GRADWELL OILFIELD PRIVATE LIMITED

OPERATION MANUAL GR-OM-0201

PRODUCT DESCRIPTION: WIRELINE SET PERMANENT BIG BOY BRIDGE PLUG

MODEL: GR-BP-W2 DATE: 04-08-2018

A. DESCRIPTION:
The Big Boy Bridge Plug has proven to be a product that can be depended on. It has
excellent running characteristics and secure sets. The plug can be set on different types of
wireline pressure setting tools.
The Big Boy is designed for rapid drill-out while maintaining sufficient strength during the set.
This plug sustains high pressures and temperatures.

B. APPLICATION:
• Zonal Isolation during stimulation or cementing jobs
• For temporary and permanent abandonments

C. FEATURES:
• Electric wireline set
• Drillable
• Cast iron construction
• One piece slips - hardened to depth of wicker only
• Sets in any grade casing including P-110
• Form-fitting metal back-ups prevent rubber extrusion
• For temporary or permanent service
• Ratcheting lock ring holds setting force

D. ELEMENT SELECTION GUIDE:

PACKING ELEMENT SYSTEM

TEMPERATURE RATING

MATERIAL 80 DURO 90 DURO

NITRILE 70 TO 275°F 70 TO 300°F

HNBR 70 TO 325°F 70 TO 350°F

VITON 70 TO 350°F 70 TO 400°F

AFLAS 70 TO 400°F 70 TO 450°F

GR-BP-W2

PREPARED BY DK DATE 04-08-2018 REV. No. 00 Page No.

APPROVED BY R.K DATE 04-08-2018 DATE - Page 1 of 8

 GRADWELL OILFIELD PRIVATE LIMITED
OPERATION MANUAL GR-OM-0201
PRODUCT DESCRIPTION: WIRELINE SET PERMANENT BIG BOY BRIDGE PLUG

MODEL: GR-BP-W2 DATE: 04-08-2018

E. SPECIFICATION GUIDE:

Casing Plug Setting Tool

I.D Range in which
Bridge Plug Release
O.D. Weight O.D. Pressure Release
May Be Run Baker Size Stud Shear
Inch Lb/ft Rating (PSI) Stud Size
Min Max Value (lbs)
Inch
Inch Inch
2-3/8 3.3-5.9 1.867 2.107 1.71 5
2-7/8 6.4-6.5 2.280 2.563 2.10 5
11/16 - 16 13,000
3-1/2 5.7-10.2 2.867 3.258 2.75 5

3-1/2 12.7 2.625 2.750 5.00 5

4 5.6-14 3.340 3.732 3.12 10

4-1/2 9.5-16.6 3.826 4.090 3.50 10

7/8 - 14 30,000
4-1/2 9.5-13.5 3.920 4.560 3.71 10

5 11.5-21 3.920 4.560 3.71 10

5-1/2 13-25 4.580 5.047 4.24 20

5-3/4 22.5-25.2 4.580 5.047 4.24 20

10,000
6 14-26 5.140 5.595 4.75 20

6-5/8 34 5.140 5.595 4.75 20

6 10.5-12 5.595 6.366 5.34 20

6-5/8 17-34 5.595 6.366 5.34 20

7 23-40 5.595 6.366 5.34 20

6-5/8 17-22 5.989 6.655 5.61 20

7 17-35 5.989 6.655 5.61 20

7-5/8 20-39 6.625 7.263 6.09 20

1-1/4- 12 50,000
8-5/8 24-49 7.511 8.248 6.96 20

9-5/8 29.3-53.5 8.435 9.063 7.71 20

10-3/4 54-81 9.250 9.784 8.71 20

10-3/4 32.7-51 9.850 11.150 9.50 20

11-3/4 38-60 9.850 11.150 9.50 7,500 20

13-3/8 77-102 11.633 12.464 11.56 20

13-3/8 48-72 12.347 12.715 12.00 20

16 65-109 14.688 15.250 14.25 20

18-5/8 76-96.5 17.655 18.730 17.25 3,500 20

20 133-169 17.655 18.730 17.25 20

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 GRADWELL OILFIELD PRIVATE LIMITED
OPERATION MANUAL GR-OM-0201
PRODUCT DESCRIPTION: WIRELINE SET PERMANENT BIG BOY BRIDGE PLUG

MODEL: GR-BP-W2 DATE: 04-08-2018

F. OPERATING INSTRUCTIONS:

F.1 Pre-Job Instructions:

Use casing scraper before running any equipment in the well to remove scale and other materials from the casing wall.
Any tool that is expected to grip the casing wall has to first reach the casing wall. Follow scraper with gage ring and junk
basket.
Always follow cleaning, redressing and operational procedures on the setting tool. Make certain oil levels in pressure
setting tool are correct for the well environment involved. Take into consideration the heat expansion of the oil in your
manufacturers guidelines that should be supplied with your pressure setting tool.

Use the correct plug for the temperature, pressure, casing size, casing weight and environment.

Run magnet for old wells to clear metallic bur inside the well.
Casing should have 100% cement bond before running plug in the well.

Do not overtighten plug onto setting tool. This action causes the slips to crack which leads to premature setting. Snug
tight is sufficient for a bridge plug. The lock spring or nut, depending on make of setting tool, must accompany the tension
mandrel to prevent plug from backing off.
Do not allow the setting tool weight to rest on the plug after making up. This can cause the slips to crack.

Help guide the setting tool and plug through lubricators, wellhead and blowout preventer. When running under pressure
raise tools to the top of lubricator before equalizing the pressure into lubricator.

Running speed should not exceed 300 feet per minute to avoid fluid displacement cutting on elastomer. Should setting
tool misfire, retrieve equipment no faster than it went in. Slow down for liners and other restrictions.

Never set plug in casing collar or where milling has occurred. Always set plugs in static well conditions (no fluid or gas
movement). Shock to the plug can result in failure. Warn service companies of the plug depth to avoid high impact
collisions. When using the plug for locating purposes, be gentle and ease tools onto plug. Never place tubing weight on
plug.

G. OPERATIONAL PROCEDURE:

Wireline/Hydraulic Set:
The Model GR-BP-W2 Wireline Set Permanent Big Boy Bridge Plug is set using a E-4 Wireline Pressure Setting
Assembly and a Wireline Adapter Kit. The Model GR-BP-W2 Wireline Set Permanent Big Boy Bridge Plug may also be
set hydraulically using a Model GR-HST Hydraulic Setting Tool.

G.1 On GR-E-4 Wireline Pressure Setting Tool method,

Lower tubing / work string to the required setting depth.

Charge the E-4 Wireline Pressure Setting Tool and allow 10 minutes minimum to allow the setting sleeve of WAK to fully
anchor against the host casing and energize the GR-BP-W2 Big Boy Bridge Plug. As the plug set completely, an
additional load transfer from Pressure Setting Tool will shear the release stud of Big Boy Bridge Plug and as a result the
setting tool w/ WAK is disjointed from plug.

Pressure setting tool failure can result from several causes (ex: out of date power charge or bad o-ring). In the event that
a pressure setting tool does not shear off of the big boy bridge plug and you have to pull out of the rope socket, the shear
stud will still part in a normal manner when the setting tool is fished out. This happens most commonly because the
power charge did not put-up sufficient pressure to shear the stud in the plug. The Gradwell release studs are made to
shear correctly and are held to high standards of accuracy.

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 GRADWELL OILFIELD PRIVATE LIMITED
OPERATION MANUAL GR-OM-0201
PRODUCT DESCRIPTION: WIRELINE SET PERMANENT BIG BOY BRIDGE PLUG

MODEL: GR-BP-W2 DATE: 04-08-2018

When perforating, big boy bridge plug should be protected with a minimum of ten feet of cement dumped directly on top
of plug. Cement should be given sufficient time to set up before perforating.

Perforating should not be done closer than fifty feet of big boy bridge plug.

G.2 SETTING PROCEDURE: On GR-HST Hydraulic Setting Tool method,

Drop setting ball into tubing string. Allow at least 5 minutes per 1000 ft. for ball to travel in water, and more in mud or
viscous completion fluids.

Apply pump pressure to tubing string in 500 psi increments and establish a max pressure of 3200 psi Hold pressure for
5-10 minutes. This moves and breaks slip. The application of pressure causes the piston of the Big Boy Bridge Plug to
move downward and thus the upper slip to move downward into contact with the upper cone, breaking the slip and
forcing the slips into contact with the casing.

Note: If max activation pressure is reached without any indication of activation, increase pressure by 500 psi above max
activation pressure and hold for 5 minutes. If after 5 minutes, there is still no indication of activation, there may be debris
blocking the activation pressure area. Reverse circulate in order to wash out debris that may be lodged in the ball seat
area.

Pick up on the work string to determine if the upper slips have broken. This will be indicated by additional drag on the
work string. If no additional drag is noticed, set back down and apply an additional 500 psi higher than the previous
attempt. (note: in this case if only Setting tool is still in connection with the plug).

Pull at least the minimum tension 30% of shear rating of stud. And Hold tension on the plug for a minimum of 10
minutes. Holding tension allows the packing element and backup rings to reach their full limit of expansion.

Pick up work string with an over pull load above shear rating of stud(as show in Acc Guide) to disengage the GR-HST
w/ WAK and GR-BP-W2 model Big Boy Bridge Plug.

G.3 Precautions during the Job:

During cementation on top of plug, re-tag / confirmation process for plug set depth and plugged in place, Do not apply
mechanical set down weight (over-weight) on installed big boy bridge plug. which may impact on the plug performance.

Over weight must not be above 1-3 kips on top of the plug. Over weight or retagging might aid to break/jamming of
setting tool/WAK – tension mandrel in plug body.

PREPARED BY DK DATE 04-08-2018 REV. No. 00 Page No.

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 GRADWELL OILFIELD PRIVATE LIMITED
OPERATION MANUAL GR-OM-0201
PRODUCT DESCRIPTION: WIRELINE SET PERMANENT BIG BOY BRIDGE PLUG

MODEL: GR-BP-W2 DATE: 04-08-2018

H. Recommended Drill Out Procedures For Big Boy Bridge Plug:

If conditions are normal and the instructions shown below are followed, GRADWELL Model GR-BP-W2 Big Boy Bridge
Plugs are relatively easy to drill up. The materials used in this product must satisfy strict quality control specifications
and are designed to break up into small pieces during the drilling-out operation.

It is nearly impossible to cover all the problems that may arise under every condition; however, there are certain
procedures that can be followed in most instances. Thus the recommendations listed below should be used as a guide
only and, under conditions other than normal past experience and common sense should govern the drilling-out
operation.

Suggested Rotary Operation:

1. GRADWELL Junk Basket should be installed in the drilling string in order to trap cuttings. This will serve two
purposes. It will help to eliminate the condition of continuing to drill on the same loose material. It will trap cuttings that
might cause trouble during subsequent operations in the well.

2. A new, high quality, medium hard formation rock bit with medium to short, regularly spaced teeth should be used.
Select a bit that will not “track,” and of a size that will give minimum clearance between the bit and the casing. It is
recommended that bits with “wings” between the outer teeth not be used.

3. Circulating down the drill pipe or tubing will allow larger pieces of the tool to be circulated up into the junk basket
rather than reverse circulating. This will usually result in faster drill out. When feeling for the tool, try to avoid any
impact which might break some of the teeth on the bit. Experience has shown that rotary speeds between 50 and 75
rpm will give the best results under normal conditions. Gradually set down 5,000 lbs on the tool and drill for 5-10
minutes. Drill up the mandrel which extends above the slips and allow the bit to seat on the full diameter. Gradually
increase set down weight to about 2,000 lbs per inch of bit diameter. If the rate of penetration drops, increased weight,
or varying the speed should be tried until the rate of penetration picks up.

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 GRADWELL OILFIELD PRIVATE LIMITED
OPERATION MANUAL GR-OM-0201
PRODUCT DESCRIPTION: WIRELINE SET PERMANENT BIG BOY BRIDGE PLUG

MODEL: GR-BP-W2 DATE: 04-08-2018

I. ASSEMBLY DRAWING AND PARTS LIST

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 GRADWELL OILFIELD PRIVATE LIMITED
OPERATION MANUAL GR-OM-0201
PRODUCT DESCRIPTION: WIRELINE SET PERMANENT BIG BOY BRIDGE PLUG

MODEL: GR-BP-W2 DATE: 04-08-2018

I.1 PARTS LIST

S .NO DESCRIPTION QTY.

1 BODY 1
2 SLIP 2
3 CONE 2
4 SHOE 1
5 LOCK RING BACK-UP 1
6 LOCK RING 1
7 OUTER METAL BACKUP 2
8 INNER METAL BACKUP 2
9 PACKING ELEMENT 1
10 SHEAR STUD 1
11 ROLL PIN 7

J. ASSEMBLY PROCEDURE:
1. Take Body(1) and make up Shoe(4).
2. Install Slip(2).
3. Install Cone(3) and Roll Pin(11).
4. Install Inner Metal Backup(8) and Outer Metal Backup(7).
5. Install Packing Element(9).
6. Install Inner Metal Backup(8) and Outer Metal Backup(7).
7. Install Cone(3) and Roll Pin(11).
8. Install Slip(2).
9. Install Lock Ring(6) and Lock Ring Back-Up(5).
10. Install Shear Stud(10).

Note: The Roll Pins can also be installed after complete assembly.

K. DISASSEMBLY PROCEDURE:
1. Remove Shear Stud(10).
2. Remove Lock Ring Back-Up(5) and Lock Ring(6).
3. Remove Slip(2).
4. Remove Cone(3) and Roll Pin(11).
5. Remove Outer Metal Backup(7) and Inner Metal Backup(8).
6. Remove Packing Element(9).
7. Remove Outer Metal Backup(7) and Inner Metal Backup(8).
8. Remove Cone(3) and Roll Pin(11).
9. Remove Slip(2).
10. Remove Shoe(4) from Body(1).

PREPARED BY DK DATE 04-08-2018 REV. No. 00 Page No.

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 GRADWELL OILFIELD PRIVATE LIMITED
OPERATION MANUAL GR-OM-0201
PRODUCT DESCRIPTION: WIRELINE SET PERMANENT BIG BOY BRIDGE PLUG

MODEL: GR-BP-W2 DATE: 04-08-2018

L. PRE-INSTALLATION INSPECTION PROCEDURES:

INSTRUCTION
Ensure the Size of Casing or Tubing Prior to running the Tool into the Well. Inspect Tool’s basic/major
dimensions (e.g. ID, OD, Length & Drift Ids etc.) as shown in this Literature or Pre-Dispatch Inspection
Report, also verify material grades (Of Both Metal & Non-metals) to confirm about its compatibility with
the Well Environmental conditions.

M. SPECIAL PRECAUTIONS AND HANDLING:

CAUTIONARY:
Use of GRADWELL equipment contrary to manufacturer’s specification may result in property damage,
serious injury or fatality. So always refer to this Technical Literature/Operational Manual and follow the
instructions strictly while operating and handling this tool.
Handle with care hand tight end thread connections, do not hold the tool by tong or wrench over seal
surface area.

N. STORAGE RECOMMENDATIONS:

Packed Product should always kept in temperature restricted environment (-10°C ~ 50°C) and safe
from water & chemical contaminated environment, all the time during transport & storage.
Once unpacked should not be exposed to any absurd atmospheric conditions, radiation, etc. for
longer time & handle with intensive care to protect external packing elements, sealing surfaces and
exposed thread connections from any debris, that could be harmful & lead to deteriorate or degrade
products performance ability.

•Packing Elements, Elastomers, Non-elastomeric Seals should be in a relaxed state –free from tension,
compression or any other deformation.
•Store the tool, if possible, in an enclosed, temperature and humidity controlled environment.
•Avoid high temperature exposure of the product over long periods of time.
•Protect elastomeric part from ultraviolet light Sources.
•Keep the tool dry and protected from condensation with thread protectors installed at ends.
•Do not store the tool in contact with or near corrosive Chemicals.
•Do not store the product near ozone generating equipment or operations such as welding.
•Product will be wrapped with oil-soaked paper for storage.
•Transparent Polythene to be used to wrap the product while storing.

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