SAUDI ARABIAN OIL COMPANY (Saudi Aramco) G. I.

Number APPROVED
1853.001
GENERAL INSTRUCTION MANUAL
ISSUE DATE REPLACES
ISSUING ORG. DRILLING & WORKOVER 06/03/18 11/10/2014
ISOLATION BARRIERS FOR WELLS DURING DRILLING & APPROVAL PAGE NO.
SUBJECT
WORKOVER OPERATIONS (WITH AND WITHOUT RIG) AAR 1 OF 7

CONTENT:

* This document provides guidelines for Drilling & Workover when using well isolation barriers. Isolation
barriers are required when removing surface control equipment during drilling or workover of oil or gas
wells. These instructions are also applicable to Drilling & Workover wellhead repair work when
performed with and without a rig on location.

1. OBJECTIVE
2. BACKGROUND
3. MINIMUM REQUIREMENT
4. TYPES OF ISOLATION BARRIERS
5. RELIABILITY OF ISOLATION BARRIER
6. WAIVER

1.0 OBJECTIVE:

* The purpose of this GI is to ensure to ensure safe operations during drilling, workover, completion,
routine intervention and wellhead repair activities via strict compliance to the guidelines contained
in this GI. Deviation from these guidelines will not be permitted unless a waiver is obtained from the
Vice President of Drilling & Workover or designated representatives.

2.0 BACKGROUND:

* When drilling or working over wells, with or without a rig, situations arise where surface equipment
such as Blowout Preventers (BOPs), wellheads, master valves and trees have to be removed for
various reasons. For these operations, surface well control equipment (WCE) must be temporarily
removed. Before removal of surface WCE, down-hole isolation barriers must be in place and tested
providing isolation of reservoir pressure and allowing safe work operations to continue around the
wellhead. More than one isolation barrier is normally required in certain wells in case of unexpected
failure of the primary barrier. Adequate barrier redundancy reduce the chances of uncontrolled
surface flow (blowout) and costly repair work.

3.0 MINIMUM REQUIREMENT:

The following guidelines will apply at all times unless a waiver has been obtained from Vice
President of Drilling & Workover (as described in paragraph 6.2). The mandatory number of
barriers in each case is the minimum; any additional barriers are optional, dictated by the well
condition and down-hole completion equipment.

* CHANGE ** ADDITION NEW INSTRUCTION COMPLETE REVISION

SAUDI ARABIAN OIL COMPANY (Saudi Aramco) G. I. Number APPROVED
1853.001
GENERAL INSTRUCTION MANUAL
ISSUE DATE REPLACES
ISSUING ORG. DRILLING & WORKOVER 06/03/18 11/10/2014
ISOLATION BARRIERS FOR WELLS DURING DRILLING & APPROVAL PAGE NO.
SUBJECT
WORKOVER OPERATIONS (WITH AND WITHOUT RIG) AAR 2 OF 7

3.1 Oil Wells (GOR less than 850 scf/bbl)

2 (two) barriers, at least one of which is mechanical. (See notes below)

3.2 Oil Wells (GOR more than 850 scf/bbl)

3 (three) barriers, at least two of which are mechanical. (See notes below)

3.3 Oil Wells (Dead Wells – 0 psi when the ESP is not running)
1 (one) mechanical barrier for tubing - While continuously pumping kill fluid down the
Tubing / Casing Annulus.

Notes:
a) For completing wells with tubing and down-hole packer, the barrier guideline is
applicable to tubing only. A minimum of 2 (two) barriers are required for the
Tubing/Casing Annulus (tubing hanger and packer seals).
b) For de-completing well with down-hole packer, the barrier guideline is applicable to the
Tubing. The shut-offs for the tubing/casing annulus (TCA) are:
1. Packer.
2. Tubing Hanger.
3. Positive pressure test of Casing. 1
If any one of the barriers are deemed to be ineffective or questionable, an additional
Cement Plug or a Thru-Tubing Drillable Bridge-Plug (TTBP) must be placed above the
producing / injecting zone, capped with cement. The Top of Cement (TOC) must be tagged.
1
If test fails and it is not possible to isolate the reservoir, then a tested tubing hanger and
TCA standing full with kill-weight fluids or continuously pumping kill-weight viscous
fluid down the TCA is acceptable.

c) For de-completing wells with up-hole packer completions it is mandatory that full
circulation is established with kill fluid. If full circulation is not achieved a Cement Plug or a
TTBP capped with cement is required. The TOC must be tagged.
d) For Wells equipped with ESP (without ‘Y’- assembly) and positive Wellhead
Pressures, the barrier guideline is applicable to the Tubing. The barriers for the
tubing/casing annulus (TCA) are:
 Tubing Hanger
 TCA standing full with kill-weights fluid or continuously pumping kill-weight
viscous fluid down the TCA.
e) When changing the tree above the master valve on wells that have a pressure tested
master valve, only one barrier in addition to the master valve is required. This additional
barrier should be mechanical.

* CHANGE ** ADDITION NEW INSTRUCTION COMPLETE REVISION

SAUDI ARABIAN OIL COMPANY (Saudi Aramco) G. I. Number APPROVED
1853.001
GENERAL INSTRUCTION MANUAL
ISSUE DATE REPLACES
ISSUING ORG. DRILLING & WORKOVER 06/03/18 11/10/2014
ISOLATION BARRIERS FOR WELLS DURING DRILLING & APPROVAL PAGE NO.
SUBJECT
WORKOVER OPERATIONS (WITH AND WITHOUT RIG) AAR 3 OF 7

f) ** For oil wells completed with ESP without packer and positive SIWHP, the guideline
is applicable for the tubing only. A tested tubing hanger in addition to continuously
pumping kill fluid down the TCA is acceptable for NU/ND BOP’s.

3.4 Water Injection Wells

 If positive WH pressure, 2 (two) barriers are required, one of which is mechanical.

 If no WH pressure, 1 (one) barrier is required.

Notes:
a) Water Injection Wells encountering Loss Circulation (LC) after pumping kill fluid.
It is acceptable to Nipple-Up (NU) or Nipple-Down (ND) the BOPE on top of the injection
tree by closing the Master Valve and continuously pumping kill fluid down the well-bore.
No additional barriers are required as long as the Master Valve was never removed and has
been pressure tested prior to NU/ND of the BOPE.

b) Injection Wells with guide string extended into the Open Hole.
If the Tubing/Casing Annulus (TCA) is not standing full, the guideline is applicable for the
tubing only. A tested tubing hanger in addition to continuously pumping kill fluid down the
TCA is acceptable for NU/ND of BOP’s.

c) Injection Wells equipped with 10” PWI Trees and Master Valve passing.
A cement plug pumped from surface and tested in addition to the well standing full with kill
fluid is acceptable.

3.5 Gas Wells

3 (three) barriers, two of which are mechanical.

Notes:
a. For completion, the 3 (three) barrier guideline is applicable to the tubing only. A minimum
of 2 (two) barriers are required for the tubing-casing annulus (tubing hanger and packer
seals).
b. For de-completion positive pressure test of the tubing & TCA with kill fluid in both sides
is mandatory.

c. When changing the tree above the master valve on wells that have a pressure tested master
valve, 2 (two) barriers in addition to the master valve (barrier) are required.

* CHANGE ** ADDITION NEW INSTRUCTION COMPLETE REVISION

SAUDI ARABIAN OIL COMPANY (Saudi Aramco) G. I. Number APPROVED
1853.001
GENERAL INSTRUCTION MANUAL
ISSUE DATE REPLACES
ISSUING ORG. DRILLING & WORKOVER 06/03/18 11/10/2014
ISOLATION BARRIERS FOR WELLS DURING DRILLING & APPROVAL PAGE NO.
SUBJECT
WORKOVER OPERATIONS (WITH AND WITHOUT RIG) AAR 4 OF 7

3.6 Water Supply Wells (with or without submersible pump)

- * If well flows to surface, 1 (one) mechanical barrier or cement plug (tagged and tested) is
required with kill weight fluid in the well-bore. For wells with less than or equal to 150 psi
SIWHP and GPM ≤250, a kill fluid with stable fluid column (per 5.2.2) will be considered
a barrier. In addition, the well has to be secured and monitored during crew breaks.

- If well does not flow to surface, no barrier is required.

4.0 TYPES OF ISOLATION BARRIERS:

4.1 A number of acceptable isolation barriers or shut-off alternatives are available and can be
used under different operating conditions. These barriers can be separated into two main
groups: Mechanical and Non-Mechanical.

4.2 The following are examples of Mechanical and Non-Mechanical isolation barriers. The type of
barrier to be utilized will depend on the well condition and down-hole completion equipment.
These barriers include, but are not limited to:

Mechanical:
- Drillable or Retrievable Bridge Plug
- Retrievable Tubing Plug
** - Tubing Hanger (for TCA side)
- Back Pressure Valve
- Surface Valve
- Un-perforated Casing
** - Cement plug, tagged and positive tested
** - SCSSSV with zero leakage or mechanical plug installed and positive tested.

Non-Mechanical:
- Kill Weight Fluid
- Cement
- Freeze Plug (Well must be standing full with kill wt. fluids and the temporary freeze plug
subsequently tested.)

GLASS AND CERAMIC DISKS:

Both types can be considered a barrier when completing a well under the following
conditions:

a. The disks must be rated to hold the formation pressure from below. The working
pressure must be a minimum of 20% higher than the anticipated formation pressure.
b. They are only used during BOP nipple down and tree nipple up operations.
c. A negative test must be successfully performed on the disks.
d. After the negative test, the integrity of the disks may not be compromised by any
subsequent operation (e.g.: wire-line, CT work, dropped objects, etc.)
e. They must be used in conjunction with a BPV.
* CHANGE ** ADDITION NEW INSTRUCTION COMPLETE REVISION
SAUDI ARABIAN OIL COMPANY (Saudi Aramco) G. I. Number APPROVED
1853.001
GENERAL INSTRUCTION MANUAL
ISSUE DATE REPLACES
ISSUING ORG. DRILLING & WORKOVER 06/03/18 11/10/2014
ISOLATION BARRIERS FOR WELLS DURING DRILLING & APPROVAL PAGE NO.
SUBJECT
WORKOVER OPERATIONS (WITH AND WITHOUT RIG) AAR 5 OF 7

5.0 RELIABILITY OF ISOLATION BARRIERS:

5.1 Equipment Testing

5.1.1 * Vendor Testing: Prior to approval of a mechanical pressure isolation device, the
vendor must complete the testing requirements as detailed in the Saudi Aramco
Testing/Acceptance Criteria for Bridge Plugs / Ceramic Discs / Downhole Valves
Used as Barriers.

5.1.2 Field-Testing: Whenever a mechanical isolation barrier is installed in a well, every

effort should be made to field test and insure the barrier is holding. Since plugs are
designed to hold pressure from above, below or from both directions, the field test
should be designed according to the plug functionality.

5.1.3 During drilling or working over a well, if BOPE repairs are required, the
mechanical isolation barriers must be installed and positive tested.

5.2 Kill Fluid

5.2.1 Kill weight fluid can be used as one of the isolation barriers as mentioned in
section 4.2 above. In order for the kill fluid to be effective as an isolation barrier,
two conditions must be met:

a) * The hydrostatic pressure of the kill fluid column must exceed the reservoir
pressure by a minimum of:
 100 psi overbalance for water supply wells
 200 psi overbalance for oil wells and PWI wells.
 300 psi overbalance for gas wells.

b) The wellbore kill fluid must remain static at surface for a period of time (as
per item 5.2.2 below) to insure the presence of a reliable barrier.

5.2.2 The following are the minimum mandatory observation times for a kill fluid to
be declared static:

Oil Well (GOR less than 850 scf/bbl): 1 hour

Oil Well (GOR more than 850 scf/bbl): 2 hour 1
Gas Well 3 hours 1
Water Injector 1 hour
Water Supply Well 30 minutes
1
The depth and permeability of the producing formation should be taken into consideration.
Deeper or less permeable producing formations may need longer observation period.

* CHANGE ** ADDITION NEW INSTRUCTION COMPLETE REVISION

SAUDI ARABIAN OIL COMPANY (Saudi Aramco) G. I. Number APPROVED
1853.001
GENERAL INSTRUCTION MANUAL
ISSUE DATE REPLACES
ISSUING ORG. DRILLING & WORKOVER 06/03/18 11/10/2014
ISOLATION BARRIERS FOR WELLS DURING DRILLING & APPROVAL PAGE NO.
SUBJECT
WORKOVER OPERATIONS (WITH AND WITHOUT RIG) AAR 6 OF 7

6.0 WAIVER:

6.1 The above instructions will be mandatory when drilling or workover of a well (with or without
a rig) by the Drilling & Workover organizations, unless prior management approval has been
secured. A written waiver to divert from the established guidelines must be obtained when an
unusual well situation dictates the need for fewer barriers than stipulated. Obtaining a waiver
to reduce the number of isolation barriers is highly discouraged and should only be considered
when there are no other alternatives.

6.2 The waiver will be requested by submitting Waiver Request Form Waiver - 01 (see
Appendix I) documenting the well situation, explaining why a waiver is necessary and
explaining the impact of the waiver. Waiver signature approval level will be Vice President
of Drilling and Workover or designated representative.

Recommended by:

Hussain M. Al-Haleimi
Chairman, Well Control Committee

Concurred by:

O.S. Al-Husaini, General Manager K.A. Al-Abdulgader, Chief Drilling Engineer

Drilling & Workover Operations Drilling Engineering

Approved by:

A. A. Al-Rushaid, Vice President

Drilling and Workover

* CHANGE ** ADDITION NEW INSTRUCTION COMPLETE REVISION

 Appendix I GI 1853.001
Page 7 of 7
WAIVER REQUEST FOR ISOLATION BARRIER
Saudi Aramco Form: Waiver 01(10/98) Date Requested Waiver Request#

Well Name & Number Plant# Facility Connected to

Include number, Paragraph, and Issue date of this affected GI

Waiver request After-the-fact Y N

Justification (include discussion of impact assessment) Impact Assessment

Y N
Financial Impact
WAIVER ORIGINATOR

Y N
Safety Impact

Discuss under justification

Alternative to waiving requirements

Originating Department Originator’s Name Signature Date

Phone:
Originating Department Manager Signature Date

REMARKS

Well Control Committee Chairman Signature Date

Name:
APPROVAL

Vice President or Designated Representative Signature Date

Name:

Saudi Aramco: Company General Use