increment e Bring well up to a maximum rate within 2 3 hours to prevent filter cake hardening on the sand screens e Petrotech Technician is responsible for all samples All samples to be recorded the sampling log to be generated by Petrotech e Commence methanol injection upstream of the choke manifold prior to gas reaching surface Continue injecting until directed by Santos Completion Supervisor e Monitor for indications of sand production and H2S e Maintain annulus pressure between 100 1000psi Record annulus bleed off details e Monitor BS amp W readings to establish when the well has cleaned up e Sample as per Appendix O e lf the Completions Supervisor deems liquids production manageable the well can be diverted to the separator prior to the clean up specification being reached to allow for sampling to c
12. 79 of 83 Rev 0 CASINO 5 COMPLETION PROGRAMME Santos 5 Sections 11 0 amp 12 0 THRT made up to Tubing Hanger Running 9 5 8 Landing String e Ensure two 9 5 8 NEW VAM x 4 72 IF xovers are on the rig floor made up to well control valves ready to be used Situation Running 9 5 8 Landing String SSSV control line across BOPs Actions if Well Flows Pick up crossover 9 5 8 NEW VAM x 4 72 IF and well control valve Make up 5 drill pipe Space out mid 7 completion joint across the BOP s Close the BOP annular around the 7 tubing amp SSSV control line If annular does not seal close the BOP shear rams PRIVATE AND CONFIDENTIAL Page 80 of 83 Rev 0 CASINO 5 COMPLETION PROGRAMME Santos APPENDIX S MANAGEMENT OF CHANGE FORM PART A To be completed by Originator Date Well Name Originator Change Required Risks if Change Not Approved Change in Risks and Risks Costs if known PART B To be completed by Drilling Engineer RequestNo Recommend to Proceed Yos Proceed to PART C No Completed Reasons For Not Proceeding RECOMMENDED APPROVED CONCUR PART C To be completed by SDE if SDG change recommended Variation to DMS Yos Summarise No C Summary of Costs and Benefits Review Manager Yes a No THIS FORM IS SUPPORTED BY THE FOLLOWING ATTACHMENTS PRIVATE AND CONFIDENTIAL Pag
13. Bit Sub 1 x joint drillpipe Approx 1730m 1788m PRIVATE AND CONFIDENTIAL Page 58 of 83 Rev 0 CASINO 5 COMPLETION PROGRAMME Santos APPENDIX C SANDFACE COMPLETION EQUIPMENT SCHEMATIC PRIVATE AND CONFIDENTIAL Page 59 of 83 Rev 0 ESS Sandface Completion Schematic Well Casino 5 EXP ESS Hanger Packer w 5 5 Mk II ESS Plus ESS Expansion String O 1 75 Setting Ball EXP Hanger Packer Setting Tools Lift Nipple HPG Setting Tool _ j Spacer Sub TNG RCU Drain Unit ALN Ball Seat EXY Tie Back Receptacle 9 5 8 x 7 5 8 EXP ESS Hanger Packer c w 7 5 8 29 7 Fox Pin Down 7 5 8 29 7 Pup Joint Fox SC OD 8 Connections Length 1 5m 7 5 8 29 7 Blank Pipe 1 Jt Fox SC OD 8 Connections Length 38ft 7 5 8 29 7 Pup Joint Fox SC OD 8 Connections Length 1 5m Cross Over 7 5 8 29 7 Fox Box x 7 5 8 p 29 7 Vam FJL Pin 5 5 Expandable Top Connector ETC 150 micron weave w 7 5 8 29 7 Vam FJL Box x 5 5 ESS Pin A II 5 5 Expandable Sand Screen ESS Joint 316L 150 micron 38ft p 5 5 Mk II ESS Box x Pin 3 jts II aii 5 5 Expandable Bottom Connector EBC
14. Collar Appen Casino 5 Slickline Runs lrev2primary2 Page 6 of 6 Santos CASINO 5 COMPLETION PROGRAMME PRESSURE VS VOLUME GRAPH FOR DIESEL DISPLACMENT APPENDIX M K __ I i i i S CLE bee F T o fa k a ted oc Postea jc i era qasi E A AA Io ines REME Luctus pa tl E ENA i Ages qeepee paros E e Pak pos pe pe I I I 1 I c 1 1 m NI SENE MN UR J TN O r l 1 p 2 1 paahi O MULA IEEE AMI a PN L alas NS RE A M SA miai um s o i i Dl ap e p A A git E C EE O tae re bes i Y e T T T T T T T T T T n e 1 1 1 1 Wu es M 1 1 1 1 _ PO O O 1 1 L nodo L o __ I
15. Contact Paul Donald Tel 08 9217 7100 Fax 08 9217 7101 Mob 0412 263 180 Tel 08 6363 8900 Fax 08 6363 8999 Mob 0431 507 423 Tel 08 9455 0155 Fax 08 9455 1117 bae 960 665 Tel 08 6424 4600 Fax 08 6424 4699 Mob 0418 836 408 Tel 08 9325 4822 Fax 08 9325 1897 Mob Wu 971 769 Tel 08 9212 4600 Fax 08 9226 4638 Mob 0418 514 759 Tel 08 9455 5233 Fax 08 9455 5244 Mob 0400 109 176 Tel 03 9254 1546 Fax 03 9254 1659 Mob 0408 488 382 Tel 08 9430 5434 Mobile 0411 430 669 Tel 03 9361 4443 Perth 08 9483 4444 Fax 03 9361 4400 Mob 0411 704 920 Tel 08 9420 4845 Fax 08 9420 4715 Mob 0411 022 967 Tel 08 9456 7619 Mob 0411 865 779 Tel 08 9456 7619 Mob 0403 242 966 Tel 08 6241 1351 Mob 0427 779 190 Tel 08 9262 7100 Fax 08 9249 8200 Mob 0438 385 755 Production Packer Drilling Fluids Wireline Logging Drilling Contractor SSSV Casing Running Service Lowe Completion Equipment 4 625 QN nipple amp associated equipment Workboats Workboats Wellhead Horizontal Tree Tubing hanger and landing string Cementing services Slickline Testing amp Landing String Casing and riser Scrapers jetting tools PRIVATE AND CONFIDENTIAL Page 82 of 83 Rev 0 CASINO 5 COMPLETION PROGRAMME Santos APPENDIX U ID amp OD INTERFACE TABLE DRIFT ID DOGC XT with Bore Protector Cameron XT w out Bore Protector Cameron
16. Flow ger M 48 16 0 WELL SUSPENSION 52 16 1 Inflow Test SSSV and Recover the Wireline Short Protection Sleeve 52 16 2 Install Lower Tubing Hanger Plug u J nnne 52 16 3 Recover Landing String eiae id 53 164 Running ITO siii iia 54 16 5 Recover Rig BOP s Run Spool Tree Debris 55 170 APRENDICES coccion iio ici 57 APPENDIX A CASINO 5 PROPOSED COMPLETION 57 APPENDIX B CASING AND RISER SCRAPER 58 APPENDIX SANDFACE COMPLETION EQUIPMENT SCHEMATIC 59 APPENDIX D1 COMPLETION FLUIDS innatum nita hin u u u uuu T 60 APPENDIX D2 PIT LAYOUT CHANGE FROM DRILLING MUD TO CALCIUM CHLORIDE 61 APPENDIX COMPLETION TUBING INFORMATION amp MAKE UP DATA 62 APPENDIX COMPLETION ASSEMBLY IDENTIFICATION 63 APPENDIX COMPLETION SUB ASSEMBLY DRAWINGS 64 APPENDIXH TREE TUBING HANGER ORIE
17. Ft m STICK UP m T 28 430 THRT DEPTH OF RAMS RIG INFORMATION UPPER ANNULAR UPPER PIPE RAM END USER SANTOS 1 LOWER ANNULAR MIDDLE PIPE RAM NSTALLATOM OOOO SHEAR RAM LOWER PIPE RAM w T4 o cht EXPRO NoRTH DO NOT SCALE IF IN DOUBT ASK Drawn by Date Drawn Responsible Engineer SEA LIMITED This documen S Fong 09 06 2004 M A Burns and all the information it THE WIE SANTOS CASINO ls contains is confidential and the property of EXPRO NORTH SEA LIMITED and is not to be reproduced communicated to a EXPRO third party or used in any OCEAN PATRIOT CAMERON THRT SPACEOUT TH MODE Drawing No 117538 Ee Pi manner whatsoever withou the prior written consent o GROUP EXPRO NORTH SEA LIMITED 3 l CASINO 5 COMPLETION PROGRAMME Santos APPENDIX 12 PATRIOT BOP SCHEMATIC THRT SSTT ITC SPACE OUT PRIVATE AND CONFIDENTIAL Page 67 of 83 Rev 0 REV DRAWING AND DIMENSIONAL APPROVAL EE FOR AND ON PRINT NAME SIGNED DATE BEHALF OF L SANTOS ALL DIMENSIONS IN INCHES IF IN DOUBT ASK
18. Guide sub assembly UC01 and set in rotary table with slips and a dog collar 9 2 4 Make up to 1 joint of 7 29 13Cr80 KSBear range 3 tubing 9 2 5 Pick up and make up the 4 625 QN nipple sub assembly UC02 9 2 6 Make up to 1 joint of 7 29 13Cr80 KSBear range tubing 9 2 7 Pick up and make up the Halliburton Production Packer sub assembly e Maximum running speed for packer 1 minute per joint not including pulling and setting the slips e Confirm hydrostatic setting feature on the production packer has been disabled 9 2 8 Pick up and make up the Chemical Cut sub assembly UC04 9 2 9 RIH with 7 29 13Cr80 KSBear range 3 tubing to the SSSV as per the tally e Be aware of the potential to surge reservoir when running packer 9 2 10 Remove the diverter bag from the RT PRIVATE AND CONFIDENTIAL Page 29 of 83 0 CASINO 5 COMPLETION PROGRAMME Santos 9 3 Make Up Tubing Retrievable Sub Surface Safety Valve SSSV e Only NAS 6 cleaned HW525 control fluid to be used for SSSV control lines pump and all fittings flushed with filtered Flush with only the BOT supplied chemical injection pump gauge manifold and hoses This equipment is to be dedicated for use with the SSSV e An inventory of SSSV clamps on the rig must be made and verified by the Completions Supervisor prior to operations commencing e Locate SSSV spooler on rig floor Spool out sufficient control line and connect dedicated test pump and chart record
19. PRIVATE AND CONFIDENTIAL Page 62 of 83 Rev 0 CASINO 5 COMPLETION PROGRAMME Santos APPENDIX F COMPLETION ASSEMBLY IDENTIFICATION Lower Completion Assembly Naming Convention ITEM DESCRIPTION LC Lower Completion LC01 Order to run in hole Assembly 01 is first in the hole LC01 01 Individual identifier Planned Upper Completion Specific Numbering Running Number Identification Description Completion number 1 Expandable Bottom sa Connector EBC E Expandable Top EPIA Connector ETC LC 03 EXP Packer Hanger 01 02 Upper Completion Assembly Numbering Convention ITEM DESCRIPTION UC Upper Completion UC01 Order to run in hole Assembly 01 is first in the hole UC01 01 Individual identifier Planned Upper Completion Specific Numbering Running Number Identification Description Completion number 1 UC 01 Wireline Entry Guide 02 03 2 UC 02 4 625 QN Nipple 02 03 3 UC 03 Production Packer 02 03 4 UC 04 Chemical Cut Sub 02 03 5 UC 05 SSSV 02 03 6 UC 06 Tubing Hanger 02 03 PRIVATE AND CONFIDENTIAL Page 63 of 83 Rev 0 CASINO 5 COMPLETION PROGRAMME Santos APPENDIX G COMPLETION SUB ASSEMBLY DRAWINGS PRIVATE AND CONFIDENTIAL Page 64 of 83 Rev 0 Casino 5 Lower Completion Assembly SUB ASSEMBLY RECORD Santos EXPANDABLE TOP CONNECTOR ETC ASSE
20. SG of diesel on the rig e Confirm bunker connection on deck has been isolated Port and STBD and that connection is monitored during the displacement f Confirm that diesel volumes will be monitored carefully to ensure an over displacement of diesel does not occur Diesel must not be displaced to the chemical cut sub under any circumstance e Confirm an inline flow meter is available e Confirm volumes can be monitored at the pits 14 2 Displace Tubing to Diesel Barrier Status Completion Set With 9 5 8 Lower Landing String Location Primary Barrier Secondary Barrier Tubi Kill weight calcium chloride Flowhead amp surface welltest abing brine lines Ann lis Kill weight ren chloride 10 32 rams 14 2 1 Conduct JSA Diesel Displacement e Ensure potential for well control issues are discussed e Ensure communication between cement unit and drill floor is discussed and understood 14 2 2 Confirm the SSSV is open with 6 500 psi control line 14 2 3 Flush across flowhead to the welltest choke manifold with seawater from the cement unit to fill the surface lines Close in at the welltest choke manifold when returns are seen and stop pumping 14 2 4 Ensure the SV and well test choke manifold are closed 14 2 5 Using ROV close CSM needle valve on XT 14 2 6 Review valve status prior to pumping Diesel Confirm with ROV where appropriate e XOV AAV AMV open PMV PWV AWV closed PRIVATE AND CONFIDE
21. WEIGHT Grape THREAD LD in O D in DRIFT in SUPPLIER LENGTH m p p f UP DOWN Cameron 4 5 17 New Grade E 4 1 2 IF Box N A 3 750 17 500 3 625 Cameron Tubing Hanger handling Test Tool Pt 2142721 06 Modified to be Pump Thru Tubing Hanger 7 7 29 13Cr 80ksi N A KS Bear Box 6 254 17 765 6 059 Part 2201912 06 interfaces with hyd THRT Unlocked Serial TBA on rig 14 138 PUP Joint 7 29 13Cr 80ksi KS Bear Pin KS Bear Pin 6 184 7 040 6 059 Cameron y TOTAL ASSEMBLY LENGTH RECOMMENDED TORQUE DATA MINIMUM OPTIMUM MAXIMUM SIZE WT THREAD TYPE ft Ib ft Ib ft Ib SPECIFIC SUB ASSEMBLY FUNCTION PRESSURES 29ppf KS Bear 12 770 13 215 13 660 SIZE INCH HYDROSTATIC S PRESSURE TEST 5000 PSI TEST FLUID Inhibited Water TEST FIXTURE SERIAL NO FULL BODY TEST 5000psi DATE 11 03 2005 FRICTION FACTOR 1 0 SETTING PLUG TEST 15 MINS 5000 PSI THREAD COMPOUND Bestolife 72733 TEST BELOW PLUG 5000psi DATE COMMENTS COMMENTS 7 KS Bear Tubing Hanger connection make up by Oil Tools Pte Ltd Singapore Witnessed by JFE Singapore TITLE Name SIGNATURE DATE OilTools Workshop SUPERVISOR 2 JFE SERVICES SUPERVISOR Roger Tan Santos COMPLETION SUPERVISOR John Cooper Santos SENIOR COMPLETION ENGINEER Mike Andropov O Advanced Well Technologies 5 05 2005 CASINO 5 COMPLETION PROGRAMME Santos APPENDIX H TREE TUBING HANGER ORIENTATION SCHEMATIC PRIVATE AND
22. Where connected ladders are used to join the secondary escape route at different elevation e Confirm all rupture discs and PSV s settings are as per the approved PFD PRIVATE AND CONFIDENTIAL Page 48 of 83 Rev 0 CASINO 5 COMPLETION PROGRAMME Santos f g h k m n o p q r s t u v w x Confirm the visible beacon is installed in well test area as per Well Test Fire and Escape Plan Ensure portable gas detector is available and used for hydrocarbon leak detection Ensure heat shields are installed on key rig equipment Consult with the rig management to confirm placement of the heat shields Notify all authorities as per the Completions Manual Include local emergency services as flare may be visible from shore Production of well hydrocarbons may only commence at night for the first time with prior approval from the Rig Management Santos Operations Superintendent and the Santos Drilling and Completions Manager Subsequent flow periods may be recommenced at night at the discretion of the Drilling Supervisor and the OIM Prior to opening the well the Drilling Supervisor Completion Supervisor and OIM will inspect all surface lines and well testing equipment and confirm that all equipment is installed as per the approved PFD This should be done well in advance to allow any corrections to be made Function all ESD stations OIM Drilling Supervisor and the Completions Supervis
23. be the focal point for all operations Radio communication will be established prior to any spooling operations commencing e The SSTT and LV will have been drifted to 7 300 on the rig prior to running e The THRT SSTT will have had LS IWOCS umbilical previously fitted and tested e Ensure umbilical lines are functioned through the appropriate panels prior to making up the THRT SSTT e Drift all 9 5 8 47 180 New tubing and pups to 8 525 Conduct JSA picking up THRT SSTT from deck to drillfloor Refer to Expro Landing String Operational Manual Rig up elevators suitable for 9 5 8 New Vam landing string Cameron Expro to verify THRT test cap SSTT are correctly latched prior to picking up Disconnect the HPU to reel jumper s Pick up THRT SSTT with the LS IWOCS connected and lift to rig floor spooling the umbilical accordingly Attach 9 5 8 elevators to handling sub and slowly pick up until the THRT SSTT is at 45 degrees At this point the lower assembly should be held back by a tugger to stabilise the assembly thus preventing it from swinging through the V door Continue to pick up until THRT SSTT is vertical spooling the umbilical accordingly e Spool out enough umbilical to allow the THRT SSTT to be connected to the TH Check that the umbilical routing is free from snag points and that there are no excessive bending or tensile loads Set the TH in the locked position by setting down 25 000lbs on the lock ac
24. given in Section 1 1 lt does not include detailed instruction on the following Subsea Tree Installation BOP Stack Running and Retrieval These are provided in a separate document Casino Development Installation amp Retrieval Procedures for Subsea XT BOP Installation CD 2200 P07 001 and must be read in conjunction with the Completion Programme where indicated 1 4 Barrier Status At the start of each section a barrier status table is provided A Barrier Status table in the body of the programme indicates there has been a change to either the primary or secondary barrier The barriers for all following activities will remain unchanged until the next Barrier Status table is observed within the body of the programme 1 5 Santos Completions and Subsea Supervision At any given time during the completions phase there maybe a Santos Drilling Supervisor Santos Completions Supervisor and Santos Subsea Supervisor on board The Santos Completions PRIVATE AND CONFIDENTIAL Page 7 of 83 Rev 0 CASINO 5 COMPLETION PROGRAMME Santos Supervisors and Subsea Supervisors will be responsible for ensuring the lower and upper completion procedures are followed by all relevant parties Both the Completions and Subsea Supervisors will report to the Senior Drilling Supervisor who has ultimate responsibility over the operation Any queries should be addressed to the Completions Team Leader Any changes to the work scope in this programme will
25. lt o Q 2 Hi Vis Surfactant Pill Pe PRIVATE AND CONFIDENTIAL Page 60 of 83 Rev 0 CASINO 5 COMPLETION PROGRAMME Santos APPENDIX D2 Pit 5 Volume 520 bbls Calcium Chloride Brine 440 bbls pumpable PIT LAYOUT CHANGE FROM DRILLING MUD TO CALCIUM CHLORIDE Mud Pit Lay out Pit4 Pit 3 B Volume 520 bbls Volume 248 bbls Calcium Chloride Brine 440 bbls pumpable Dead Volume 40 bbls Volume 248 bbls Dead Volume 80 bbls Dead Volume 40 bbls Total Pit Capacity 2 191 bbls SCE Pit Capacity 191 bbls Pit 2 Volume 350 bbls Dead Volume 52 bbls Pit 1 Volume 235 bbls Back up volume of Calcium Chloride Brine Dead Volume 35 bbls flow PRIVATE AND CONFIDENTIAL Page 61 of 83 Rev 0 CASINO 5 COMPLETION PROGRAMME Santos APPENDIX E COMPLETION TUBING INFORMATION amp MAKE UP DATA Size Weight ID Drift mm Kg m Grade Connection inches inches inches Ib ft 9 5 8 47H L80 NEW VAM 8 681 8 525 7 298 13Cr80 KSBEAR 6 184 6 059 7 5 8 29 74 13Cr80 FOX 6 875 6 750 Make Up Data Min torque Opini Max torque Makeup Eoc Tubing Ibf ft torque Ibf ft mm Ibf ft inches 9 5 8 47 NEW VAM L80 13 050 14 450 15 850 140 84 5 545 7 29 KSBear 12 150 13 500 14 850 127 76 13Cr80 5 030 7 5 8 29 7 FOX 10 900 11 720 12 540 133 10 13Cr80 5 240
26. of the well 6 4 8 Continue to RIH ACE tool on the required number of joints of HWDP confirmed after TD of the well 6 4 9 Continue to RIH the ACE BHA on 5 drill pipe to 1670m approximately 30m above the top of the EXP packer 6 4 10 Conduct JSA Expanding of ESS 6 4 11 Review weather conditions and review need for expansion with compensation with Weatherford Technician e Expansion should be carried out with no compensation if possible With compensation it can be very difficult to keep a constant weight on the BHA 6 4 12 RIH slowly as instructed by the Weatherford Technician and tag the ETC with minimal weight Mark the pipe at RT and record the tide position 6 4 13 Expand the ESS with the Retrievable Fixed Cone Pre Expansion tool section of the ACE assembly by RIH at 3m min sitting down 30 000 40 000lbs Tag the Expandable Bottom Connection EBC Mark the drill pipe e rotation to be used with tools inside ESS e Anincrease in the required weight may be seen at ESS connections e Podger tool bottoms out 0 3m above the EBC 6 4 14 Pull back the ACE tool 1 2m above the ETC looking for the original mark on the pipe 6 4 15 Commence pumping at the same rate determined during the surface testing PRIVATE AND CONFIDENTIAL Page 23 of 83 Rev 0 CASINO 5 COMPLETION PROGRAMME Santos 6 4 16 Once required flowrate has stabilised at 1 2 m min increasing to a maximum of 3m min or as
27. off to neutral during the setting procedure The Weatherford Packer Specialist will be responsible for directing the packer setting operation 6 3 1 Conduct JSA Packer setting 6 3 2 Break circulation to check line up and ensure there are no blockages in the string Do exceed 500psi 6 3 3 Inspect and calliper the 1 brass ball drop ball into tubing and pump from the cement unit at 2BPM or 500psi whichever is lower e Completions supervisor to witness ball calliper 6 3 4 With ball on seat apply 1 800psi using the cement unit down the drill pipe above the ball Increase the pressure to 3 000psi and hold for 15 minutes to set the EXP packer Bleed off to zero A pressure of 3 600psi will shear release the running tools 6 3 5 Perform a overpull to a maximum of 15 000lbs above neutral weight to check the upper slips have set 6 3 6 Set down a maximum of 15 000lbs below neutral weight to confirm lower slips set Bring back to neutral weight 6 3 7 Close the BOP pipe rams and pressure test the packer elements with 1000psi for 10 minutes from the cement unit Bleed off to zero Record on chart Completions Supervisor to witness e Ensure Drill pipe is open to trip tank to monitor for returns e This test is to confirm that the packer element is set 6 3 8 Open the BOP pipe rams and with running tools in neutral turn to the right 5 turns Stop rotation and monitor for back torque If no back torque experience continue to
28. riser through the choke and kill lines 7 3 5 Drop the 2 1 2 ball to the SABS tool and apply 2800 psi to shear the tool Flow is now diverted to the bit Circulate 1 25 riser volumes of mud approx 125bb to lift debris that may have fallen into the well during the jetting e Completions Supervisor to witness ball calliper and record shear pressure 7 3 6 RIH to position the Riser Brush Tool at its deepest depth i e approx 3m above the flex joint 7 3 7 Conduct JSA Handling calcium chloride brine 7 3 8 Flush all surface lines with seawater 7 3 9 Circulate a 50bbl viscousified surfactant brine pill chased with a minimum of 1 2 cased hole and riser volumes of inhibited kill weight calcium chloride brine 600 bbl or until clean calcium chloride returns are observed at maximum rate to displace the drill in fluid from the cased hole and riser Flush the choke and kill lines with seawater whilst circulating out mud and then fill with inhibited calcium chloride brine Ensure that all surface are clean and displaced to inhibited calcium chloride e Circulate at a maximum achievable rate e Rotate and reciprocate the string during this circulation e The recipe for the high viscous pill and inhibited calcium chloride is included in Appendix D1 PRIVATE AND CONFIDENTIAL Page 26 of 83 Rev 0 CASINO 5 COMPLETION PROGRAMME Santos e Take clean calcium chloride brine returns to a clean pit bypass the sand trap e Ensure shakers an
29. rotate to the right 15 20 turns to release the running tools from the packer as directed by Weatherford Technician 6 3 9 Pull back 5m to remove running tools from the EXP packer 6 3 10 POOH with running tools At surface Weatherford Technician to inspect the running tools for correct operation and confirm to the Completions Supervisor that the packer setting ball has been recovered PRIVATE AND CONFIDENTIAL Page 22 of 83 0 CASINO 5 COMPLETION PROGRAMME Santos 6 4 ESS Expansion e The Weatherford Technician will be responsible for directing the ESS expansion operation Drill pipe DC s and HWDP must be free from scale to prevent the ACE tool from becoming blocked 6 4 1 Conduct JSA make up of the ACE BHA 642 Pick ACE tool assembly c w 4 Y IF xover and set in slips on the 5 drill pipe handling pup 6 4 3 Make up a stand of 5 drill pipe to the ACE tool assembly 6 4 4 Connect top drive to the BHA and pump through the tool to determine a flow rate for a back pressure of 1500psi as determined from Weatherford charts confirm the rollers activate and no leaks are observed e Ensure circulation ports below RT e Maximum pressure at ACE roller is 1900psi 6 4 5 Cease pumping and allow pressure to bleed off Manually retract the compliant rollers using a wooden hammer 6 4 6 Remove the drill pipe stand 6 4 7 RIH ACE tool making up the required number of joints of 6 Y DC s e To be confirmed after TD
30. supplied drift Largest OD tool TH wireline short protection sleeve to be run through the SSTT to the THRT is 7 26 OD Min ID of SSTT is 7 375 which corresponds to the UBV LBV THRT has a restriction of 7 040 The TH wireline short protection sleeve is set above the minimum restriction of the THRT Pressure test all SSTT valves Leave all SSTT valves UBV and LBV in OPEN position Carry out THRT pre running preparations in accordance with Cameron OMM These should include as a minimum Test flush and purge all THRT functions and verify component movement as appropriate Pump through SSSV line until clean fluid is returned Take sample and verify cleanliness NAS 6 using the Cameron test kit Ensure THRT LATCH ASSIST port on top of the SSTT is left unplugged OPEN to atmosphere situated on the slick joint above 10 ram facing downwards PRIVATE AND CONFIDENTIAL Page 33 of 83 Rev 0 CASINO 5 COMPLETION PROGRAMME Santos 11 2 Connect THRT SSTT to the TH RIH Completion on Landing String 11 2 1 11 2 2 11 2 3 11 2 4 11 2 5 11 2 6 11 2 7 11 2 8 11 2 9 11 2 10 11 2 11 11 2 12 11 2 13 e Ensure landing string space out has been completed and approved by both Completions and Subsea Supervisors Spaceout landing string assemblies as per section 6 3 Confirm the spaceout with the Completions Team in the Perth office prior to commencing running of the landing string e The Driller will
31. surface test package and the well test choke manifold to prevent a hydraulic lock when landing off Cameron Engineer to be present for the following operation Lower TH and land off a maximum of 30 000lbs on the soft landing sleeve in the XT e Record string weights before and after land off e Do not exceed 30 000lbs on the soft landing sleeve e Monitor the string rotation to verify the TH has landed properly Rotation should be clockwise the angle relating approximately to the alignment made at the rig floor e Observe for premature loss of weight in the event the Lower Completion Packer is tagged due to incorrect space out Pressure the SIV line to approx 500psi Using ROV open SIV needle valve and flush through line for 10 minutes to prove communication and clear debris from the landing shoulder Cycle the SIV twice during the flushing Leave SIV open Adjust THRT SSTT pressures to landing values as per the Cameron OMM Open the TH Soft Land from the LS IWOCS and vent for 5 minutes or until no returns from TH soft land seen to allow soft land sleeve to retract Increase total set down weight to 100 000lbs maximum for a further 5 minutes or until no returns from TH soft land seen 13 2 10 Set down full downhole completion weight PRIVATE AND CONFIDENTIAL Page 40 of 83 Rev 0 CASINO 5 COMPLETION PROGRAMME Santos 13 2 11 Close the AMV and AAV confirm with ROV leaving PMV and XOV open 13 2 12 Confirm with Cameron and E
32. the BOP spaceout has been checked by functioning the rams during the drilling program k Confirm RT to MSL measurement l Take a representative sample of the drill in fluid and determine the salinity pH and chlorides This will be used to aid in determining the well has fully cleaned up during well testing See Appendix O for details of samples required PRIVATE AND CONFIDENTIAL Page 12 of 83 Rev 0 CASINO 5 COMPLETION PROGRAMME Santos m Take a sample of the diesel on the rig and measure the SG n Review tidal information for the forthcoming two weeks o In conjunction with the Mud Engineer produce a pit management fluids handling plan for pit cleaning and displacement of the cased hole to inhibited calcium chloride brine The proposed set up of the pits in included in Appendix D2 PRIVATE AND CONFIDENTIAL Page 13 of 83 Rev 0 CASINO 5 COMPLETION PROGRAMME Santos 4 0 COMPLETION OUTLINE AND TIME ESTIMATE All depths approximate to be confirmed after TD of the well a Time Step Operation Description Hrs 1 Function blind amp 10 rams Make up Expandable Sand Screens ESS 3 7 5 8 tubing 8 Lower Completion Packer Assembly 2 RIH ESS on Drill pipe to 1785m amp set test packer and unlatch running 14 tools POOH running Tools Make up ESS Expansion tool to SABS circulation tool Make up DC s 3 and HWDP RIH the Expansion Too
33. to sign off the Pre Flow Checklist in the Casino Completions Manual which at a minimum must confirm the following a Rig up of surface equipment in accordance with the approved PFD and layout drawing Appendix P1 amp P2 Pressure test all well test equipment as specified in the Completions Manual b Review the location of the well test specific fire fighting equipment in the Well Test Fire and Escape Plan in Casino Completions Manual The OIM Drilling Supervisor and Completions Supervisor to sign off on final fire fighting equipment locations c As far as practicable locate hydrocarbon containing vessels and equipment within designated deluge well test area Any hydrocarbon containing vessels outside of the deluge area must be considered when reviewing the location of firefighting equipment d In conjunction with the Well Test and Fire Escape Plan check the escape routes in and around the well test area are adequate and confirm the following i Two escape routes present primary and secondary ii Where practicable width of escape routes 0 9 m wide primary and 0 8 m secondary iii Escape routes are clearly marked and adequately illuminated iv As much as practicable escape routes are free from obstructions Wherever possible use steps over pipework v There are no dead ends greater than 7 m in length vi Where connected stairways are used to join the primary escape route at different elevation vii
34. trend for volumes returned Contingency tubing leak procedures are detailed in Completions Manual Data acquisition frequency is set up and functioning as per Appendix N Take representative samples of the drill in fluid and completion brine and measure salinity chlorides pH Ensure separator and surge tank have been purged with nitrogen Inspect separator for sand prior to and after flowing PRIVATE AND CONFIDENTIAL Page 49 of 83 Rev 0 CASINO 5 COMPLETION PROGRAMME Santos 15 4 Flow Well to Clean Up e Refer to Table in Section 2 0 for Well and Reservoir data Barrier Status Location Primary Barrier Secondary Barrier Tubing Flowhead ol welltest SSTT Kill weight calcium chloride brine Annulus Upper Completion Packer 15 4 1 Conduct JSA Well Test Operations 15 4 2 Open the well gradually on the adjustable choke flowing to the surge tank e Initial under balance is expected to be 675 psi e The Santos Reservoir Engineer shall advise Completions Supervisor of choke sizes and durations e Retain at least 20 bbls of diesel in the Surge tank for later use to light gas flare Consult with Expro Well Test Supervisor e Monitor the temperature of surface equipment with laser thermometer throughout the flow Record temperature measurements e Steam exchanger will be bypassed until the water diesel interface is reached to minimise cooling of the steam exchanger before gas to surface 15
35. up TH wireline short protection sleeve recovery toolstring as per Toolstring e in Appendix L Pressure test Cromar sub to 5000psi e Clamp slickline for welltest with tools above SV Ensure the surge tank valve downstream of the drain hose DV s is tagged OPEN to prevent over pressurisation of the drain line Close KWV Confirm the CSM is closed using the ROV Barrier Status Completion displaced to diesel standing valve retrieved Location Primary Barrier Secondary Barrier Tubing Flowhead y rand welltest SSTT Annulus Upper Completion Packer Ue oi chionde 14 3 29 Confirm valve status on Cameron subsea tree PRIVATE AND CONFIDENTIAL Page 46 of 83 0 CASINO 5 COMPLETION PROGRAMME Santos PWV AWV PMV and XOV closed AAV and AMV open TCT and CSM needle valves closed SIV needle valve open with SSSV control line pressured to 5 000 psi PRIVATE AND CONFIDENTIAL Page 47 of 83 Rev 0 CASINO 5 COMPLETION PROGRAMME Santos 15 0 WELL CLEAN UP AND TEST 15 1 Objectives a Clean up well to a BS amp W that is constant or not measurable b Determine the well productivity c Determine Radon concentration of the Waarre C gas d Prove the effectiveness of the sand face completion design 15 2 Expected Flow Schedule Flow Period Duration Maximum rate Clean Up Approx 6 hours 45 MMSFCD 15 3 Pre Flow Checks The Santos Completions Supervisor is
36. 10 3 4 Casing Santos 10 3 4 x 9 5 8 Santos 9 5 8 Casing Santos 5 3 4 PCE Expro 8 7 8 PCE incl BOP s Expro 11 1 2 PCE Expro Flowhead Expro Landing String Expro LLSA Expro Expro Cameron Internal Tree Cap Cameron Tubing HangerfCameron TH Wireline Prot Sleeve Cameron TH Wireline Isol Sleeve Cameron 7 292 KSB Tubing Santos BOT BOT TRSV Wear Sleeve BOT 7 292 KSB Tubing Santos CCS X over Santos Chem Cut Sub Santos CCS X over Santos HHT Packerfalliburton 7 29 KSB Tubing Santos 4 626 Landing Nipple Vveatherf WEGJalliburton LC Blackcat Packer Weatherf Packer X over Weatherf LC 6 5 8 24 KSB Tubing Weatherf Screens unexpanded Weatherf Lipstick Muleshoe X over Santos Lipstick Muleshoe Santos inches 18 750 13 275 13 275 9 604 9 604 8 525 3 000 5 000 7 000 7 375 8 732 7 375 7 375 7 040 6 730 7 000 6 250 4 620 6 059 5 875 5 840 5 875 6 059 4 904 4 767 4 904 5 900 6 184 4 626 6 184 4 875 4 875 5 796 5 500 4 767 0 000 CD Pid U zg 5 b p P i d d 8 338 E y 5 a j 02883021854 iii AE T pa 9 9 9 3 ef 4 3 E gee g gg OK OK OK OK OK ok OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK
37. 13Cr 80ksi KS Bear Box KS Bear Box PUP Joint 13Cr 80ksi KS Bear Pin KS Bear Pin Muleshoe 13Cr 80ksi KS Bear Box Halliburton TOTAL ASSEMBLY LENGTH m RECOMMENDED TORQUE DATA MINIMUM OPTIMUM MAXIMUM ft Ib ft Ib ft Ib SPECIFIC SUB ASSEMBLY FUNCTION PRESSURES 7 29ppf KS Bear 12 770 13 215 13 660 COMMENTS NO PRESSURE TEST REQUIRED FRICTION FACTOR 1 0 SIZE INCH WT THREAD TYPE THREAD COMPOUND Bestolife 72733 Halliburton Workshop SUPERVISOR Peter Berge Halliburton SERVICES SUPERVISOR James Bochel Santos COMPLETION SUPERVISIOR John Cooper Santos SENIOR COMPLETION ENGINEER Mike Andronov Advanced Well Technologies 5 05 2005 Casino 5 Completion SUB ASSEMBLY RECORD WEATHERFORD 4 625 QN NIPPLE SUB ASSEMBLY NO UC02 02 ACTUAL ACTUAL sub Assembly DIAGRAM TORQUE DESCRIPTION WEIGHT GRADE THREAD DRIFT in SUPPLIER LENGTH m ft lb p p f 4 u Dow Coupling 29 13Cr 80ksi KS Bear Box KS Bear Box 6 203 7 678 6 059 Santos PUP Joint 13Cr 80ksi KS Bear Box KS Bear Pin A f Santos 4 625 QN Nipple 13Cr 80ksi KS Bear Box KS Bear Pin d ji Weatherford Part 0204625000001 Serial 6141939 Coupling 13Cr 80ksi KS Bear Box KS Bear Box l E Santos PUP Joint 13Cr 80ksi KS Bear Pin KS Bear Pin Santos 7 353m TOTAL ASSEMBLY LENGTH m RECOMMENDED TORQUE DATA MINIMUM OPTIMUM MAX
38. 150 micron 316L 10ft c w 5 5 Mk II ESS Box x 5 5 8 8TPI Stub ACME pin down Bull Nose w 5 5 8 8 TPI Stub ACME box up 2005 Weatherford Completion Systems All Rights Reserved Y Weatherford ESS Expansion String 5 HWDP x20 w 4 72 IF Connections w 5 DP to Surface 6 72 Drill Collars x20 IF Connections Cross Over 4 12 IF Box x 3 1 IF Pin SLA 5 5 Axial Compliant Expansion Tool ACE gt Tool Ww Retrievable Fixed Cone Pre Expansion Tool Podger Tool w 6 625 Cone Ring This drawing is a representaion only and NOT to scale CASINO 5 COMPLETION PROGRAMME Santos APPENDIX D1 COMPLETION FLUIDS Completion Brine i 10 3 ppg 1 000 bbls AA 01 2259 afe Cor Calcium Tolerant Corrosion Inhibitor 55 gal 1 drum 100bbls afe Cide Calcium Tolerant Biocide can 300 bbls Solvent Surfactant flocculates solids from brine 55 gal dm Conc Quantity per well bb i Vis Surfactant Pill Seperation of DIF from Brine clean casing 50 bbl afe Vis E Polymer base viscosifier Calcium Tolerant gal per bbl afe Surf WN Surfactant cleans wall cake from casing pipe etc A Calcium Chloride 74 77 Purit Weighted Brine for Well Control Conc Quantity ppb required per well Bbi
39. 3 0 CASINO 5 COMPLETION PROGRAMME Santos e Ensure the completion string is open to the well test package when landing off the completion to prevent a hydraulic lock e SVis closed to catch wireline tools in the event they become loose and fall PRIVATE AND CONFIDENTIAL Page 39 of 83 Rev 0 CASINO 5 COMPLETION PROGRAMME Santos 13 0 LAND OFF AND TEST TUBING HANGER AND XT 13 1 Preparation a Prior to landing out tubing hanger Subsea Supervisor is to instruct the Driller and other relevant personnel on the emergency shutdown and emergency disconnect procedures as per the Expro Landing String Operational Manual This is to be repeated for all new relevant personnel as job progresses b The cement unit must have sufficient personnel on board for 24 hour continuous operations c Flowhead control panel valve positions will be tagged during all slickline operations 13 2 Land off Tubing Hanger Barrier Status Location Primary Barrier Secondary Barrier Tubing Kill weight T chloride BOP Annus Kill weight ead chloride BOP 13 2 1 13 2 2 13 2 3 13 2 4 13 2 5 13 2 6 13 2 7 13 2 8 13 2 9 Using XT IWOCS open the PMV XOV AAV and AMV Confirm with ROV Pressure the CSM line to approx 500psi Using ROV open CSM needle valve and flush through the line to prove communication Keep line vented after flushing Engage rig compensators Confirm that Flowhead valves are open to the
40. 3 9 RIH as per tally with 7 13Cr KSBear range 3 tubing installing control line clamps at each tubing connection e Baker Technician to torque up clamps SSSV hold open pressure to be regularly monitored during RIH 9 3 10 Check the tally by performing a count of the remaining 7 13Cr tubing joints pups left on deck and the number of control line clamps remaining e This check must be carried out by the Completions Supervisor PRIVATE AND CONFIDENTIAL Page 30 of 83 Rev 0 CASINO 5 COMPLETION PROGRAMME Santos 10 0 INSTALL TUBING HANGER Barrier Status Location Primary Barrier Secondary Barrier Tubing Kill weight m chloride BOP Ans Kill weight calcium chloride BOP brine 10 1 Preparation a Identify the Tubing Hanger TH system equipment on rig Refer to Cameron Scope of Supply b Record serial numbers of the parts to be installed i Tubing Hanger including isolation sleeve ii 6 7 wireline plug iii 7 0 wireline plug ITC c Prepare Tubing Hanger and install THHTT as per Cameron OMM d Carry out a full inspection of the TH 6 7 and 7 0 wireline plugs and internal tree cap including seal areas e Ensure Isolation Sleeve is pre installed in TH and the THHTT Tubing Hanger Handling and Test Tool is pre installed on top of the TH f Deck pressure test the TH THHTT isolation sleeve and tubing pup to 5 000 psi for 10 minutes g Remove the x 4 TH spacers and install the spli
41. 6 500psi at least 2 000 psi above tubing pressure to keep SSSV open 6 500psi must not be exceeded due to the rating of the XT control system e This tests the tubing and the PMV from the production side Close the SSSV by bleeding off the control line to Opsi e BOT Engineer to confirm that the SSSV has closed Inflow test the SSSV for 10 minutes by bleeding pressure in tubing using the welltest choke manifold to 1 500psi Record this test on a chart Pressure above SSSV using seawater to 3750psi Open SSSV by pressuring up the SSSV control line to 6 500psi e The tubing pressure will increase when the SSSV opens e Engineer to confirm that the SSSV has opened Bleed back tubing pressure from the welltest choke manifold to 100psi above the expected underbalance pressure to leave a slight overbalance on the standing valve e Expected underbalance pressure approximately 675psi e The standing valve will allow flow from below Close KWV Reduce the SSSV control line pressure to 5 000psi e 5 000 psi SSSV control line pressure will be sufficient to keep the SSSV open for the remainder of the programme Close the XOV ROV to confirm Open the PMV ROV to confirm PRIVATE AND CONFIDENTIAL Page 45 of 83 Rev 0 CASINO 5 COMPLETION PROGRAMME Santos 14 3 17 14 3 18 14 3 19 14 3 20 14 3 21 14 3 22 14 3 23 14 3 24 14 3 25 14 3 26 14 3 27 14 3 28 Pressure test annulus between Halliburton
42. AND CONFIDENTIAL Page 35 of 83 Rev 0 CASINO 5 COMPLETION PROGRAMME Santos 11 2 29 Continue RIH as per tally until the TH is approximately 8 metres above the tubing hanger land out point e Monitor the umbilical line pressure integrity at the LS IWOCS reel while RIH e Ensure the Annular BOP s are fully open e Check that the riser angle is within DOGC criteria before entering flex joint Make adjustments as necessary PRIVATE AND CONFIDENTIAL Page 36 of 83 Rev 0 CASINO 5 COMPLETION PROGRAMME Santos 12 0 RUN FLOWHEAD 12 1 Preparation a b c d e f g h A Range 3 9 5 8 New Vam joint 9 5 8 New Vam saver sub swivel and xover 9 5 8 New Vam x stub acme will have been pre installed on the Flowhead on the deck Hand make up saver sub to bottom of joint Final make up of the saver pup to the full joint shall be done in mouse hole prior to flowhead installation Mark connection on saver pup HAND TIGHT ONLY Paint vertical line from swivel body through lower flowhead crossover and onto the 9 5 8 landing joint The ROV should be launched during Flowhead rig up operations so as to be ready for landing off the completion The XT IWOCS umbilical flying stabplate with parking plate is to be rigged up through the cutter offline Install Coflexip hose to standpipe prior to Flowhead installation Function and pressure test Flowhead on deck in accordance with Expro Landing String Ope
43. AP 2 SL B WELLTEST EQUIPMENT RIGGED H1 4 UP AS PER PFD YAA L E CHECKED ARA 3 MAY 05 ISSUED FOR CONSTRUCTION MS DATE 2 13 MAY 05 NEW EQUIPMENT CHANGE AND REVIEW Ms 105 MAY 05 POST EQUIPMENT INSPECTION REVISIONS ust SIGNED SUP mo DATE Bv AUTH THE DRAWN Seddon PROCESS FLOW DIAGRAM PFD SANTOS CASINO OCEAN PATRIOT CUSTOMER SANTOS ma No REV EV PFD J05 351 JOB No J05 351 EXPRO Group Australia West Perth Western Australia Telephone 08 9213 5555 GROUP the information it contains is confidential and the property of THE EXPRO GROUP and is not to be reproduced communicated to a third party or usedwhatsoever without the prior written consent of THE EXPRO GROUP CASINO 5 COMPLETION PROGRAMME Santos APPENDIX P2 WELLTEST LAYOUT PRIVATE AND CONFIDENTIAL Page 75 of 83 Rev 0 ga Je aL THE EXPRO GROUP prior written 2 s SA We N SAN NO VR The EXPRO Group West Perth WA Australia elephone 61 8 9213 5555 AY J05 351 CASINO 5 COMPLETION PROGRAMME Santos APPENDIX Q COMPLETION HANG OFF PROCEDURES amp EMERGENCY RELEASE Cases 1 2 3 and 4 To be used if sufficient time is available e g deteriorating weather Case 5
44. Appen L_Casino 5 Slickline Runslrev2primary2 Page 3 of 6 EXPRO Santo GROUP Proposed Toolstrings an S Santos Casino Toolstring d Run 4 Retrieve 4 625 RNQN standing valve ITEM OUTSIDE FISHING CONNECTION 8 DESCRIPTION DIAMETER NECK LENGTH SUPPLY TYPE 1 Rope Socket 125 1 875 1 75 12 Expro QRJ 2 Stem 1 875 1 75 60 Expro QRJ lt Stem 1 875 1 75 36 Expro QRJ l 4 Spring Jar 1 875 1 75 60 Open Expro QRJ lt 5 Spang Jars 1 875 1 75 84 Open Expro QRJ lt 6 Crossover 1 75 1 75 4 Expro QRJ 1 1 16 Box lt 7 3 SB 2 7 2 313 16 Expro 1 1 16 Pin TOTAL LENGTH 22 67ft TOTAL WITH 25 72ft STANDING VALVE Tool Breakout Point is Yellow Collar Appen Casino 5 Slickline Runs lrev2primary2 Page 4 of 6 GROUP Proposed Toolstrings Santos Casino Toolstring e Run 5 Pull TH Short Protection Sleeve Santos OUTSIDE FISHING CONNECTION ITEM DESCRIPTION DIAMETER NECK LENGTH SUPPLY TYPE lt 1 Rope Socket 125 1 875 1 75 12 Expro QRJ 2 Accelerator 1 875 1 75 60 Expro QRJ lt 3 Stem 1 875
45. CONFIDENTIAL Page 65 of 83 Rev 0 Rig and Subsea Orientation TUBING HANGER ORIENTATION x DRILL 250deg RIG ORIENTATION HORIZONTAL TREE ORIENTATION c Ls TM PRODUCTION FLANGE CASINO 5 COMPLETION PROGRAMME Santos APPENDIX 11 PATRIOT BOP SCHEMATIC THRT SSTT TH SPACE OUT PRIVATE AND CONFIDENTIAL Page 66 of 83 Rev 0 j 3 IREV DATE TE No CN No DRAWING AND DIMENSIONAL APPROVAL FOR AND ON PRINT NAME SIGNED DATE B 04 10 04 2061 BEHALF OF C 22 11 04 2204 MT L wem PA _ DIAMOND OFFSHORE TT A CMERON C ALL DIMENSIONS IN INCHES IF IN DOUBT ASK B B LMRP CONNECTOR C C q x D 1 lt i ES E y E La gt ol lt Q E 7 Tm Mp rod NE BON 5 gt 8 3 _ OF HXT B P CONNECTOR F
46. Confirm with Cameron and Expro personnel that the THRT latch functions are pressured to 5 000psi ready for pressure below the lower annular to prevent unlatch of the SSTT Close the annular around the annular slick joint Pressure up from the cement unit in small increments to 3 000psi as per the Cameron OMM Pressure above the ITC wireline plug to 3 000psi for 10 minutes to set the ITC plug e Monitor TCT for any returns e 5 000psi may be required below the annular should the ITC fail to seat with 3 000psi Lock the as per the Cameron OMM Open the annular and perform 60 000lb overpull to confirm lock down Close the AMV and AAV confirm with ROV Pressure test cavity between the ITC 7 0 wireline plug and the 6 7 wireline plug to 5 000 psi for 10 minutes via the TCT and record on a chart recorder Bleed pressure to zero Using ROV close the TCT Set THRT in neutral and unlatch the THRT from ITC and POOH 16 5 Recover Rig BOP s Run Spool Tree Debris Cap 16 5 1 16 5 2 16 5 3 16 5 4 16 5 5 e Disconnect XT IWOCS stab plate and electrical stabs from the XT and park on the BOP parking plate e Prior to running install biocide sticks in the spool tree debris cap through the 1 72 NPT pipe plug on the side e Grease the J slot in the spool tree debris cap running tool with water resistant grease e corrosion inhibitor will be pumped into the spool tree debris Conduct a JSA Pulling riser a
47. FACE TABLE uu uu ek dcc 83 PRIVATE AND CONFIDENTIAL Page 6 of 83 Rev 0 CASINO 5 COMPLETION PROGRAMME Santos 1 0 INTRODUCTION 1 1 Scope The Casino Completion Programme details the procedures and references required for the installation of the Casino 5 lower and upper completions A summary of the scope of work covered by this document is as follows Install lower completion comprising packer tubing amp sand screens in 8 72 horizontal hole Install upper completion and tubing hanger using landing string Clean up and flow well Suspend Following completion of the work scope Casino 5 will be suspended in readiness for tie in and well commissioning 1 2 Safety Framework The systems which Santos will use during the Casino Drilling and Completions campaign are described in the Casino Drilling and Completions EHSMS document number CD 4000 P03 003 The Hazard Identification Workshop Report details hazards identified specific to the upper completion programme The Completions HAZID Recommendations Close Out Report provide details of the actions undertaken to reduce associated risk Both documents should be reviewed by all Santos Offshore Supervisors prior to commencement of completions All documents must be readily available to all personnel on the rig in both hard and soft format 1 3 Document Structure This document provides the overall procedures and references to complete the work scope
48. IMUM SIZE INCH WT THREAD TYPE ft Ib ft Ib ft Ib SPECIFIC SUB ASSEMBLY FUNCTION PRESSURES 29ppf KS Bear FE FE TEST 5000 ws TEST FLUID Inhibited Water TEST FIXTURE SERIAL NO 55555 COMMENTS Test was conducted utilising Weatherford QX Uni Set Lock Assembly c w test cap Halliburton Workshop SUPERVISOR Peter Berge Halliburton SERVICES SUPERVISOR James Bochel Santos COMPLETION SUPERVISOR John Cooper Santos SENIOR COMPLETION ENGINEER Mike Andronov Advanced Well Technologies 5 05 2005 Casino 5 Completion SUB ASSEMBLY RECORD HALLIBURTON HHT PACKER ASSEMBLY SUB ASSEMBLY NO UC03 02 ACTUAL ACTUAL sub Assembly DIAGRAM TORQUE DESCRIPTION WEIGHT THREAD LD in in DRIFT in SUPPLIER LENGTH m Es UP DOWN Coupling 13Cr 80ksi KS Bear Box KS Bear Box 6 193 7 685 6 059 Santos Made up at mill PUP Joint 13Cr 80ksi KS Bear Pin KS Bear Pin 6 059 Santos HHT Packer Model 9 x 7 HHT 13Cr 80ksi KS Bear Box KS Bear Pin Halliburton Note No nipple profile Part 212HNT9511 FBBU Serial 1204106 3 Coupling 13Cr 80ksi KS Bear Box KS Bear Box 6 059 Santos PUP Joint 13Cr 80ksi KS Bear Pin KS Bear Pin 8 833 TOTAL ASSEMBLY LENGTH m RECOMMENDED TORQUE DATA MINIMUM OPTIMUM MAXIMUM ft lb ft lb ft lb SIZE INCH W
49. L NO COMMENTS THREAD COMPOUND Bestolife 72733 COMMENTS Halliburton Workshop SUPERVISOR Peter Berge Halliburton SERVICES SUPERVISOR James Bochel Santos COMPLETION SUPERVISOR John Cooper Santos SENIOR COMPLETION ENGINEER Mike Andronov Advanced Well Technologies 5 05 2005 Coupling 1 13Cr 80ksi KS Bear Pin KS Bear Pin 4 767 Casino 5 Completion Santos Santos TUBING RETRIEVABLE SURFACE CONTROL SUB SURFACE VALVE SUB ASSEMBLY NO UC05 02 ACTUAL Sub Assembly DIAGRAM ACTUAL TORQUE ft DESCRIPTION WEIGHT GRADE THREAD LD in DRIFT in SUPPLIER LENGTH m Ib p p f es UP DOWN A Coupling 29 13Cr 80ksi KS Bear Box KS Bear Box 6 184 7 706 6 059 Santos 13 205 1 5m PUP Joint 29 13Cr 80ksi KS Bear Pin KS Bear Pin 6 184 7 047 6 059 Santos I 13 225 Flow Coupling 29 13Cr 80ksi KS Bear Box KS Bear Pin 6 184 7 701 6 059 Halliburton 2 219m 13 265 Y y Baker Jam Nut TSME 5 connection Note Self Equalising SC TRSV c c 5 875 29 13Cr 80ksi KS Bear Box KS Bear Box 5 875 9 192 5 845 Baker OT 2 405m BRQ Nipple Profile Part H 057534300020 Serial 246235 13
50. L TUBING HANGER ran th anu tina ne n UU dp en rain 31 10 1 Preparation 31 10 2 Install Tubing Hanger oi 31 MAKE UP AND RUN THRT SSTT AND LANDING STRING 33 PRIVATE AND CONFIDENTIAL Page 4 of 83 Rev 0 CASINO 5 COMPLETION PROGRAMME Santos 11 1 Preparation of TT cuisine 33 11 2 Connect THRT SSTT to the TH RIH Completion on Landing String 34 120 RUNFLOWHEAD cocinan id 37 12 1 PEO meeo 37 12 2 Up Flowhead and Slickline Pressure Control Equipmen t 37 13 0 LAND OFF AND TEST TUBING HANGER AND XTI 40 13 1 PA ced 40 13 2 Land off Tubing Hanger J J J J J J 40 13 3 Test Tubing Hanger and XT 41 14 0 DISPLACE TO DIESEL AND SET PRODUCTION 43 141 JPreparatlpbhiuy u u L ak ata tas 43 14 2 Displace Tubing to Diesel U SD riti ao ee liia 43 143 SetProduction Packer UU ic 44 15 0 WELL CLEAN UP AND TEST U U u uuu uuu u 48 15 1 Obj ctiv S uu deis 48 15 2 Expected Flow Schedule U u uu uu u 48 15 3 Pre
51. MBLY LC 02 01 ACTUAL ACTUAL MODULE DIAGRAM TORQUE DESCRIPTION SIZE WEIGHT THREAD LD in in DRIFT in SUPPLIER LENGTH m itb In p p up Dow E 9 78 7 5 8 29 78 E 7 5 8 13 Cr L 80 Fox SC Box Fox SC Box Santos 10 371 7 5 8 29 7 7 5 8 29 78 Eja o 7 5 8 13 Cr L 80 Fox Pin Fox Pin 7 5 8 29 7 7 5 8 29 78 Fox SC Box Vam FLJ Pin 7 5 8 29 74 5 5 5 5 Expandable Top 5 Cr amp 316 FLV Box ESS Pin Weatherford Connector ETC Part 723391 Serial 8530 01 2 870 z TOTAL ASSEMBLY LENGTH m RECOMMENDED TORQUE DATA MINIMUM OPTIMUM MAXIMUM ft Ib ft Ib ft Ib WT THREAD TYPE SPECIFIC SUB ASSEMBLY FUNCTION PRESSURES 29 7 Fox HYDROSTATIC PRESSURE TEST Not Applicable TEST FLUID 29 7 Vam FJL TEST FIXTURE SERIAL NO SET INDICATION FULL BODY TEST FRICTION FACTOR COMMENTS THREAD COMPOUND Bestolife 72733 COMMENTS The Top Connector to Cross Over Connection was over torqued initially 10 391 ft lbs The connection was broken out inspected for damage then made up again with no problems Weatherford PROJECT ENGINEER Eamonn Arandiga Halliburton SERVICES SUPERVISOR Bill Power Santos COMPLETION SUPERVISIOR John Cooper Santos SENIOR COMPLETION ENGINEER Mike Andronov Advanced Well Technologies 3 05 2005
52. MME Santos 16 0 WELL SUSPENSION e All pumping operations to be conducted with 50 50 water glycol mix unless otherwise stated 16 1 Inflow Test SSSV and Recover the Wireline Short Protection Sleeve 16 1 1 Confirm valve status on subsea tree AAV and AMV open PMV PWV XOV amp AWV closed 16 1 2 Conduct JSA Well Suspension 16 1 3 Isolate welltest Lo pilots Record SITHP on the Rig Floor Completion Valve Status Board 16 1 4 Close SSSV by bleeding the control line pressure to Opsi e The SSSV will remain closed for the remainder of the programme 16 1 5 Bleed tubing pressure above the SSSV to 100 psi through the well test choke manifold Inflow test the SSSV for 15 minutes Bleed tubing pressure to 0 psi above the SSSV e Submit chart to Completions Supervisor 16 1 6 Open KWV Pump approx 26bbl of 50 50 water glycol mix from the cement unit to fill the tubing and landing string above the SSSV e Ensure pumping pressure is below that required to pump through SSSV e The water glycol mix will act as the suspension fluid on top of the SSSV 16 1 7 Open the SV With the welltest choke manifold open RIH slickline latch and pull the TH wireline short protection sleeve from the THRT POOH to surface 16 1 8 Close the MV Close the SV Confirm pressure is Opsi through needle valve Break lubricator at the 13 Bowen connector inspect and recover TH wireline short protection sleeve 16 1 9 Close AMV Confirm with ROV
53. NTATION SCHEMATIC 65 APPENDIX PATRIOT BOP SCHEMATIC THRT SSTT TH SPACE OUT 66 APPENDIX 12 PATRIOT BOP SCHEMATIC THRT SSTT ITC SPACE OUT 67 APPENDIX J RIG FLOOR COMPLETION VALVE STATUS SCHEMATIC 68 APPENDIX FLOWHEAD AND SLICKLINE PRESSURE CONTROL SCHEMATIC 69 APPENDIX L PLANNED SLICKLINE TOOL STRINGS 70 APPENDIXM PRESSURE VS VOLUME GRAPH FOR DIESEL DISPLACMENT 71 APPENDIXN DATA ACQUISITION cassie cnc e poni anon uuu u uu 72 APPENDIX SAMPLING REQUIREMENTS U U u u u 73 APPENDIX WELL TESI PPD us iiteiconinsciclio cil lili 74 PRIVATE AND CONFIDENTIAL Page 5 of 83 Rev 0 CASINO 5 COMPLETION PROGRAMME Santos APPENDIX P2 LAYOUT sin cius iE pn iba mixed cec ecd cx ea KR ERE SE rk E 75 APPENDIX COMPLETION HANG OFF PROCEDURES 8 EMERGENCY RELEASE 76 APPENDIX R WELL CONTROL GUIDELINES RUNNING THE COMPLETION 78 APPENDIX S MANAGEMENT OF CHANGE FORHM l 81 APPENDIX T CONTACTIS p nix U UL Eaa asinna nnan Eara ix FRE ca SLE aS UR ER 82 APPENDIX U ID amp OD INTER
54. NTIAL Page 43 of 83 Rev 0 CASINO 5 COMPLETION PROGRAMME Santos SIV needle valve open TCT CSM needle valves closed SSTT LBV UBV LV open SV and welltest choke manifold closed FWV Open Slickline Lubricator Drain Valves Closed SSV MV and KWV open Confirm the SSTT chemical injection valve is locked in 10 closed SSSV Open with 6 500 psi SIV control line pressure Confirm annulus is lined up to the rig choke and the rig choke is fully open 14 2 7 Break circulation to confirm correct valve line up from the cement unit to the Flowhead down the tubing taking returns from the rig choke Pump Diesel down tubing forward circulation to position the interface 75m approx 9bbl above the chemical cut sub approx 200bbl taking returns via the rig choke kill line to the pits Chase with 3 5 bbls drill water to clear surface lines of Diesel e The formation is open and care must be take not to bullhead Ensure returns to the pits throughout the procedure e Break slowly and slowly increase to Y BPM while carefully monitoring the back pressure on the tubing This is to minimise the possibility of prematurely setting the packer e Pump rate may be slowly increased to a maximum of 3 bpm as directed by Halliburton Technician to ensure that packer elements do not swab off e Rig choke must be lined up to annulus and be fully open during pumping Do not hold back pressure on annulus e Contingent chemical cut can o
55. OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK 7280 THW dine ha Sexe 6620 THWidinelsd Sexe 7000 Upper Gom Aug 6700 Lone QroanRug OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK ok OK OKJOK OK OK OK x OKJOK OK OK OK x OK OK OK OK OK x x OK OK OK OK x OK OK OK OK x lok OK OK OK x x x x x x x 7 161 Sirtered Soreers PRIVATE AND CONFIDENTIAL Page 83 of 83 0
56. Pin for the Upper Completion ii 2 x 4 1 2 IF Box x 9 5 8 New Vam Pin running the landing string PRIVATE AND CONFIDENTIAL Page 15 of 83 Rev 0 CASINO 5 COMPLETION PROGRAMME Santos e f A 9 5 8 DLT packer and storm valve must be available and will be used to hang the completion off in the 9 5 8 or 10 casing in an emergency situation Refer to the Completions manual for the detailed procedure Schlumberger cementer to provide supervision for setting The emergency hang off procedure on the 9 5 8 DLT packer for each stage of equipment across the BOP s is detailed in Appendix Q 5 3 Spaceout of the Completion Assemblies All depths to be confirmed by the Santos Completions Supervisor Refer to Appendix A for proposed completion schematic Completion is to be spaced out as follows 5 3 1 Lower Completion a b c d The Expandable Bottom Connector LC01 approx 3m from TD of the 8 77 open hole TBC after LWD interpretation 7 5 8 13Cr blank pipe to approximately 10m outside of the 9 5 8 casing shoe Expandable Sand Screens completely across the Waarre C sand with the Expandable Top Connector LC02 approx 3m above the top of reservoir The ETC can be placed at a shallow depth than this to aid spaceout but criteria 5 3 1 b must be adhered to The Lower Completion EXP packer LC03 set mid way across the lowest 9 5 8 Chrome Casing Joint include the 13Cr KSBear x Top Xover jo
57. Santos CASINO DEVELOPMENT COMPLETION PROGRAMME CASINO 5 CD 4000 P15 006 e gt Tliccuuell 24 02 05 Issued for CWOP Review wass 15 06 05 Issued for Use 2 ya b CASINO 5 COMPLETION PROGRAMME Santos DOCUMENT CONTROL STATUS Casino 5 Completion Programme REVIEW AND APPROVALS Manager Drilling and Completions Offshore Australia Approval Brett Darley Completions Team Peter Dodd Leader Approval Operations Richard Buitenhuis Superintendent Reviewer Staff Reservoir Mike Lahiff Engineer Reviewer UU d PRIVATE AND CONFIDENTIAL Page 2 of 83 Rev 0 CASINO 5 CONPLETION PROGRAMME Santos DISTRIBUTION OF CONTROLLED COPIES NUMBER NAME OF COMPANY POSITION COPIES 1 Drilling Supervisor rig copies 10 Santos Drilling Supervisor Drilli leti 2 Brett Darley 1 Santos ug ane operons Manager 3 Peter Dodd 1 Santos laam Leader 4 Richard Buitenhuis 1 Santos Superintendent 5 Darren Greer 1 Santos h i Leader 6 Mike Lahiff 1 Santos Staff Reservoir Engineer 7 Steve Ramsey 1 DOGC Rig Manager 8 Paul Laroche 1 Baker Oil Tools Project Engineer 9 Willie Ching 1 Halliburton Senior Technical Advisor 10 Eamonn Arandiga 1 Weatherford Applications Engineer i 11 Martin Seddon 1 Expro parating Engineer 12 Pa
58. T THREAD TYPE SPECIFIC SUB ASSEMBLY FUNCTION PRESSURES 29ppf KS Bear HYDROSTATIC T PRESSURE TEST 5000 PSI TEST FLUID Inhibited Water iui wo Pom J COMMENTS Test pins fitted and shear screws removed for testing Test pins removed and shear screws re fitted Hydrostatic set mechanism disarmed Modifications carried out by Halliburton Cheltenham Victoria THREAD COMPOUND Bestolife 72733 COMMENTS Halliburton Workshop SUPERVISOR Peter Berge Halliburton SERVICES SUPERVISOR James Bochel Santos COMPLETION SUPERVISOR John Cooper Santos SENIOR COMPLETION ENGINEER Mike Andronov Advanced Well Technologies 5 05 2005 Casino 5 Completion SUB ASSEMBLY RECORD ACTUAL THREAD Sub Assembly DIAGRAM TORQUE f DESCRIPTION u O D in DRIFT in SUPPLIER 2 i u pw Made up at mill Cross Over 13Cr 80ksi KS Bear Box n a Santos Serial 13Cr 80ksi n a KS Bear Pin S 1994 01 03 Coupling 29 13Cr 80ksi KS Bear Box KS Bear Box 6 184 7 689 6 059 MI 7 396 Made up at mill 7 MI Joint 17 13Cr 80ksi KS Bear Pin KS Bear Pin MI 7 396 Cross Over 13Cr 80ksi KS Bear Box N A Serial 13Cr 80ksi N A KS Bear Pin S 1994 03 03 TOTAL ASSEMBLY LENGTH m RECOMMENDED TORQUE DATA MINIMUM OPTIMUM MAXIMUM SIZE INCH WT THREAD TYPE ft Ib ft Ib ft Ib SPECIFIC SUB ASSEMBLY FUNCTION PRESSURES 29ppf KS Bear HYDROSTATIC T N A TEST FIXTURE SERIA
59. TER NECK LENGTH SUPPLY TYPE lt 1 Rope Socket 125 1 875 1 75 12 Expro QRJ 2 Stem 1 875 1 75 60 Expro QRJ 3 Stem 1 875 1 75 36 Expro QRJ 4 Spring Jar 1 875 1 75 60 Open Expro QRJ H lt 5 Spang Jar 1 875 1 75 84 Open Expro QRJ al 6 X Over 1 875 1 75 4 Expro QRJ 1 1 16 Box lt 7 7 3 4 GS Pulling tool 6 94 3 125 20 25 Cameron 1 1 16 Pin 8 Short bore protector 7 26 6 25 19 2 Cameron TOTAL LENGTH 24 6 FT Break out point is Black 13 Bowen Pin amp Collar Appen L_Casino 5 Slickline Runslrev2primary2 Page 2 of 6 E THE EXPRO Santo GROUP Proposed Toolstrings an S Santos Casino Toolstring c Run 3 Run 4 625 RNQN standing valve OUTSIDE FISHING CONNECTION me DESCRIPTION DIAMETER NECK LENGTH SUPPLY TYPE 1 Rope Socket 0 125 1 875 1 75 12 Expro QRJ 2 Stem 1 875 1 75 60 Expro QRJ H x 3 Stem 1 875 1 75 36 Expro QRJ 5 Spang 1 875 1 75 84 Open Expro QRJ lt M 6 X Over 1 75 1 75 4 Expro QRJ 1 1 16 Box lt 7 3 SB running tool 2 7 2 313 16 Expro 1 1 16 pin I B TE lt _ 8 4 625 RNQN 4 686 2 313 36 66 Word TOTAL LENGTH 20 72 FT TT Toolstring Breakout Point is Yellow Collar
60. THODS for gas CO Draeger tube Mercaptan RSH Draeger tube Radon Inhouse method utilising a scintillator counter WATER ANALYSIS Includes conductivity resistivity pH density chlorides Barium Strontium sulphate alkalinity MUD SAMPLES Drilling Mud and completion brine to be sampled from pits prior to test 2 x 1L per set PRIVATE AND CONFIDENTIAL Page 73 of 83 Rev 0 CASINO 5 COMPLETION PROGRAMME Santos APPENDIX P1 WELL TEST PFD PRIVATE AND CONFIDENTIAL Page 74 of 83 Rev 0 SUPERGREEN 4 GL A BURNER GAS LINE 3 OL A TX122 008 ie AR UNE WATER LINE PROPANE IGNITION n RECEIVER 4 X AIR COMPRESSORS 125 145 ps B A u a ZONE 2 RATED 58 T 2 3 VL A 3 GL A SURGE TANK T1X183 22 es OIL MANIFOLD TX186 013 or O EN 0 0 24 P lt o 3 X X 3 OL A O 1440 psi FSV Ed 3 OL A A TAG OPEN 50 psi ios 3 OL A TAG OPEN a te i 3 OL A gt TAG Q DIL 500 PSI EA FENG 4 TRANSFER PUMP TX5 9 18 27 mE DRILL FLOOR EXPRO MINIMISE POCKETS TEST DECK ESD2 AS PER LAYOUT DRAWING OUTSIDE ACCOMODATION PANEL PORT BURNER BOOM MSRV STARBOARD BURNER BOOM psu rset Y CELLAR DECK ZN a E27 uso lem E ys E 9 x 9 27 PS 6 FL A 3 FL A C 5 lt I 0 V RIG SSV A CHOKE MANIFOLD METHANOL INJECTION PUMP
61. Type Acquisition Frequency Wellhead Pressure and Temperature 1 minute throughout test BS amp W 15 minutes initially 30 minutes stabilised If possible H2S CO2 Content 15 minutes initially 30 minutes stabilised Choke changes Take additional BSW Downstream Condensate Gravity 15 minutes initially 30 minutes stabilised Gas Gravity 15 minutes initially 30 minutes stabilised Tank Level 15 minutes initially 30 minutes stabilised NOTE ALL EVENTS TO BE RECORDED ON DATA READING SHEETS ONLY PRIVATE AND CONFIDENTIAL Page 72 of 83 Rev 0 CASINO 5 COMPLETION PROGRAMME Santos APPENDIX O SAMPLING REQUIREMENTS CASINO 5 SAMPLING TRACE ANALYSIS PROGRAMME CLEAN UP FLOW Analysis Onsite Frequency Sample Volume Comments offsite or number Point 10 min 1 hr Draeger 10 min 1 hr Draeger 1 hr if possible for onsite analysis 2 END OF CLEAN UP FLOW Duration determined by sampling programme 30 min Draeger gas 30 min sep Draeger gas 30 min sep Draeger gas 3 sep commence when in separator water 1 hr if possible sep 1L for onsite analysis water 1 set sep 6 x 1L samples to be preserved LP cond sep 5L tin LP cond sep 1L glass gas cond PVT sep 20L 640cc commence when in separator LP cond Assay stock tank 25L taken at end of test gas Ar He H5 O sep 150 cc taken at end of test for Authorities gas sep 2 x 150cc taken at end of test ONSITE ME
62. advised by the Weatherford Technician setting down 10 000 15 000lbs at the ACE tool to fully expand the ESS e Expand each stand as far as possible Stop pumping pick up and set slips and make a connection Allow circulation parameter to stabilise prior to continuing to expand the ESS e Maximum pressure at ACE roller is 1900psi 6 4 17 Tag the EBC Stop pumping and POOH at 10m min to 5m above the top of the EXP packer taking care passing through connectors and the ETC e Confirm depth with mark on drill pipe and check the tally e Podger tool bottoms out 0 3m above the EBC 6 4 18 POOH with drill pipe HWDP DC s and ACE tool to surface At surface Weatherford Technician to inspect the ACE tool for correct operation and report condition to Completions Supervisor PRIVATE AND CONFIDENTIAL Page 24 of 83 Rev 0 CASINO 5 COMPLETION PROGRAMME Santos 7 0 CASING AND RISER CLEANING Barrier Status Location Well Primary Barrier Kill Weight drill in fluid Secondary Barrier BOP s 7 1 Overview a Drift all drill pipe and assemblies above the SABS circulation tool to 2 6 minimum prior to RIH SPS SABS ball OD is 2 b Technical reference information for the SPS Weatherford cleanup tools is included in the Casino Completions Manual Well control precautions should be as per those used during drilling of the 8 72 hole d All pumping to be conducted with kill weight drill in flu
63. and Screens ETC Expandable Top Connector OMM Field Service Manual FWV Flow Wing Valve HPU Hydraulic Power Unit HUD Hold Up Depth HWDP Heavy Weight Drill Pipe ID Internal Diameter ITC Internal Tree Cap IWOCS Installation and Work Over Control System JSA Job Safety Analysis KWV Kill Wing Valve LBV Lower Ball Valve LC Lower Completion LCP Lower Crown Plug LIB Lead Impression Block LPR Lower Pipe Rams LS Landing String LV Lubricator Valve MAASP Maximum Allowable Annulus Surface Pressure MD Measured Depth MPR Middle Pipe Rams MV Master Valve OD Outside Diameter PBR Polished Bore Receptacle PCE Pressure Control Equipment PFD Process Flow Diagram PMV Production Master Valve POOH Pull Out Of Hole PWV Production Wing Valve RIH Run In Hole RT Rotary Table SIV SSSV Isolation Valve SSV Surface Shutdown Valve SSSV Surface Control Sub Surface Safety Valve SSTT Sub sea Test Tree Expro SV Swab Valve TBC To Be Confirmed TCT Tree Cap Test TH Tubing Hanger THHT Tubing Hanger Handling Tool THRT Tubing Hanger Running Tool UBV Upper Ball Valve UC Upper Completion UCP Upper Crown Plug UPR Upper Pipe Rams WEG Wireline Entry Guide XOV Crossover Valve XT Christmas Tree Subsea PRIVATE AND CONFIDENTIAL Page 10 of 83 Rev 0 CASINO 5 COMPLETION PROGRAMME Santos 2 0 WELL AND RESERVOIR DATA Description Data Well Name Casino 5 Well Type Vertical Gas Development well Permit VIC P44 D
64. as jetting e Max set down 30 000Ib e Max pressure at jetting head 800psi e Move jetting tool slowly up and down during jetting e Boost the riser with seawater 16 4 3 POOH Internal Jetting Tool Inspect contents of junk basket and report on Daily Drilling Report 16 4 4 Pick up the ITC to the rig floor using the THHTT Remove the THHTT 16 4 5 Set the ITC in the locked position by setting down 25 000lbs on the lock actuator sleeve using the THRT e Install the Cameron re enforced cover on the TH prior to locking e The ITC must be in the locked position for installation of the THRT as the weight of the THRT SSTT is insufficient to lock the ITC 16 4 6 Prepare and function the THRT SSTT as per the Cameron OMM and the Expro Landing String Operational Manual 16 4 7 Make up the THRT to the ITC as per the Cameron OMM 16 4 8 with the on 9 5 8 landing string attaching the umbilical at every connection e Fill landing string with seawater on RIH PRIVATE AND CONFIDENTIAL Page 54 of 83 0 CASINO 5 COMPLETION PROGRAMME Santos 16 4 9 16 4 10 16 4 11 16 4 12 16 4 13 16 4 14 16 4 15 16 4 16 16 4 17 Open the AMV confirm with ROV Ensure AAV is open Flush TCT to remove potential debris Keep TCT vented e Confirm annulus pressure is zero prior to opening AMV Tag tree with 5000lbs Slack off all running string weight e Monitor returns from TCT line during the setting process
65. be done in accordance with the Santos Drilling and Completions Change Control Procedure The Subsea Supervisor is responsible for ensuring all subsea components of the programme are completed as specified including tree installation and testing tubing hanger installation landing string operations and debris cap installation The Completions Supervisor is responsible for ensuring all components of the programme are completed as specified When not directly involved in operations the Subsea and Completions Supervisors will be undertaking equipment preparation for upcoming operations and assisting where required All pressure testing and valve functioning operations will be witnessed signed off and documented by either the Subsea or Completions Supervisor dependent on the scope of work being performed Both the Completions and Subsea Supervisors will liaise with the Offshore Logistics Coordinator and Senior Drilling Supervisor for all material and personnel movements 1 6 Preparation Preparation details for specific equipment are provided immediately prior to each section of the programme The Completions and Subsea Supervisors must review the equipment preparation taking into account the lead time required for each section of the programme prior to commencing completions operations It is the responsibility of the Completions and Subsea Supervisor to ensure all equipment preparation and personnel mobilisation is completed off rig crit
66. d return lines trough are clean prior to taking any calcium chloride returns to the pits e Take mud returns to pits or dump as directed by the mud man e Dump the viscousfied brine pill Barrier Status Location Primary Barrier Secondary Barrier Well Kill weight calcium chloride BOP s brine 7 3 10 POOH to the Riser Brush Tool SABS tool and remove from string e Maximum speed POOH with Riser Brush Tool 30 m min to prevent swabbing 7 3 11 Continue POOH with scraper string e Maximum speed POOH 45 m min to prevent swabbing e Inspect Riser Brush Tool and record any damaged or missing wire e casing scraper and note any signs of damage or metal loss Record condition of casing scraper PRIVATE AND CONFIDENTIAL Page 27 of 83 Rev 0 CASINO 5 COMPLETION PROGRAMME Santos 8 0 RETRIEVE XT BORE PROTECTOR Barrier Status Location Primary Barrier Secondary Barrier Well Kill weight calcium chloride BOP s brine 8 1 Preparation a Ensure ROV is on depth with appropriate tooling for subsequent operations b Pick up Cameron Bore Protector Running and Retrieval Tool to rig floor and make up a joint of drillpipe to the top Make up a 10 ft drill pipe pup and the Cameron rubber nose jet sub to the bottom Ensure centraliser fins are not fitted Perform pre operational checks as per Cameron OMM volume 2 c Reference Cameron OMM to determine bore protector location in tree pr
67. e 81 of 83 Rev 0 CASINO 5 COMPLETION PROGRAMME Santos APPENDIX T CONTACTS Baker Atlas Level 2 200 Adelaide Terrace Perth WA 6004 Contact Dave Thorne Diamond Offshore General Company Unit 2 5 Turner Ave Bentley WA 6102 Contact Steve Ramsey Baker Oil Tools Australia 1 5 Bell Street Canning Vale WA 6155 Contact Paul La Roche District Engineer Halliburton Australia 256 St Georges Tce Perth WA 6000 Contact Willie Ching MI Australia Pty Ltd Level 11 251 Adelaide Terrace Perth WA 6000 Contact Dave Bennett Weatherford Casing Running Servces Level 1 225 St Georges Terrace Perth WA 6000 Contact Aaron Sinnott Weatherford Completions 19 Catalano Rd Canning Vale WA 6155 Contact Eamonn Arandiga Farstad Shipping Level 9 16 St Georges Tce Perth WA 6000 Contact Captain Bruce Dann Swire Pacific Offshore 2nd Floor Queensgate Centre Cnr William amp Newman Streets Fremantle WA 6160 Contact Sam Pullen Cooper Cameron 1 Glencairn Ave Deer Park VIC 3023 Dowell Schlumberger Level 5 256 St Georges Terrace Perth WA 6000 Contact Leen Vlot Expro Group Australia Pty Ltd 42 44 Wittenberg Drive PO BOX 1522 Canning Vale WA 6970 Contact Dave Meyjes Expro Group Australia Pty Ltd 42 44 Wittenberg Drive PO BOX 1522 Camning Vale WA 6970 Contact Dave Linkston Operations Engineer Fugro Contact Terry Blake SPS Weatherford 17 Truganina Road Malaga Perth WA 6090
68. er Flush through line with clean filtered HW525 e Volumes of control line fluid measured operating a 7 SSSV on deck may differ from volumes recorded in the vertical e Use the Santos supplied hole cover for control line make up and make up of the cross coupling clamps 9 3 1 Conduct JSA Make up and running of the SSSV sub assembly amp rigging up SSSV sheave 9 3 2 Rig up SSSV sheave 9 3 3 Pick up and make up SSSV sub assembly UCO5 e Ensure SSSV port is blanked 9 3 4 RIH and make up one joint of 7 13Cr KSBEAR range 3 tubing above the SSSV e SSSV is closed beware of surging 9 3 5 Pull back the SSSV above the RT and make up the control line e BOT to terminate control line jam nut fitting to SSSV body as per JAM nut make up procedure 9 3 6 Perform 7 500psi Control Chamber Pressure Test via the control line reel hold for 15 mins Bleed off Completion Supervisor to file the Chart 9 3 7 Bleed down pressure and cycle valve open and closed two times recording opening and closing pressures via the BOT gauge manifold Record volume of fluid returns via Bleed Port on manifold on each closing cycle Compare volumes to those recorded during Sub Assembly make up onshore 9 3 8 Pressure Control Line to 5 000 psi lock in at the hub mounted manifold e Locked pressure is to maintain the SSSV in the open position whilst RIH e SSSV will close if differential pressure between control line and tubing falls below 2 000 psi 9
69. f any annulus pressure via choke kill lines and confirm annulus pressure is zero Close AMV confirm with ROV Barrier Status After Setting Lower Tubing Hanger Crown Plug Location Primary Barrier Secondary Barrier Tubing Lower Crown Plug SSTT Annulus Upper Completion Packer Kil weight 16 2 8 If weather conditions permit the slickline pressure control equipment and surface lines can be rigged down from the flowhead at this point 16 3 Recover Landing String 16 3 1 Conduct JSA Retrieve landing string 16 3 2 Retract the 10 34 BOP pipe rams Remove Expro rotary bushing inserts Barrier Status Location Primary Barrier Secondary Barrier Tubing Lower Crown Plug BOP Annulus Upper Completion Packer Kill weigm m monde 16 3 3 Set down to put the THRT at neutral weight Unlatch the THRT as per the Cameron OMM and pick up to 5 m above TH e U tubing will occur due to the difference in liquid weights between the tubing and riser annulus 16 3 4 Rig up 20 bowls and set 9 5 8 tubing in slips 16 3 5 Flush surface lines including Flowhead and slickline pressure control equipment to the test package with sea water chased with drill water Expro Test Supervisor to advise when flushing is complete e Expro will have have previously flushed the surface lines with separator gas e Do flush separator vessel with water 16 3 6 Perform JSA rig down slickline PCE and flowhead lines
70. g Drain Hose amp Elbow Connections 9 5 8 N Vam Casing Joint 20ft To Expro welltest surge tank Stick up CASINO 5 COMPLETION PROGRAMME Santos APPENDIX L PLANNED SLICKLINE TOOL STRINGS PRIVATE AND CONFIDENTIAL Page 70 of 83 Rev 0 THE EXPRO GROUP Toolstring a Run 1 Pull TH Isolation Sleeve i f Proposed Toolstrings Santos Casino Santos OUTSIDE FISHING SUPPLY CONNECTION ITEM DESCRIPTION DIAMETER NECK LENGTH TYPE 1 Rope Socket 0 125 1 875 1 75 12 Expro QRJ 2 Accelerator 1 875 1 75 60 Expro QRJ 3 Stem 1 875 1 75 60 Expro QRJ 4 Spring Jar 1 875 1 75 60 Open Expro QRJ 5 Spang Jars 1 875 1 75 84 Open Expro QRJ 6 Crossover 1 875 1 75 4 Expro QRJ 1 1 16 Box 7 GS 5 83 3 125 20 36 Cameron 1 1 16 pin 8 Isolation Sleeve 6 69 5 83 29 01 Cameron TOTAL LENGTH 27 45 feet Tool break out point is Yellow Collar Appen Casino 5 Slickline 2 2 Page 1 of 6 THE EXPRO Santo GROUP Proposed Toolstrings an S Santos Casino Toolstring b Run 2 Set TH Short Protection Sleeve ITEM OUTSIDE FISHING CONNECTION DESCRIPTION DIAME
71. ght Brine Shear Rams 3 Tubing Hanger made up to the completion String THRT not installed a b c d Install THHTT onto tubing hanger Remove the Tubing hanger from the completion string Remove and lay down 7 joints of 7 KSBEAR tubing Hang off completion on 9 5 8 DLT packer as per 2a Barrier Status 9 5 8 DLT Packer Kill Weight Brine Shear Rams PRIVATE AND CONFIDENTIAL Page 76 of 83 Rev 0 CASINO 5 COMPLETION PROGRAMME Santos 4 Tubing Hanger made up to the completion String THRT installed Either a Lay down THRT and proceed as per 3a Barrier Status 9 5 8 DLT Packer Kill Weight Brine Shear Rams a RIH tubing hanger on THRT on 9 5 8 landing string and land in XT Lock the tubing hanger in the XT b Disconnect from the tubing hanger at the SSTT POOH with 9 5 8 landing string c Close Shear Rams Barrier Status Kill Weight Brine Shear Rams 5 Emergency Procedure a Adjust string elevation to locate one tubing coupling 0 5m below the shear rams b Close BOP shear rams c Open BOP Shear rams and pull string above shear rams d Close BOP Shear rams e Proceed with LMRP disconnection as per DOGC standing instruction Barrier Status Kill Weight Brine Shear Rams PRIVATE AND CONFIDENTIAL Page 77 of 83 Rev 0 CASINO 5 COMPLETION PROGRAMME Santos APPENDIX R WELL CONTROL GUIDELINES RUNNING THE COMPLETION The following is meant as a guide only for the r
72. i E 1 1 1 1 4 es sete peaj p i 5 A SSE a d lem eee cel A MENS SUI NN Il gt d SUS ME 3 o gt 5 i i T EM s S Ns NE oo DIE q pas 5 MEN M E m m A A gt a 1 5 1 1 ene alier Pea A E a Lb NM DE cc I I I I I I 1 1 I I I I LO Soh Sus 1 o G 1 c epe esos _ 0 NE SN aa ala ina hi ass85958 of fi lt lt 2 1 1 1 1 1 65 4 4 oor Z 34 1 I sat Y 1 I I I O 225562 x elo eundi Eso su a A DE Ds 6 bas s gt 2 i i perdete etii IN AS tates i e O o o o o o o o e oo o LO e N isd a1nssaly 250 200 200bbl 150 Diesel Volume bbls 100 50 1535mBRT 0 Page 71 of 83 PRIVATE AND CONFIDENTIAL CASINO 5 COMPLETION PROGRAMME Santos APPENDIX N DATA ACQUISITION Surface Data Acquisition Frequency Data
73. i Mt 15 5 2 Well Control During Completion Running 15 5 3 Spaceout of the Completion Assemblies eese 16 5 4 Sub Assemblies Tubulars Preparation 17 RUNNING THE EXPANDABLE SAND SCREEN ESS LOWER COMPLETION 19 6 1 General 19 6 2 Make up ESS and Lower Completion EXP 20 63 Setting the EXP Packer pierre HE ene dion u uuu uuu u 22 6 4 ESS Expansion u e 23 CASING AND RISER CLEANING U U id 25 7 1 25 7 2 Casing Scraper amp Riser Cleaning Assembly Space Out Notes 25 7 3 A a ia 26 RETRIEVE XT BORE PROTECTOR saint tontas 28 8 1 PODA ON a 28 8 2 Procedure o o o 28 RUN UPPER CONPLETION u 29 9 1 General ENE 29 9 2 Run Muleshoe and Tailpipe ric on init ck i iC ai 29 9 3 Make Up Tubing Retrievable Sub Surface Safety Valve SSSV 30 INSTAL
74. ial hang up point at the XT BOP s 10 974 x 9 5 8 casing crossover Set slips softly to avoid shocks to the packer String NOT to be rotated with ESS EXP packer installed Ensure back up tongs are used when running in on drill pipe for the first 200m Lock RT prior to RIH 6 2 14 Record static running and pick up weights prior to screens entering open hole section e Packer running speed inside 8 5 open hole 6m min 6 2 15 Continue RIH to TD running last stand of drill pipe compensated in case of incorrect spaceout Tag TD with no more than 5 000lbs Pick up to space out packer at the required set depth ensuring the final packer movement is upwards and the rams can be shut for pressure testing of the packer e Record static slack off and pick up weight of string on the Daily Drilling Report e Ensure there is adequate stick up to permit ball drop and cement unit connection PRIVATE AND CONFIDENTIAL Page 20 of 83 Rev 0 CASINO 5 COMPLETION PROGRAMME Santos e Count the remaining number of stands in the derrick to cross reference the running tally e Refer to spaceout criteria in Section 5 3 PRIVATE AND CONFIDENTIAL Page 21 of 83 Rev 0 CASINO 5 COMPLETION PROGRAMME Santos 6 3 Setting the EXP Packer The setting procedure for the packer will be as per the Weatherford WCPS Casino 5 Operations Manual Rev 3 Adequate stick up will be required prior to setting the packer as it will be necessary to slack
75. ical path wherever possible 1 7 Reporting and Record Management The Subsea Supervisor is responsible for ensuring all relevant reporting requirements are fulfilled including documentation submitted to the Completions Supervisor for inclusion in Daily Completions Reports and end of well filing The Completions Supervisor is responsible for ensuring reporting requirements are fulfilled the submission of the Daily Report and compilation of documentation for end of well filing and well handover The Completions Supervisor is responsible for collating all documentation relating to the completions including but not limited to Final Subsea Tree and Downhole Schematic as built Final Valve Status Schematic Service Company Reports Pressure Test Charts Results Tubing Make Up Charts PRIVATE AND CONFIDENTIAL Page 8 of 83 Rev 0 CASINO 5 COMPLETION PROGRAMME Santos Valve Operation Results Tallies and Space Out Schematics Non Conformances Lessons Learnt Recommendations Toolstring Schematics Well Handover It is the responsibility of the Santos Completions Supervisor to forward all collated documentation to the Casino Drilling and Completions Technical Assistant 1 8 Management of Change 1 8 1 Significant Deviations and Amendments to the Completions Programme shall be approved in accordance with the Santos Drilling and Completions Change Control procedure A sample Management of Change Form is included as an Append
76. id unless otherwise stated 7 2 Casing Scraper amp Riser Cleaning Assembly Space Out Notes Space out TBC by Completions Supervisor after running of the 9 5 8 casing Scraping string diagram in Appendix B No Description Supplier Qi nda 1 8 1 2 Bit nozzles removed from bit Santos 0 2 2 Bit sub amp XO to 4 Y IF Diamond 2 0 3 5 Drill pipe Diamond 10 0 4 9 5 8 Razor Back scraping tool 4 72 IF a 2 5 Weatherford 5 5 Drill pipe Diamond Approx 1550 SPS 1 6 SABS Circulation tool 4 72 IF Weatherford 1 5 7 5 Drill pipe Diamond 30 0 SPS 1 8 Riser Brush Tool 4 Y IF Weatherford 2 5 9 5 Drill pipe Diamond As required Scrape the 13Cr 9 5 8 casing from 1 562m to 1 655m Check scraping depths align with the spaceout requirements for the Lower and Upper Completions in Section 5 3 The Riser Brush Tool to simultaneously brush the riser whilst casing scraping The SABS tool one stand of drill pipe below the Riser Brush Tool The Riser Brush Tool to go no closer than 3m above the Flex Joint PRIVATE AND CONFIDENTIAL Page 25 of 83 Rev 0 CASINO 5 COMPLETION PROGRAMME Santos 7 3 Procedure 7 3 1 Make up casing scraper and riser cleaning assembly as per Section 7 2 RIH with scraping assembly on drill pipe Break circulation every 500 m to clear the tools of debris e Maximum running speed with Razorback Casing
77. ies e To avoid potential damage to the rams function the rams with no closing pressure Increase the closing pressure on the rams to a minimum to enable the rams to close Open the rams 6 2 2 Conduct JSA Running Lower Completion 6 2 3 Rig up 4 Y drill pipe elevators and the Weatherford ESS handling gear dressed for 6 OD 13Cr ESS 6 2 4 Pick up the guide shoe Expandable Bottom Connector EBC sub assembly LC01 set in the rotary using slips and a dog collar 6 2 5 Make up and run the ESS as per running tally 6 2 6 Rig up handling gear for 7 5 8 29 7 13Cr80 FOX tubing 6 2 7 Make up the Expandable Top Connector sub assembly LC02 6 2 8 Make up and run 7 5 8 29 7 13Cr80 range 3 FOX tubing as per the running tally 6 2 9 Check the tally by performing a count of the remaining 7 5 8 13Cr80 tubing joints and ESS joints and pups left on deck e This check should be carried out by the Completions Supervisor 6 2 10 Rig up 5 drill pipe elevators 6 2 11 Conduct JSA Make up and running lower completion EXP Packer 6 2 12 Pick up the EXP packer sub assembly LCO3 and make up under the direction of the Weatherford Technician Record static pick up and running string weights e Weatherford Technician to confirm the number of shear screws installed and the maximum required shear pressure 6 2 13 RIH with drill pipe to the 9 5 8 casing shoe e Maximum running speed in 9 5 8 casing 10m min e Be aware of potent
78. ig A JSA should be conducted to review the well control precautions and actions at each new stage of the completion The mud loggers and driller must monitor the well throughout the completion operations 1 Section 6 0 Running Lower Completion Situation Actions if Well Flows ESS above the BOP Close the BOP shear rams ESS over BOP s Either Space out mid joint of ESS joint across the BOP shear ram Close the BOP shear rams Drop ESS Close the BOP shear rams 7 5 8 tubing across the BOP s Packer NOT Installed Space out mid joint of ESS or 7 5 8 joint across the BOP shear ram Close the BOP shear rams Drop ESS Close the BOP shear rams 7 5 8 tubing across the BOP s Packer Installed Install well control sub onto drill pipe Space out and close the annular or variable rams around the 7 5 8 tubing 2 Section 8 0 Pulling XT Bore Protector 12 IF well control valves are ready to be used Situation Actions if Well Flows Puling the XT Bore Protector Jetting the XT BOP s Pull BHA above the BOP s Close the BOP Shear rams PRIVATE AND CONFIDENTIAL Page 78 of 83 Rev 0 CASINO 5 COMPLETION PROGRAMME Santos 3 Section 9 0 Running Upper Completion e Ensure two 7 KSBEAR x 4 77 IF xovers are on the rig floor made up to well control valves ready to be used Situation Actions if Well Flows
79. int 1 700m 5 3 2 Upper Completion a b c d e The Wireline Entry Guide sub assembly UC01 approximately 15m above the top of the Lower Completion EXP packer The 4 625 QN nipple sub assembly UC02 placed 1 x 7 13Cr range 3 joint above the WEG UC01 and 1 x 7 13Cr range 3 joint below the Production Packer UC03 and is in a deviation less than 60deg limit for slickline operations Production packer assembly set in the chrome casing Estimated depth 1645m The chemical cut sub assembly UCO4 directly above the Production Packer assembly UC03 There should be sufficient 9 5 8 13Cr above the chemical cut sub to allow for a 2nd tailpipe assembly and production packer to be run and set in 13Cr casing should the completion string be retrieved because of a problem post setting of the primary production packer The SSSV assembly UCO05 set within the 10 3 casing 50m below the mudline The bottom of the TRSV must be above the 9 5 8 x 10 34 crossover planned depth 160m 5 3 3 Landing String a b The coupling of the 9 5 8 L80 New Vam Range 3 landing joint on the bottom of the flowhead to be 6 to 8 m above the rig floor The LV a minimum of 6m below RT PRIVATE AND CONFIDENTIAL Page 16 of 83 Rev 0 CASINO 5 COMPLETION PROGRAMME Santos 5 4 Sub Assemblies Tubulars Preparation a b c d e f g h All assemblies and tub
80. ix S 1 8 2 Non standard operations not covered in existing Santos DOGC or Service Company procedures will require an on site risk assessment and a set of written procedures together with a JSA 1 9 References Casino 5 Drilling and Completions Programme CD 4000 P 15 002 Casino Development Installation amp Retrieval Procedures for Subsea XT BOP CD 2200 P07 001 Expro Wireline Operations Manual Casino Logistics Operations Plan CD 4000 A02 001 Cameron Operations and Maintenance Manual OMM SD 031548 01 to 03 Expro Landing String Operational Manual Santos Deck Management Plan Diamond Job Requests Weatherford WCPS Casino 5 Operations Manual Rev 3 Expro Well Test Planning Report Casino Completions Manual CD 4000 P 15 003 1 10 Abbreviations AAV Annular Access Valve ACE Axial Compliant Expansion Tool ACIV Annular Chemical Injection Valve AMV Annular Master Valve AVV Annular Vent Valve AWV Annular Wing Valve AXT AX Gasket Test and Isolation Valve BOP Blow Out Preventer BOT Baker Oil Tools CSM Cavity Seal Monitor and Isolation Valve CIV Chemical Injection Valve CXOV Chemical Crossover Valve DC Drill Collar DP Drill Pipe DV Drain Valve PRIVATE AND CONFIDENTIAL Page 9 of 83 Rev 0 CASINO 5 COMPLETION PROGRAMME Santos DOGC Diamond Offshore General Company EBC Expandable Bottom Connector EHT Emergency Hang Off Tool ESD Emergency Shutdown ESS Expandable S
81. l HWDP DC s to top of the ESS 8 on drill pipe Expand ESS 2 passes POOH Expansion tool above the ESS cycle 4 open SABS and displace 9 5 8 casing to inhibited calcium chloride brine 10 at 1685m POOH expansion tools Laydown HWDP amp DC s 5 Scrape 9 5 8 casing and riser amp jet BOP s 14 6 Retrieve bore protector amp jet the XT BOP s in brine 1 7 Run upper completion tailpipe and packer and chemical cut sub 2 8 RIH upper completion 7 13Cr80 KSBear tubing to 1500m 9 9 Make up SSSV and test 2 10 RIH upper completion 7 13Cr80 KSBear tubing to 1550m 0 5 11 Make up TH and terminate SSSV 4 12 Install THRT SSTT onto TH and function test 4 5 13 RIH Completion on 9 5 8 New Vam landing string Install LV Install 12 flowhead and rig up test welltest lines and slickline PCE 14 Land off completion and lock and test TH Retrieve Isolation sleeve and 6 run TH wireline short protection sleeve on slickline 15 Displace approx 200bbl diesel cushion for underbalance 2 16 Run standing valve on slickline and set packer Pressure test 6 completion retrieve standing valve 17 Perform pre flow checks Clean up the well 12 18 Retrieve TH wireline short protection sleeve from THRT 2 19 Inflow test SSSV Run and set lower plug on slickline in TH 2 20 Unlatch THRT from TH Rig down surface lines slickline PCE and 6 flowhead 21 POOH THRT SSTT laying down 9 5 8 land string and LV 2 22 RIH and jet TH XT Run and set test ITC c w
82. l Technologies 3 05 2005 Casino 5 Completion SUB ASSEMBLY RECORD ACTUAL Lene m eme mee mm ye u Down Pup Joint Cross Over 4 1 2 IF Box 3 1 2 IF Pin Weatherford XO SN 716477 E PUP SN 710158 Running Tools 3 1 2 IF Box Weatherford Setting Stub ACME PBR 13 Cr L 80 Sleeve Box Weatherford Part LEXY9RF18M Serial 5252440 2 EXP Hanger 13Cr 80ksi k ROME ps PS Weatherford Note No nipple profile Part 760558 Serial 5334528 2 13Cr 80ksi Fox Box Santos PUP Joint 13Cr 80ksi Fox Pin Fox Pin Santos 7 840 TOTAL ASSEMBLY LENGTH m RECOMMENDED TORQUE DATA MINIMUM OPTIMUM MAXIMUM ft lb ft lb ft lb WT THREAD TYPE SPECIFIC SUB ASSEMBLY FUNCTION PRESSURES 29 7 Fox HYDROSTATIC PRESSURE TEST N A TEST FLUID TEST FIXTURE SERIAL NO SET INDICATION FULL BODY TEST TEST NO FRICTION FACTOR COMMENTS THREAD COMPOUND Bestolife 72733 COMMENTS Weatherford PROJECT ENGINEER Eamonn Arandiga Halliburton SERVICES SUPERVISOR Bill Power Santos COMPLETION SUPERVISIOR John Cooper Santos SENIOR COMPLETION ENGINEER Mike Andronov Advanced Well Technologies 3 05 2005 Santos Santos SUB ASSEMBLY RECORD ACTUAL ACTUAL LENGTH Sub Assembly DIAGRAM TORQUE DESCRIPTION WEIGHT THREAD ED in O D in DRIFT in SUPPLIER m p p f Nominal Nominal
83. ly left in place A Dog Collar is to be used on all tubulars until there is a string weight of gt 20 000lbs approx 210m PRIVATE AND CONFIDENTIAL Page 17 of 83 Rev 0 CASINO 5 COMPLETION PROGRAMME Santos o All premium thread connections must be made up using the torque turn computer and recorded on the JAM unit Copies of all make ups are to be provided to the Completions Supervisor p For any connection requiring more than 3 attempts to achieve the correct make up consult with the Completion Supervisor q Lay out all tubing and completion subassemblies in order of running PRIVATE AND CONFIDENTIAL Page 18 of 83 Rev 0 CASINO 5 COMPLETION PROGRAMME Santos 6 0 RUNNING THE EXPANDABLE SAND SCREEN ESS LOWER COMPLETION Barrier Status Location Primary Barrier Secondary Barrier Well Kill weight drill in fluid BOP s 6 1 General a Completions Supervisor to generate a running tally Space out of ESS and completion assemblies as per section 5 3 Confirm the space out with the Completions Team in the Perth office prior to commencing running of the lower completion b 5 19 5 5135 2 75 ID 2 625 drift drillpipe with 4 72 IF connections is to be used as the work string for riser cleaning and lower completion deployment c No rotation can be used when running the ESS d Review well control precautions actions as per appendix R e All pumping operations to use drill in fluid unless o
84. move the rig to the next location PRIVATE AND CONFIDENTIAL Page 56 of 83 Rev 0 CASINO 5 COMPLETION PROGRAMME Santos 17 0 APPENDICES APPENDIX A CASINO 5 PROPOSED COMPLETION SCHEMATIC PRIVATE AND CONFIDENTIAL Page 57 of 83 Rev 0 Santos CASINO 5 COMPLETION PROGRAMME Santos APPENDIX B CASING AND RISER SCRAPER SCHEMATIC 2 WELL BORE CLEAN UP SCHEMATIC RUN1 Ng CUSTOMER SANTOS PREPARED BY A RIG LOCATION AUSTRALIA CHECKED BY WELL NUMBER CASINO 5 DATE 0 ENQUIRY NUMBER SANTOS 001 005 REVISION DESCRIPTION OD in Approx Tool Length m MARINE RISER RBT103 Riser Brush Tool for 20 ID riser 4 1 2 IF Box up x Pin down Stabilizer 16 Nominal 2 812 RIH POOH speed 90 fpm Max 60 RPM space out no closer Bristle 20 25 Drift 2 75 than 3m above lower flex joint BOP WELLHEAD Single Action Bypass Sub w 4 1 2 IF Box Pin Conns space out below wellhead when RBT is 3m above lower flex joint 6 50 110 3 4 CASING 160m 9 5 8 CASING 474 RB101 9 5 8 Razor Back Tool for 43 53 5 casing Connections 4 1 2 IF Box up x Pin down Max Rotating Speed 80 RPM 15 00015 max compression at tool when rotating RIH POOH speed 150 fpm Stabilizer 8 374 Nominal 2 812 Lantern 9 00 Drift 2 75 Approx 1710m Bit and
85. nd BOP s Pull the rig riser and rig BOP s as per document CD 220 P07 001 e Ensure a lightweight debris cap is installed on the top of the XT with the ROV as soon as possible after unlatching of the BOP s from the XT Conduct a JSA Running of the spool tree debris cap e should be launched to monitor running of the spool tree debris cap Skid the rig over the well centre Inspect Top of XT and ITC with the ROV Make up the spool tree debris cap running tool to 5 drill pipe PRIVATE AND CONFIDENTIAL Page 55 of 83 0 CASINO 5 COMPLETION PROGRAMME Santos 16 5 6 Stab the Debris Cap Running Tool into the Debris Cap and make up with right hand rotation to engage the debris cap pins into the running tool J slot 16 5 7 Run Debris Cap Running Tool below the rotary table and install the two arm utility guide frame to the drill pipe 16 5 8 Run Debris Cap as per the Cameron OMM e Remove the lightweight debris cap with the ROV just before landing the spool tree debris cap 16 5 9 Land Debris Cap onto the XT with minimal set down weight 16 5 10 Verify lockdown with a maximum overpull of 5 000Ib 16 5 11 Set minimal weight down and rotate approximately 20 degrees to the left to release the running tool from the Debris Cap 16 5 12 with the running tool Remove the two arm utility guide frame Remove the running tool 16 5 13 Conduct the final ROV survey as per the Cameron OMM 16 5 14 Pull anchors and
86. nly be performed in water based fluid e Note volumes recovered in pits and cross reference with volumes recorded at cement unit and pressure vs volume graph 14 2 8 Record final SITHP after circulating diesel on Rig Floor Valve Status Sheet Determine the underbalance pressure that will be in place after setting of the packer e SITHP will reduce after packer setting due to loss of the U Tube for the annulus e Once circulation has ceased hold a positive pressure on the tubing to prevent the diesel from U tubing 14 3 Set Production Packer 14 3 1 Hold JSA for slickline operations 14 3 2 Close MV Open SV Bleed off pressure via well test choke manifold When pressure is Opsi drain lubricator using DV s Close SV Close DV s e Drain hose downstream of DV s is only rated to 500psi DV s must be closed and welltest surge tank isolation valve must be tagged open e Max expected SITHP prior to setting the packer 900psi equivalent U tube pressure e Completions Supervisor to supply an installed completion schematic and tally to the Slickline Supervisor 14 3 3 Open SV Equalise and open MV using seawater Close KWV 14 3 4 RIH with slickline and install the standing valve in the 4 625 QN landing nipple in tail pipe beneath the packer e Record slickline depth tide corrected PRIVATE AND CONFIDENTIAL Page 44 of 83 Rev 0 CASINO 5 COMPLETION PROGRAMME Santos 14 3 5 14 3 6 14 3 7 14 3 8 14 3 9 14 3 10 14 3 11
87. ntrol line to keep SSSV open e BOT Engineer to confirm that the SSSV opens e Control line pressure needs to be 2 000 psi above tubing pressure in order for SSSV to stay open Barrier Status Location Primary Barrier Secondary Barrier Tubing Kill weight chloride Flowhead Ann lus Kill weight calcium chloride 10 3 rams brine 13 3 2 Close the MV and open the SV Break out the lubricator at the in situ test sub Make up the toolstring as per Toolstring a in Appendix L Open the MV RIH slickline and retrieve the TH Isolation Sleeve to surface At surface close the MV Open the lubricator needle valve not DV s Break slickline lubricator at the 13 Bowen connection remove inspect toolstring check toolstring length e The toolstring on the next slickline run TH wireline short protection sleeve is not able to drift the Cromar sub 13 3 3 Make up toolstring as per Toolstring b Appendix L Pressure test above the MV from the cement unit to 3 500psi for 5 minutes with seawater Bleed off pressure to Opsi via the welltest choke manifold Open the MV RIH and install the TH wireline short protection sleeve in the THRT e The TH isolation sleeve seals around the production bore The TH wireline short protection sleeve does not e The pressure test of the lubricator at this stage only to 3 500psi as the 13 Bowen connection will be broken to remove the protection sleeve running tools e Drain hose downst
88. ofile d If a good pipe ram mark was not established in the drilling phase after XT running then coat the 1st joint of 5 drill pipe with a coat of grease paint If using paint ensure a full joint is painted sufficient time in advance of operation in order to dry e Jetting operations to be conducted with inhibited calcium chloride brine f Review well control guidelines as per Appendix R 8 2 Procedure 8 2 1 8 2 2 8 2 3 8 2 4 8 2 5 8 2 6 8 2 7 e XT valve status all valves closed Conduct JSA Pull Bore Protector Using ROV open TCT CSM and SIV needle valves on XT RIH Bore Protector Running and Retrieval Tool rubber nosed jet sub assembly on drill pipe and latch bore protector as per Cameron OMM procedure If required cycle closed then open the relevant Pipe Rams to create marks on the greased painted joint Use full ram closing pressure Record the state of tide Unseat bore protector from the XT with 25 000lb overpull as per Cameron OMM procedures Jet XT amp BOP ram and annular cavities with calcium chloride brine Boost riser to lift debris Pump down the TCT SIV and CSM lines simultaneously while jetting to ensure the lines are not blocked When jetting is completed close the TCT CSM and SIV lines using the ROV POOH the Bore Protector Running and Retrieval Tool Once above rotary table install metal hole cover rig down Running and Retrieval Tool and Bore Protector measure marks left b
89. ommence 15 4 6 Flow the well until it has cleaned up Criteria for the well being cleaned up are PRIVATE AND CONFIDENTIAL Page 50 of 83 0 CASINO 5 COMPLETION PROGRAMME Santos 1 At least three consecutive BS amp W measurements that are within 2 of baseline BS amp W eg Baseline BS amp W 3 acceptable BS amp W range 1 to 5 Stable THP i e 10psi 5min change over 2 hr period at constant rate Stable gas rate If measurable a WGR lt 1 bbls MMscf Water salinity chlorides pH that are not representative of the drilling mud completion brine If criteria 1 to 4 have been satisfied but criteria 5 has not been met the clean up period will be terminated The Santos Reservoir Engineer will advise the baseline BS amp W measurement and when the well has cleaned up Q Se B0 pO 15 4 7 Once stable flow conditions are experienced and the well has cleaned up finish taking the samples as per Appendix O e Santos Completions Supervisor will ensure that a fixed choke size is installed prior to the end of the clean up e The Santos Reservoir Engineer will specify the choke size for the main flow e Sampling will be 15 4 8 Shutin well at well test choke manifold e Expected SITHP 2 500psi e Following completion of clean up inspect separator for any sand Report results on the well testing log of events and the Daily Completions Report PRIVATE AND CONFIDENTIAL Page 51 of 83 Rev 0 CASINO 5 COMPLETION PROGRA
90. or to witness Conduct well test specific emergency drill prior to commencing well test Zero trace H2S has been detected during previous Casino production tests and H2S is not expected during the Casino 5 clean up As a precaution an electronic H2S sensor shall continuously monitor for the presence of H2S in the test area Once reservoir fluids are detected at surface H2S and CO2 sniffer tube measurements must be made immediately and repeated every 15 minutes for the first hour Once stable H2S readings have been established the measurement interval may be increased to 30 minutes In the event that H2S levels equivalent to 10 ppm in atmosphere are detected the situation will be assessed and the well may be shut in with a view to terminate testing operations Radio communications shall be tested in advance of flowing operations Establish communication protocol and ensure it understood by all involved in the operations Confirm compressors burner ignition system and water curtain are operating Ensure contingent rig pump and power is available Confirm rig firewater pumps and well test area deluge system operational Ensure there are sufficient additives to mix kill weight fluid in the event of an unplanned well kill Make an announcement over the PA that flaring operations are about to commence Pressure shall be bled from the annulus via the rig choke rig choke line Annulus pressure to be maintained between 100 1000 psi Monitor
91. ound the 10 slick joint with minimal closing pressure to prevent damage if slick joint spaceout is incorrect Once 10 closure volumes are confirmed increase to full closing pressure Monitor CSM at surface Monitor the pressure down stream of the PWV PPTT2 Apply 200psi 10 minutes from cement unit via the choke kill line below the closed MPR s and increase to 4 000psi for 10 minutes Record on chart then bleed off to 0 psi This tests the following e BOP seal round slick joint TH production bore seals from production side AMV from above Upper TH seal from above The PWV from the production side e Steps 13 2 18 and 13 2 20 satisfy the Petroleum Submerged Land Act Schedule BOP test requirements There is no requirement to test the 5 blind variable pipe rams or the upper annular as they can no longer be used from this point onwards 13 3 Test Tubing Hanger and XT e Once landed off the pressure in the SSSV control line must not exceed 6 500psi due to the limit of the control system rating of the XT PRIVATE AND CONFIDENTIAL Page 41 of 83 Rev 0 CASINO 5 COMPLETION PROGRAMME Santos 13 3 1 Using XT IWOCS with CSM needle valve open and vented confirm the SSSV operates by opening with 6 500psi control line pressure and then close by bleeding off the control line pressure to Opsi Re open the SSSV and pressure test the control line via the open SIV to 6 500 psi for 15 mins chart record test Leave pressure on co
92. packer and TH to 3 500psi psi for 10 minutes by pumping seawater down the choke kill line from the cement unit Do not bleed off annulus pressure at end of test e Record this test on a chart e Monitor SITHP for any abnormal trend standing valve is still installed e This tests the annulus the packer from above the TH from below and the XOV from the annulus side Close the AAV ROV to confirm and inflow test the AAV by bleeding off pressure from cement unit to 250psi Hold inflow test for 10 minutes and record on chart Equalise pressure across the AAV and open AAV ROV to confirm Close the AMV ROV to confirm and inflow test the AMV by bleeding off pressure from cement unit to 250psi Hold inflow test for 10 minutes and record on chart Equalise pressure across the AMV and open AMV ROV to confirm Bleed pressure from annulus to 100psi via the rig choke kill line Close the PMV ROV to confirm e This pressure will be used to monitor the annulus during the welltest Close the MV Open KWV Bleed pressure from welltest choke to 0psi Open the SV Equalise above the MV with seawater and open MV Close KWV RIH with slickline and retrieve standing valve POOH with slickline Close MV Open KWV Bleed off pressure via the welltest choke manifold When pressure is 0psi drain lubricator using DV s Close SV Close DV s e Bleed hose downstream of DV s is only rated to 500psi e Monitor volumes to ensure MV not leaking Make
93. panel the SV MV and KWV will be controlled by the Expro Flowhead control panel 12 2 11 Confirm MV KWV FWV SSV and well test choke manifold are open 12 2 12 Close the SV Rig up the slickline PCE Refer to schematic in Appendix K e Ensure the lubricator needle valve is open This is not the DV s e This step may be carried out after the string has been landed 12 2 13 Record the pick up and set down and static weights of the completion 12 2 14 Spool out enough landing string umbilical on the deck to allow land off of the completion Reconnect the deck jumpers with hydraulic stabplate to the reel 12 2 15 Tag open welltest surge tank isolation valve e This valve to remain tagged open for the remainder of the program to prevent over pressurisation of the drain line which is rated to 500psi 12 2 16 Close the LV Open SV Ensure slickline lubricator DV s are closed Flush across Flowhead from cement unit with seawater Close the well test choke manifold and the lubricator needle valve and pressure test the Flowhead slickline equipment Coflexip landing string and kill line to 5 000 psi for 10 minutes Bleed pressure to 0 psi via the well test choke Leave the welltest choke open e Drain hose downstream of DV s is only rated to 500psi DV s must be closed and welltest surge tank isolation valve must be tagged open 12 2 17 Ensure welltest choke manifold is open Close the SV Open the LV PRIVATE AND CONFIDENTIAL Page 38 of 8
94. pressurised as per Cameron OMM and Expro Landing String Operational Manuals Lock in pressures at reel and continuously monitor during deployment e THRT LATCH TH UNLOCK SSSV TH SOFT LAND VENT TEST RETURN LATCH ASSIST UBV OPEN LBV OPEN SSTT RELATCH Bleed down line pressures at HPU disconnect deck jumper from reel Pick up string and carefully rig down the TH Split landing bowl taking care not to damage TH seals and TH running circuit ring e THRT is rated for 725 00lbs string weight Confirm TH running circuit ring is spaced out correctly using one of the 4x spacers to gauge the length Install 3x shear pins in side of TH running circuit ring Rig up 20 split bowls amp slips RIH THRT SSTT spooling out the umbilical accordingly Remove lifting clamps e Take care of stainless lines when running THRT SSTT through RT Set slips across SSTT handling sub and make up first joint of 9 5 8 landing string Secure umbilical to 9 5 8 tubing using fibre glass tape RIH 9 5 8 landing string as per tally to LV securing umbilical every full joint coupling e Monitor SOFT LANDING pressure gauge while RIH if pressure raises by 1000 psi the THRT outer sleeve is experiencing 47 000lbs drag indicating the completion is becoming stuck or hung up inside the riser e Monitor SSSV on RIH Pick up and install Lubricator Valve as per the tally Install umbilical and function as per the Expro Landing String Operational Manual PRIVATE
95. rational Manual and make up 10 3 4 elevators to Flowhead Pressure tests are to consist of low high and then final low pressure Install test cap on top of Flowhead Ensure suitable fittings and hoses are available DOGC Supply to use the air supply to the link tilt bag for the slickline air winch To be rigged up when topdrive at the RT Prior to picking up Flowhead to the rig floor ensure the MV and SV are open and FWV locked open with the cap Note all flowhead valve positions Ensure the Rig Floor Completion Valve Status Schematic Appendix J is on the rig floor and used from this point onwards The Driller will be the focal point for all valve operations in agreement with the Completions and Subsea Supervisor Confirm status of XT valves with Subsea Supervisor and note on Rig Floor Completion Valve Status Schematic 12 2 Make Up Flowhead and Slickline Pressure Control Equipment As per Casino Drilling and Completions HAZID in January 2005 the decision to rig up slickline PCE after landing off may be made by rig personnel based on an assessment of weather conditions at the time of the installation Barrier Status Location Primary Barrier Secondary Barrier Tubing Kill weight On chloride BOP Annius Kill weight calcium chloride BOP brine 12 2 1 Conduct JSA Rig up bails and lifting Flowhead Refer to Expro Landing String Operational Manual 12 2 2 Install the Expro top drive sub and Expro slickline air
96. ream of DV s is only rated to 500psi DV s must be closed and welltest surge tank isolation valve must be tagged open 13 3 4 POOH slickline to surface Close the MV Open the needle valve not DV s Break slickline lubricator at the 13 Bowen connection remove and inspect toolstring Make up the Standing Valve Toolstring as per Toolstring c in Appendix L Open SV and pressure test above the MV from the cement unit to 5000psi for 10 minutes with seawater e Drain hose downstream of DV s is only rated to 500psi DV s must be closed and welltest surge tank isolation valve must be tagged open 13 3 5 Close the PMV and open AMV ROV to confirm XOV and AAV remain open PRIVATE AND CONFIDENTIAL Page 42 of 83 Rev 0 CASINO 5 COMPLETION PROGRAMME Santos 14 0 DISPLACE TO DIESEL AND SET PRODUCTION PACKER 14 1 Preparation a The Completion Supervisor and Halliburton Technician shall be present at the cement unit when diesel pumping is initiated The Halliburton Technician shall remain throughout pumping operations b A pressure vs volume pumped graph must be prepared in advance to allow careful monitoring during diesel displacement Plan to displace diesel 75m 9bbl above the chemical cut sub Do not over displace Appendix M uses estimated values and is included as a guide c Test function of rig choke The rig choke to be lined up to the annulus should be left fully open and monitored on trip tank d Confirm
97. rilling Contractor DOGC Drilling Rig Ocean Patriot Surface Location Easting Northing 651 603mE 5 704 471mN Water Depth LAT 70 8 m RT Elevation above LAT 22 0 m AR Primary Objective Description Waarre C sands 1788 m MD Luz aa 1788 m TVDRT 1743 m MD Formation Depth 1743 m TVDRT Expected Porosity 20 Expected Permeability 100 10 000 md Maximum Deviation degrees 5 Expected Gas Gravity 0 595 Air 1 0 Boom dole Temp 81 deg C 1753mTVD 1731m TVDSS 178 deg F Bottom Hole Pressure 2828 psia 1753mTVD 1731m TVDSS Expected max SITHP well cleaned up 2540 psi H2S 0 ppm CO 0 8 Sand None Expandable Sand Screens in lower completion Hydrates Possible PRIVATE AND CONFIDENTIAL Page 11 of 83 Rev 0 CASINO 5 COMPLETION PROGRAMME Santos 3 0 WELL STATUS All depths in this programme are referenced to m MD RT metres measured depth relative to rotary Table unless otherwise stated 3 1 Pre Completion Status Assumptions This Completion Program is based on the following assumptions a The Horizontal Subsea Tree BOP s and riser system have been run b 95 8 x 10 Casing has been run to 1730m with the crossover at 160m c The8 77 hole has been drilled to TD d The XT Bore Protector is installed 3 2 Pre Completion Status Review The Completions Supervisor shall review the well statu
98. rtake JAM Nut connection operations 10 2 10 BOT to perform two SSSV function tests Flapper Open amp Close recording volume 10 2 11 returns consistent results required with previous tests Pressure test the SSSV line to 7 500 psi for 15 minutes Bleed off Record and provide chart to Completion Supervisor Bleed off control line pressure after test e SSSV will remain closed until make up of the THRT Beware of surge when moving the string 10 2 12 Carefully re attach the helix to the TH ensure the lifting eyes are removed 10 2 13 Confirm orientation of TH Helix lies approximately 45 degrees port of forward in relation to rig heading e Keyway on TH is 180 deg out of alignment with the TH production bore e Keyin XT faces forward when compared to the rig heading e f orientation exceeds 60 degrees port of forward slowly rotate entire completion string in a clockwise direction to gain correct orientation e Refer to Appendix H for the orientation schematic 10 2 14 Land off the TH split landing bowl directly onto the rotary table master bushing 10 2 15 Remove the well control valve Unlatch the THHTT from the TH as per the Cameron OMM and lay down Cover the bore of the TH PRIVATE AND CONFIDENTIAL Page 32 of 83 0 CASINO 5 COMPLETION PROGRAMME Santos 11 0 MAKE UP AND RUN THRT SSTT AND LANDING STRING 11 1 Preparation of THRT SSTT The following preparation should be conducted offline prior to comple
99. rubber or soft wrapping to protect chrome tubulars from hard impacts Rubber matting will be laid at the rig floor end of the catwalk in preparation for handling tubulars Matting or wood is only required at the top of the vee door When removing from the shipping racks ensure tubing is layered on wood or soft spacers for protection Tubulars must have thread protectors fully installed before handling The completion sub assemblies have been made up and pressure tested onshore but must be inspected for damage All completion subassemblies to be drifted strapped ID s and OD s checked serial numbers recorded and numbered as per the running tally and cross referenced against their sub assembly sheets All Sub Assemblies will have clearly marked lifting points All onboard pressure testing must be witnessed and signed off by the Completion Supervisor Copies of tool calculations operating pressures rupture disc shear pin settings drawings and space out calculations will be provided to the Completion Supervisor Power tongs to be dressed with low penetration dies for all tubing sizes except 9 5 8 landing string No Subassembly handling will take place without the direct supervision of BOT Weatherford or Halliburton engineers as appropriate Sub assemblies are to be walked in before using the make up tongs Visually check each sub assembly box connection to ensure that no low torque pressure test seal rings have been inadvertent
100. s prior to completion operations As a minimum the following should be undertaken for the relevant well a After drilling of the 8 72 hole and consideration of factors such as metal captured by the ditch magnet and time taken to drill to TD a decision will be made by the Completions Team Leader as to whether a casing wear log will be run to identify suitable locations for setting of the lower and upper completion production packers b Checking the Daily Drilling Reports for the well to confirm the well status c Confirm the kill fluid weight of drill in fluid Brine weight is to be 0 1 ppg less than when drilling d Review the definitive directional survey well casing tallies and depth of the 95 8 casing shoe 95 8 x 10 casing crossover 13Cr 9 5 8 casing Final TD of the 8 12 open hole e Confirm the 9 5 8 and 10 casing test pressures from the Daily Drilling Reports and determine annulus pressure limits for casing and tubulars to be run f Run the IWOCS umbilical offline and confirm communication of the SCM Monitor the SCM throughout the operations g Confirm the kill weight drill in fluid in the well has been conditioned thoroughly after TD of the well h Check the well heading vertical height and alignment of XT i Confirm the rig BOP s have been configured as per the schematic in Appendix 11 and the 10 Middle Pipe Rams have been pressure tested to 4000psi at surface j Confirm
101. scraper 45 m min e Maximum running speed with Riser Brush Tool 30 m min e DONOT allow the Riser Brush Tool to tag the flex joint e All depths to be confirmed by the Santos Completions Supervisor 7 3 2 Whilst RIH make 3 scraper passes of the 9 5 8 casing and the riser over the required depths as detailed in Section 7 2 e Circulate with mud at maximum rate during the scraping whilst RIH e Rotate at a maximum of 0 e Brushing of the riser and casing scraping to take place simultaneously where possible e Keep the bit away from the lower completion packer 7 3 3 With the bit at its deepest point after the scraper passes approx 1670m spaceout and function all the BOP rams and annulars Except 10 amp blind rams Condition mud at maximum achievable rate e Take all returns over the shakers to monitor for scale debris cuttings e Circulate a minimum of 1 2 cased hole riser volumes 600 bbls or until no more debris is observed at the shakers 7 3 4 Pick up to position the SABS tool just below the wellhead drop the 2 3 8 ball and allow 5 mins for the ball to seat Apply 900 psi to shear the tool closed to the bit Jet the BOP and annular cavities with mud e Completions Supervisor to witness ball calliper and record shear pressures e Maximum rotation of 10 rpm during jetting e Maximum circulation of 18 bpm when jetting tool is across rams e Maximum circulation of 8 bpm when jetting tool is across annulars e Boost the
102. t Allow 24 hours settling time for the brine in the pits to allow settlement and removal of solids Prior to any slickline toolstrings being RIH an as run schematic with all toolstring components connection details OD s and ID s is to be generated and signed off by the Expro Slickline Supervisor and Santos Completions Supervisor An ID amp OD Interface table is included in Appendix U The Santos Completions Supervisors to review the slickline fishing tools inventory is sufficient for the toolstrings in Appendix L 5 2 Well Control During Completion Running a b c d The Lower and Upper Completions will be run in a well with overbalance fluid for the primary barrier A review of the well control precautions and actions should be undertaken for each stage of the completion program Appendix R is included as a guide for each stage of running of the completion Ensure a sufficient volume of inhibited kill weight calcium chloride brine is available in case of seepage losses Displacements must be monitored and recorded by the driller and mud loggers throughout the completion operations The trip tank should be monitored at all times to ensure tubing is self filling Well control crossover subs shall be available on the drill floor with one made up to the well control valve to suit the relevant tubing size during the current operation The following xovers will have been shipped out to the rig i 3x4 IF Box x 7 KS Bear
103. t landing bowls to the TH on deck h Review well control guidelines as per Appendix R 10 2 Install Tubing Hanger 10 2 1 Conduct JSA Running Tubing Hanger 10 2 2 Change handling gear to 5 Drillpipe Elevators 10 2 3 Pick up Tubing Hanger sub assembly UCO06 c w the THHTT to the rig floor 10 2 4 Make up the TH to the string e The THHTT is rated to 500 000lbs with no pressure in the tubing 10 2 5 Make up a well control valve to the top of the THHTT Record pick up running and static weights 10 2 6 Raise string to bring bottom of TH to working height and set in slips 10 2 7 Install 2 x lifting eyes into side of helix remove helix securing pins and lower helix to the RT PRIVATE AND CONFIDENTIAL Page 31 of 83 Rev 0 CASINO 5 COMPLETION PROGRAMME Santos 10 2 8 10 2 9 Attach SSSV test line to port B on the THHTT Flush through until clean fluid exits from below the TH Confirm the port is correct e Only NAS 6 cleaned HW525 control fluid to be used for SSSV control lines pump and all fittings flushed with filtered Flush with only the BOT supplied chemical injection pump gauge manifold and hoses This equipment is to be dedicated for use with the SSSV Terminate SSSV line to port as per JAM Nut Installation Procedures in the Casino Completions Manual e Bleed off pressure locked in lines prior to commencing termination e Use the JAM Nut seating fixture to swage down the ferrules e BOT Engineer to unde
104. therwise stated f A maximum of 5000lbs set down weight can be placed on the ESS before packer setting g Lift sub installation for ESS to be undertaken by only the Weatherford Technician h Only the Weatherford supplied micro grip wrench to be used on the ESS No chain tongs to be used i Slips to be set between the black bands marked on the ESS j Flush box and pin connections of ESS with water prior to make up k ESS connections to be stabbed and made up by the by Weatherford Technicians only l Weatherford Technician to remain on the drill floor at all times for make up and running of the ESS to TD m A dog collar to be used when making up all ESS amp completion tubing connections n Rig crew to watch ESS make up video prior to operations o The number of 6 77 Drill Collars 5 HWDP for the ESS expansion will be determined after TD of the 12 Y hole section p The Drill Collars and HWDP to be used in ESS expansion should be inspected for cleanliness and drifted to 2 6 minimum Scale and debris could block the ESS expansion tools Use HWDP and DC s recently used in drilling where possible q Drift all drill pipe above the EXP packer to 2 minimum EXP Packer setting ball is 1 PRIVATE AND CONFIDENTIAL Page 19 of 83 Rev 0 CASINO 5 COMPLETION PROGRAMME Santos 6 2 Make up ESS and Lower Completion EXP packer 6 2 1 Function the BOP shear rams and 10 rams to displace any solids from the cavit
105. tion running if possible a b c d e f g h j Identify all Expro Landing String System equipment on rig and check all equipment referring to Scope Of Supply drawing The LS IWOCS umbilical reel and both HPUs shall be located on the forward starboard deck refer to Deck Management Plan Connect appropriate rig clean air supplies to the two control panels and the umbilical reel Spool out some umbilical to check that reeler is functioning correctly Conduct JSA installing umbilical Install cable sock on umbilical Spool out umbilical and install over sheave and tie off tail to main umbilical Pick up sheave and umbilical to derrick and secure Continue to spool out umbilical routing it suitably within the derrick down to the drillfloor Position THRT SSTT assembly on the forward deck near the catwalk refer to Deck Management Plan Connect the HPUs to reel jumper s Flush and pressure test all umbilical lines as per Expro Landing String Operational Manual Connect hydraulic pigtails of umbilical to THRT SSTT Carry out Landing String pre running preparations in accordance with Expro procedures These should include as a minimum Pressure test hydraulic functions under Cameron supervision to check that the umbilical to THRT SSTT connections are leak tight Verify that the THRT is connected to the SSTT correctly Function testing and drift of all valves to the THRT to 7 300 with the Santos
106. to be used in an Emergency eg loss of anchors or for well control 1 Completion string close to surface POOH and lay down 7 KSBEAR tubing joints completion assemblies Change over to 5 Drill pipe handling equipment Make up 25 000lbs of Drill Collars HWDP Install a 9 5 8 DLT packer RIH on 5 Drill pipe and hang off DLT packer in 1 joint of 9 5 8 casing Pressure test the DLT packer POOH above the BOP s Close the BOP Shear rams Pressure test between DLT packer and shear rams Disconnect LMRP ideally after displacement of the marine riser with water Barrier Status 9 5 8 DLT Packer Kill Weight Brine Shear Rams 2 Completion string inside casing a Remove 7 KSBEAR tubing joints as required so as to space out once humg off in the 9 5 8 casing the Wireline Entry Guide above the lower completion and the SSSV above the 9 5 8 x 10 casing xover If TRSSSV in hole cut control line if required and plug end Install a 7 KSBEAR x 4 77 IF Xover on top of the 7 KSBEAR completion Change over to 5 Drill pipe handling equipment Install a 9 5 8 DLT packer to the top of the completion RIH on 5 Drill pipe and hang off DLT packer in 1st joint of 9 5 8 casing Pressure test the DLT packer POOH above the BOP s Close the BOP Shear rams Pressure test between DLT packer and shear rams Disconnect LMRP ideally after displacement of the marine riser with water Barrier Status 9 5 8 DLT Packer Kill Wei
107. tuator sleeve using the THRT SSTT e Install the Cameron re enforced cover on the TH prior to locking e The TH must be in the locked position for installation of the THRT as the weight of the THRT SSTT is insufficient to lock the TH Connect the HPUs to reel jumper s Lower the THRT SSTT to drill floor and remove THRT test cap under Cameron supervision Pick up the THRT SSTT and prepare for latching to the TH as per the Cameron OMM Align the key on the THRT with the TH slot and lower and latch into TH as per the Cameron OMM Function THRT LATCH and observe piston movement Test the THRT to TH interface connection by pressuring up VENT TEST RETURN to 5000 psi for 5 minutes PRIVATE AND CONFIDENTIAL Page 34 of 83 Rev 0 CASINO 5 COMPLETION PROGRAMME Santos 11 2 14 11 2 15 11 2 16 11 2 17 11 2 18 11 2 19 11 2 20 11 2 21 11 2 22 11 2 23 11 2 24 11 2 25 11 2 26 11 2 27 11 2 28 Test the SSSV control line through the LS IWOCS to the TH to 5000psi for a 5 minute confidence test Maintain 5000psi running in hole e SSSV will close if differential pressure between control line and tubing falls below 2 000 psi Perform Unlock function on TH as per the Cameron OMM Install 2 x shear pin assemblies into side of TH actuator ring while ring is in UNLOCKED position Ensure SOFT LANDING SUPPLY pressure is set to 3000 psi as per Cameron OMM Prior to RIH ensure that the following lines are
108. tugger to the top drive and function test Slickline air tugger will be connected to the top drive air supply PRIVATE AND CONFIDENTIAL Page 37 of 83 Rev 0 CASINO 5 COMPLETION PROGRAMME Santos 12 2 3 Changeout the 15ft bails for 22ft bails 12 2 4 Connect 45 ft bails by shackling to the 22 ft bails 12 2 5 Pick up Flowhead over wind wall to rig floor Whilst horizontal install hydraulic control lines to flowhead if line length allows and remove test caps and top blanking sub e Ensure lifting bridle will clear derrick A frame as Flowhead must lift above wind wall level to enter drill floor e The Flowhead is an unbalanced load beware of Flowhead flipping over when transferring load to the blocks 12 2 6 Install the no cross coupling on the top of the 9 5 8 New Vam tubing ready for flowhead makeup 12 2 7 Pick up the flowhead to the vertical position Make up the saver pup and the flowhead landing joint to the landing string e Pin end of landing joint must be tied off to more than 1 tag line to control movement during this operation e Monitor the painted line on the swivel to ensure no connections back out 12 2 8 Connect the Coflexip onto FWV of the Flowhead 12 2 9 Connect the kill hose to the check valve on the KWV of the Flowhead Line up the cement unit via the KWV for pressure testing 12 2 10 Rig up remainder of Flowhead hydraulic control lines as required e The FWV will be controlled by the Well test ESD
109. ul Chipperfield 1 Cameron Project Manager 13 Terry Blake 1 Fugro Operations Manager ti M 14 Leen Vlot 1 Schlumberger C Manas Well Services PRIVATE AND CONFIDENTIAL Page 3of 83 Rev 0 CASINO 5 COMPLETION PROGRAMME Santos 1 0 2 0 3 0 4 0 5 0 6 0 7 0 8 0 9 0 10 0 11 0 TABLE OF CONTENTS INTRODUCTION sicario ta 7 1 1 SCOPE Mec MH 7 1 2 nn HR 7 1 3 Doc ment Str cture__ U U U aras 7 1 4 ler cota 7 1 5 Santos Completions and Subsea Supervision 7 1 6 PreparatiOM re iaaa 8 1 7 Reporting and Record 8 1 8 Management of Change sisi iii tii 9 1 9 hie a Aa 9 110 ADDrFeVIatI oS u LIU Rx 9 WELL AND RESERVOIR DATA aa 11 DisBEYpaptlc 12 3 1 Pre Completion Status ASSUMPTIONS u 12 3 2 Pre Completion Status 12 COMPLETION OUTLINE AND TIME ESTIMATE 14 PREPARATION FOR COMPLETION INSTALLATION 15 5 1 t
110. ulars in the Upper Completion are 13 Chrome and should be handled accordingly Deck crews are to be briefed on the correct handling of chrome tubulars Refer to the Casino Completions Manual for JFE KS Bear Connection data and Chrome Handling Procedures Each joint of 7 tubing has been drifted laser measured and had its threads inspected onshore The tubing will be shipped offshore in re usable racks holding 9 joints with each joint numbered near the pin end and with tally details attached The threads have been treated onshore with Rust Veto 51 a protective coating designed to prevent corrosion All dope application will be done on the rig Re drift on the rig will only be required if damage to a tubular is suspected The 7 5 8 13Cr FOX tubing joints have been prepared as per the 7 tubing but have not been drifted The 7 5 8 tubing will require drifting on the rig prior to running Expandable Sand Screens and sub assemblies to be tailed in to the rig floor Bestolife 72733 is to be used to dope any connections The Rust Veto 51 must be wiped with a cloth from the pins and boxs just prior to make up Bestolife 72733 is to be applied sparingly to the pin end and only the seal face of the box connection with a small brush at the rig floor These operations are not to be conducted over the hole Racks will be positioned on deck such that all pin ends face Forward i e pins away from the rig floor Vertical posts must be wrapped in
111. upper plug on 6 THRT SSTT POOH 23 Pull BOP s 16 24 Run XT debris cap 1 25 Pull anchors amp move to next well 20 Total Hrs 165 Total Days 6 9 PRIVATE AND CONFIDENTIAL Page 14 of 83 Rev 0 CASINO 5 COMPLETION PROGRAMME Santos 5 0 PREPARATION FOR COMPLETION INSTALLATION 5 1 General a b c d e f g k This section is to be used in conjunction with the remaining sections of this program Hand tools must be tethered and the hole must be covered with the Santos supplied hole cover when any work is being carried out over the RT To minimise man riding operations use the cherry picker or supplied temporary work platforms The proposed completion schematic is given in Appendix A Make up torques and completion tubular information is included in Appendix E Confirm make up torques with the Weatherford casing crew Details of the completion sub assemblies to be run in this well and the naming convention are included in Appendices F and G Ensure the pits and all surface lines are thoroughly cleaned prior to taking on the calcium chloride brine The cleanliness of the pits must be verified by the Mud Engineer Final verification of the pit cleanliness will be made by the Santos Completions Supervisor Calcium chloride to be handled as per the MSDS sheet The calcium brine will be pre mixed and unfiltered The weight must be adjusted on the rig to achieve the desired kill weigh
112. xpro personnel that the THRT latch functions are pressured to 5 000 psi ready for pressure below the lower annular 13 2 13 Close the lower annular round the annular slick joint and apply 1500 psi from the cement unit line below the closed rams until returns from TH soft land have ceased Monitor CSM line e This pressure will apply the additional force required to fully set the TH seals 225 000lbs required 1500 psi equates to an additional 138 000 Ibs 13 2 14 Lock TH as per Cameron OMM 13 2 15 Open the lower annular and perform a 50 000 Ibs overpull above downhole completion weight 13 2 16 Set down completion weight less 25 000 Ibs to keep SSTT in tension Install Expro rotary bushing inserts e Maintain this tension throughout the remainder of the completion operation e Check compensator position should be set around mid stroke and travel due to tide and heave monitored closely 13 2 17 Confirm with Cameron and Expro personnel that the THRT latch functions are pressured to 5 000psi ready for pressure below the lower annular and 10 34 rams e Ensure THRT Latch pressure exceeds applied annulus pressure to prevent unlatching 13 2 18 Close the lower annular round the annular slick joint and pressure test to 200psi for 5 minutes and 3 000 psi for 10 minutes from the cement unit line below the closed annular Monitor the CSM line Open the lower annular 13 2 19 Open AAV confirm with ROV 13 2 20 Close the 10 pipe rams r
113. y BOP s on greased painted joint Record height of the ram marks from the bore protector retrieval tool Determine the depth of ram mark e Strap dillpipe on POOH to confirm RT to XT datum e Inspect Drill Through Bore Protector for damage and report condition on Daily Completions report PRIVATE AND CONFIDENTIAL Page 28 of 83 0 CASINO 5 COMPLETION PROGRAMME Santos 9 0 RUN UPPER COMPLETION Barrier Status Location Primary Barrier Secondary Barrier Tubing Kill weight calcium chloride BOP brine Ang Kill weight calcium chloride BOP brine 9 1 General a Completions Supervisor to generate a running tally Spaceout upper completion assemblies as per section 6 3 Highlight the potential points where the WEG may hang up on i e BOP s XT and 10 27 x 9 5 8 xover Confirm the spaceout with the Completions Team in the Perth office prior to commencing running of the lower completion b All Jam Nuts to be made up as per Jam Nut Installation Procedures in the Casino Completions Manual c Review well guidelines as per Appendix R d All pumping operations to use inhibited kill weight calcium chloride unless otherwise stated e Refer to Appendix E for make up torque values 9 2 Run Muleshoe and Tailpipe 9 2 1 Conduct JSA Handling and Running Tubulars and Completion Assemblies 9 2 2 Rig up Weatherford handling equipment and tongs dressed for 7 29 13Cr80 KSBear tubing 9 2 3 Pick up Wireline Entry

CD-4000-P15-006 CASINO 5 COMPLETION PROGRAMME REV0

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