SKM 3413 - DRILLING ENGINEERING

Chapter 6 Well Control

Assoc. Prof. Abdul Razak Ismail
Petroleum Engineering Dept.
Faculty of Petroleum & Renewable Energy Eng.
Universiti Teknologi Malaysia
The drilling well must at all time be under control
The driller/operator must be in the full control over the
well and at all time be able to prevent the formation
fluids from flowing up the well
The necessity for adequate well control and its effects on
the drilling operation can be significant
At best, the loss of well control results in both rig time
and additional chemicals required to kill the well
At worst, the loss of control can result in the loss of both
crew lives and the well and additionally can require vast
amounts of expenditure to control the well and to
compensate for the undesirable effects the blow out may
have had on the environmental around the well
In offshore environment, the effects can be even more
catastrophic since:
The safe evacuation of the crew is critical (weather,
etc.)
Offshore rig is very expensive
Logistic problem and delay of the supply of the
necessary materials and equipment
If the control of the well is unsuccessful, pollution
will occur due to oil spill
The loss of rig or platform could result in delay of
FDP programs
What is Blow Out ?
Any uncontrolled pressure
or formation fluids that
enter into the well during
drilling operation and starts
to explode
Causes of Blowout
Underbalance (low density mud, water, foam, air)
Reduce formation damage
Save money but the risk of occur blowout increased
Overbalance
Safety but has its limitation
If overbalance pressure is too high may break the formation and
cause lost circulation lead to a blowout
Swabbing (tripping out)
Pulling the drill string too fast out of the hole will cause suction
Reduce the pressure below the bit invites a kick
Going too fast in the hole (tripping in)
Break the formation can cause lost circulation
Falling object hitting and ruining the BOP
Equipment, such as plugs, BOP, DHSV fails in a critical
moment
Why well control and blow out
prevention is important?
Higher drilling costs
Injuries and possible loss of life
Lost of revenue
Waste of natural resources when blow out occur
Environmental effects
Government regulation and restriction
How to prevent blowout?
The best solution is to prevent before it happen
Develop a drilling plan, including a drilling fluid design
The proficiency of rigs crew and supervisors and their
ability to put contingency to work
Added precautions often taken in drilling exploratory wells
Identify the presence of shallow gas
Types of well control
Firstly, well control can refer to the prevention of
formation fluids entering the well bore referred to
as primary control
Secondly, should primary control fail and fluids enter
the well bore, there is the requirement to be able to
allow the influx to be discharged at surface in a
controlled manner and concurrently to prevent
additional influx of fluid into the well bore referred
to as secondary control
The control of a well refers to the ability to prevent
formation fluids flowing up the well bore and being
released at the surface
Primary control
This is the prevention of the influx of formation
fluids into the wellbore by ensuring that the
hydrostatic pressure in the wellbore is at all times
greater than the formation pressure:
P
hyd
> P
f
The hydrostatic pressure may be too low because of
the following reasons:
1. Insufficient fluid density
2. Insufficient height of fluid column
1. Insufficient fluid density
Inaccurate measurement of fluid density
High temperature encountered hence a reduction in
density occurs due to fluid expansion
At watering back (after mud return, water loss due to
evaporation, filtration loss, etc) excessive dilution
may occur
Too fine mesh used at the shale shaker lead to
removal of weighting solids
Insufficient fluid density could have been created by the
following:
2. Insufficient height of fluid column
Failure to keep the hole full when tripping out
Swabbing effect (drill pipe acts as a piston):
Pulling the pipe upwards too quickly
Using mud of very high gel strength
Having small annular clearance
Ineffective cleaning of the bit to remove drill cuttings (e.g.
bit balling)
Loss circulation occurring into the formation
Collapse of casing or leakage into the wellbore
The majority of blowouts occurs when the height of the
fluid column reduced:
Secondary control
When primary control is lost, it is not normally
possible to kill the well immediately
The well is then shut in to prevent further influx into
the wellbore; and usually, this is only a temporary
measure
Secondary control therefore refers to the use of
mechanical devices used to close off the well
This device is called a blowout preventer (BOP)
The safety and efficiency of the control depends on
the integrity of the casing strings, well head and
fittings
Secondary control could be lost due to several reasons:
Mechanical failure of the BOP
Late identification of the influx
Casing fails to burst which will render a loss to the
annular pressure seal, hence the BOP will be
ineffective
Bad cement bond the influx will channel through
the cement, hence it will be discharged uncontrollably
Operational guidelines to the maintenance of primary control
Maintenance of the correct mud weight
Gas cutting
Solids removal
Excessive dilution
Maintenance of sufficient height of mud column
Precautions whilst drilling
Precautions before tripping
Precautions whilst tripping
Precautions whilst running casing
Lost of circulation
Drilling break
Careful attention should be paid to the following factors to ensure that primary
control is maintained:
To bring oil and gas to the surface drill hole
When the rock on earth that hold back formation
pressures are removed:
The pressure will be released and free to flow
To control use drilling fluid (create hydrostatic column
of sufficient weight)
Generally, the deeper the well goes, the higher the
formation pressures that must be retained, therefore,
mud weight must be increased to keep the well
formation pressure
Some blowouts stop by themselves by one of
these reasons:
Depletion of source
Bridging of the well bore by cave-in of open hole
Choking of the formation by entrained material
Choking the well bore by entrained sand, etc
Who shall stop blowouts ?
When a blowout occurs, the operators shall leave the
location immediately and never make heroic attempts
to stop it. That would simply be too risky!
In the stressed situation the possibility of making
fatal mistakes is overwhelming
Any attempt to stop a blowout required proper
planning, equipment and a special type of people
What is kick?
1he pressure found wlLhln Lhe drllled
rock ls greaLer Lhan Lhe mud hydrosLaLlc
pressure acLlng on Lhe borehole or face
of Lhe rock
1herefore, Lhe formaLlon pressure has a
Lendency Lo force formaLlon flulds lnLo
Lhe wellbore
lf Lhe flow ls successfully conLrolled
Lhe klck has been kllled, lf noL
blowouL
Calculations
Example: What overbalance would there be in a hole
drilling at 7,000 ft if the mud weight is 9.5
ppg and the formation pressure is 3,255 psi?
Solution:
P = 0.052 (9.5) (7,000) 3,225 = 203 psi
Example: A well is drilling at 7,000 ft using 10.5 ppg mud. A
kick is encountered and the well is closed in. The
SIDPP registers 250 psi. What is the new formation
pressure and what mud weight will be required to
balance?
Solution:
New P
f
= 0.052 (10.5) (7,000) + 250 = 4,072 psi
4,072
New mud weight = ----------------- = 11.2 ppg
0.052 (7,000)
Example: A well is drilling at 5,000 ft using 10 ppg mud. A kick
occurs and the well is closed in. The SIDPP builds up
to 400 psi. What is the new formation pressure? What
mud weight will be required to enable us to drill ahead
using 150 psi overbalance?
Solution:
New P
f
= 0.052 (10) (5,000) + 400 = 3,000 psi
(3,000 + 150)
New mud weight @ 3,000 psi and 150 psi P = ------------------
0.052 (5,000)
= 12.1 ppg
What turns a kick into a blowout?
The key objectives in blowout prevention are:
To detect the kick as soon as possible
To take steps to control the circulation of the kick out of the
well
To take steps to increase the density of the fluid in the well
to prevent further fluids from entering the well
Lack of proper control !!
All kicks in some way are related to drilling fluid
The severity of the kick depends upon
several factors:
The ability of the rock (porosity, permeability) to
allow fluid flow to occur
A rock with high porosity and permeability has a greater
potential for severe kick (e.g. sandstone is considered to
have a greater kick potential than shale)
The amount of pressure differential involved
Causes of kicks
1. Insufficient mud weight
2. Improper hole fill-up during trips
3. Swabbing
4. Cut mud
5. Lost circulation
1. Insufficient mud weight
One of the predominant causes of kicks
Pressure imbalance fluids begin to flow into the wellbore
Normally associated with abnormal formation pressures
Very high mud weight (overbalance) cannot be used because:
High mud weight may exceed the fracture gradient of the
formation and induce an underground blowout
Slightly reduce penetration rates
Pipe sticking
Therefore, maintain the mud weight slightly greater than the
formation pressure until that time the mud weight begins to approach
the fracture gradient requiring an additional string of casing
2. Improper hole fill-up during trips
As the drill pipe is pulled out of the hole, the mud
level falls because the drill pipe steel had displaced
some amount of mud
With the pipe no longer in the hole, the overall mud
level will reduce, therefore, the hydrostatic pressure
of the mud will decrease
Therefore, it is necessary to fill the hole with mud periodically
to avoid decreasing of hydrostatic pressure
3. Swabbing
Swab pressures are pressures created by pulling the
drill string from the borehole
This action will reduce the effective hydrostatic
pressure throughout the hole below the bit
If this pressure decrease is large enough, there will be
potential kick
Reasons
Pipe pulling speed
Mud properties
Hole configuration (large swab pressure for small hole)
Bit balling effect
4. Cut mud
Gas contaminated mud will occasionally cause a kick
although this occurrence is rare
Mud density will decrease
As gas is circulated to the surface, it may expand and
decrease the overall hydrostatic pressure to a point
sufficient to allow a kick to occur
Although the mud weight is cut severely at the
surface, the total hydrostatic pressure is not decreased
significantly since most of the gas expansion occurs
near the surface and not at the bottom of the hole
5 Lost circulation
Decreased hydrostatic pressure occurs due to a
shorter column of mud
When a kick occurs as a result of lost circulation, the
problem may become extremely severe since a large
amount of kick fluid may enter the hole before the
rising mud level is observed at the surface
Warning signs of kicks
1. Flow rate increase
2. Pit volume increase
3. Flowing well with pumps off
4. Pump pressure decrease and pump stroke increase
5. Improper hole fill-up on trips
6. String weight change
7. Drilling break
8. Cut mud weight
1. Flow rate increase
When pumping at a constant rate, the flow rate increase more than
normal i.e. formation is aiding the rig pumps in moving the fluid up
the annulus by forcing formation fluids into the wellbore
2. Pit volume increase
If the volume of fluid in the pits is not changed as a result of surface
controlled actions, therefore, an increase in pit volume indicates that
a kick is occurring
The fluids entering the wellbore as a result of the kick displace an
equal volume of mud at the flow line and result in a pit gain
3. Flowing well with pumps off
When the rig pumps are not moving the mud, a continued flow from
the well indicates that a kick is in progress
4. Pump pressure decrease and pump stroke increase
A pump pressure change may indicate a kick
The initial entry of the kick fluids into the borehole may cause the
mud to flocculate and temporarily increase the pump pressure
As the flow continues, the low density influx will displace the heavier
mud and the pump pressure may begin to decrease
As the fluid in the annulus become less dense, the mud in the drill
pipe will tend to fall and the pump speed may increase
5. Improper hole fill-up on trips
When the drill string is pulled out of the hole, the mud level should
decrease by a volume equivalent to the amount of steel removed
If the hole does not require the calculated volume of mud to bring the
level back to the surface, a kick fluid has entered the hole and filled
the displacement volume of the drill string
6. String weight change
The mud provide a buoyant effect to the drill string, heavier muds
have a greater buoyant force than less dense muds
When kick occurs, the mud density will decrease and as a result, the
string weight observed at the surface begin to increase
7. Drilling break
An abrupt increase in bit penetration rate (shows a new rock type),
called a drilling break, is a warning sign of possible kick
Although the drilling break occur, it is not certain that a kick will
occur, therefore, it is recommended to drill 3 5 ft into the sand and
stop to check for flowing formation fluids
8. Cut mud weight
Decreased mud weight observed at the flow line has occasionally
caused a kick to occur
Possible causes is gas (also oil and water) entering the formation
However cut mud weight have small effect
Procedures in the event of a kick
At the first indication of a kick
Stop drilling
Raise the bit off the bottom of the well (to shut in the well)
Stop the pumps and check to see if there is a flow from the well
If the well does flow, close the BOP and shut in the well
Readings are taken to stabilize shut in drill pipe and
casing pressures
Calculation are made to determine the density of the
mud that will be used to kill the well
Calculations are also made to determine the kick out,
and to fill the hole with new mud
Handling procedures of a kick may vary, and no one
method can be employed to each kick situation
Factors affecting kill procedures are:
The area where the well is being drilled
The depth of the well
The operational procedures adopted by the contractor
The equipment available
Methods of killing kicks
There are many kick-killing methods, some of these
have utilized systematic conventional approach
while others were based on logical, but perhaps
unsound, principles
Commonly used methods:
1. One circulation method
2. Two circulation method
3. Concurrent method
If applied properly, each of these 3 methods will
achieve the constant pressure at the hole bottom and
will not allow any additional influx into the well
1. One circulation method
After the kick is shut in, weight the mud to kill density, then pump
out the kick fluid in one circulation using the kill mud
Other names: wait and weight method, engineers method, graphical
method, constant drill pipe pressure method
2. Two circulation method
After the kick is shut in, the kick fluid is pump out of the hole before
the mud density is increased
Other names: drillers method
3. Concurrent method
Pumping begins immediately after the kick is shut in and the
pressures are recorded
The mud density is increased as rapidly as possible while pumping
the kick fluid out of the well
1. One circulation method
At point 1, the SIDPP is used to calculate the kill mud weight, after which
the mud weight is increased to kill density in the suction pit
As the kill mud is pumped down the drill pipe, the static DPP is controlled
to decrease linearly, until at point 2 the DPP would be zero
This results from heavy mud having killed the DPP
Point 3 illustrate that the initial pumping pressure on the drill pipe would be
the total of the SIDPP plus the kill rate pressure, or 1,500 psi:
Initial pumping P = SIDPP + kill rate P
= 500 + 1,000
= 1,500 psi
While pumping kill mud down the pipe, the circulating pressure should
reduce until at point 4, only the pumping pressure remains
From the time that the kill mud reaches the bit until the kill mud reaches the
flow line, the choke controls the DPP at the circulating pressure while the
driller insures that the pump remains at the klll speed
2. Two circulation method
Kill mud is not added in the first circulation, i.e. DPP
will not decrease during this period
The purpose of this circulation is to remove the kick
fluid from the annulus
In the second circulation, the mud weight is increased
and causes a decrease from the initial pumping
pressure at 1 to the final circulating pressure at 2
The final circulating pressure is held constant
thereafter while the annulus is displaced with the kill
mud
3. Concurrent method
As soon as the kick is shut-in, pumping begins immediately
after reading the pressures and the mud density is pumped as
rapidly as possible
However, it is difficult to determine mud density being
circulated and its relative position in the drill pipe
Since this position determines the DPP, it will give irregular
pressure drops
As a new density arrives at the bit or some predetermined
depth, the DPP is decreased by an amount equal to the
hydrostatic pressure of the new mud density increment
When the drill pipe is completely displaced with kill mud, the
pumping pressure is maintained constant until kill mud reaches
the flow line
Choice of method
Determining the best control method, suitable for the
most frequently met situations, involves several
important considerations:
The time required to execute the entire kill procedure
The surface pressures arising from the kick
The complexity of the procedure itself, relative to the ease
of carrying it out
The downhole stresses applied to the formation during the
kick killing process
All of these factors must be analyzed before a
procedure can be selected
Advantages and disadvantages
of drillers method
Simple to teach and
understand
Very few calculations
In case of saltwater, the
contaminant is moved out
quickly to prevent sand
settling around drilling
assembly
Higher casing shoe pressure
(kick)
Higher annular pressure
(kick)
Takes two circulations
Advantages Disadvantages
Advantages and disadvantages
of wait-and-weight method
Lowest casing pressure
Lowest casing seat pressure
Less lost circulation (if not
over killed)
Killed with one circulation
if contaminant does not
string out in washed out
sections of hole
Requires the longest non-
circulating time while
mixing heavy mud
Pipe could stick due to
settling of sand, shale,
anhydrite or salt while not
circulating
Requires a little more
arithmetic
Advantages Disadvantages
Advantages and disadvantages
of concurrent method
Minimum of non-circulating
time
Excellent for large increases
in mud weight (under
balanced drilling)
Mud condition (viscosity
and gels) can be maintained
along with mud density
Less casing pressure than
drillers method
Can be easily switched to
weight-and-weight method
Arithmetic is a little more
complicated
Requires more, on-choke,
circulating time
Higher casing and casing
seat pressure than wait-and-
weight method
Advantages Disadvantages
What is BOP?
The BOPs are a series of powerful sealing elements designed
to closed off the annular space between the drill pipe and the
hole through which the mud normally returns to the surface
Valves are installed on the pipe or wellhead to prevent the
escape of pressure either in the annular space between the
casing and drill pipe or in open hole during drilling,
completion and work over operations
By closing this valve, the drilling crew usually regains control
of the reservoir with increase the mud density until it is
possible to open the BOP and retain pressure control the
formation
They can be hydraulically, manual or air operated and in some
cases a combination of all three
Types of BOP
BOPs come in a variety of styles, size and pressure ratings
Some BOPs can effectively close over an open wellbore, some
are designed to sealed around tubular components in the well
(drill pipe, casing and tubing) and others are fitted with
hardened steel shearing surface that can actually cut through
drill pipe
AnnularSurfaceBlowout Prenventor
PipeRamBlindRamShearRam
Ram-TypeSurfaceBlowout Preventor
SurfaceBOP DownholeBOP
BOP
Annular preventers
A large valve used to control wellbore fluids
Design to shut off around any size of equipment run through
the hole
Most blowout preventer (BOP) stack contains at least one
annular BOP at the top of the BOP stack, and one more ram-
type preventers below
It can close around drill pipe, drill collars and casing, and also
pack off an open hole
Is a wells master valve and normally closed first in the event
of a well kick, owing to flexibility of the closing rubbers
It can only be closed hydraulically by directing fluid under
pressure to the operating cylinder through the closing chamber
Pipe rams
Design to close around a particular size of drill pipe,
tubing or casing
The pack off is provided by two steel ram blocks
containing semi-circular openings with each ram
being fitted with a two-piece rubber seal
The semi-circular openings can seal around the
outside diameter of the drill pipe, tubing, drill collar,
kelly or casing, depending on the size of the rams
chosen
It can be close manually or hydraulically to seal off
the annular
Blind rams
Quiet similar to pipe rams
Except that packer are replaced by ones that have no
cutouts in the rubber
Has no space for pipe and is instead blanked off in
order to be able to close over a well that does not
contain a drill string
Designed to seal off the bore when no drill string or
casing is present
Shear rams
A BOP closing element fitted with hardened tool steel
blades
Designed to cut the drill pipe when the BOP is closed
Normally used as a last resort to regain pressure
control of a well that is flowing
Once the drill pipe is cut, it is usually left hanging in
the BOP stack and kill operations become more
difficult
The joint of drill pipe is destroyed in the process, but
the rest of the drill sting is unharmed by the operation
of shear rams
Nowadays BOPs
Can be instrumented to sense, quantify and remember
pressures, temperatures, on/off status and incremental ram
positions
The BOP Stack can be cleaning
Top and bottom unions are removable
The hydraulic actuators require a very low hydraulic
pressure to close and they close easily at high pressure
Nowadays BOPs
Equalizing valves are strong, durable, and their flow is very
controllable
Minimum height enables service rigs to work closer to ground
level
An innovative attribute on the BOP is the plumbing feature.
Single point open and close ports in each modular body permit
operation of both hydraulic for each set of rams
Operating volumes are lower, resulting in faster closing times
and smaller accumulator requirements
Control system equipment
Pressure accumulator system
Power availability
Accumulator pump capacity
Locking devices
Remote controls
Choke and kill line
BOP stack cleaning
Combination of mechanical and
chemical cleaning technology to
remove undesirable solids and other
debris from the interior of the stack
Mechanical jetting is one of the most
effective cleaning methods- water
jetting application
Innovative and modern BOPs
Coiled tubing BOP is available in bore sizes from 2
9/16" to 7 1/16" and working pressures from 5000 to
15,000 psi, with the following features:
Manual or hydraulic open/close bonnets for easy
ram change
Internal hydraulics; no external hoses assemblies
All rams hydraulically actuated with visual position
indicator and manual lock
One-piece, forged-steel body
Available in single, dual, triple and quad
configurations
Hydraulic over air pressure transmitters to convert critical
hydraulic pressures to low-pressure air signals to be
transmitted by the control air hose bundles to the remote
panels
Fail-safe, air motor-driven, pressure-reducing and -regulating
valve (with manual override) to control hydraulic pressure to
annular-type BOP
Remote Control Panels
Choke Manifold Valve Control Panels
Designed for remote control of choke
manifold hydraulic-actuated valves
Wall-mounted Panels
Designed to be used as driller's station
remote panel or auxiliary panel
Stand-alone Panels
Air-operated panels for driller's station
remote panel or auxiliary panel
BOP safety
Well control equipment that is to be install must be rate
above the maximum expected formation pressure of the
well about to be drilled
Tested immediately after installation
Maintained ready for use until drilling operations are
completed
Control panel must be located at sufficient distance from
well head
BOP equipment must be pressure tested