Sop Consolidated (Revision 2019)

STANDARD OPERATING
PROCEDURES MANUAL FOR

DRILLING OPERATIONS
Institute of Drilling Technology

ONGC
Kaulagarh Road, Dehradun
2019
1
CHAPTERS
S.No Chapter Page

1. Drilling Operations 3
2. Bottom Hole Assemblies 35
3. Drilling Bits 44
4. Drilling Hydraulics 58
5. Drilling Fluid Management 72
6. Casing Operations 140
7. Cementing Operations 156
8. Installation of Well Head 205
9. Directional Drilling 220
10. Fishing 239
11. Well Control 262
12. Wire Rope 304
13. Safety in Drilling Operations 322
14. Completion Fluid Management 331
1
1 Drilling
Operations
Drilling operations need to be carried out in a safe, efficient, and

environmental friendly manner for successfully completing the well to
meet the desired objectives. By following recommended practices, a
well can be drilled in shortest possible time and with minimum of
complications.
This chapter includes the following topics on drilling operations:
a) Preparation for spudding the well
b) Common drilling practices for all phases
c) Drilling 26" hole section
d) Drilling 17 ½" hole section
e) Drilling 12 ¼” hole section
f) Drilling 8 ½" hole section
g) Drilling 6” hole section
h) Casing test
i) Leak off test
j) Recommended practices for tripping out
k) Recommended practices for tripping in
l) Recommended practices for reaming
m) Recommended practices for back-reaming
n) Recommended practices for pack-off
o) Recommended practices for wiper trip in deviated hole
p) Recommended practices for surface seepages
q) Coring
a) Preparation for spudding the well:

1. Ensure mast centering is carried out before spudding.
2. Check and test all surface equipment viz engines, mud pumps, draw
works, compressors, mud handling equipment, mud tanks etc prior to
spudding the well.
3. Pressure test high pressure mud lines, mud pump safety valve, rotary
hose and standpipe to 3,000 psi.
4. In normal area, false conductor may be grouted 3 m below cellar pit
bottom.
5. In surface seepage prone area, false conductor may be pre-installed to a
depth of approximately 20-25 m below bottom of cellar pit along with
concrete grouting with minimum 1 meter concrete layer at surface.
6. Ensure surface casing and casing handling equipment are on location.
7. Ensure availability of GTO at appropriate places on the rig.
8. Ensure that minimum 5-7% pre hydrated bentonite suspension is
available for spudding. LCM material must be available at site for
contingency of seepage loss.
9. Hold Pre Spud meeting to short out any discrepancies.
b) Common drilling practices for all phases:

1. Hold tool box meeting.
2. Record bit make, type, serial number and height.
3. Check and record bit nozzle size before lowering the bit.
4. Check the availability of proper size of slips and condition of the
inserts with one complete set of spare dies.
5. Drill-off tests should always be carried out after lowering a new bit and
on encountering a new formation with significant reduction in ROP
and should be recorded in IADC Report. (Refer to
Chapter on Drilling Bits)
6. Record BHA weight in mud from weight indicator.
7. Ensure required bits along with the bit breakers are available on
location.
8. Ensure pump output and nozzle sizes are specified in program.
9. Gauge all stabilizers and check connections of all BHA components
10. Ensure make-up torque for all size of drill pipe, drill collars, casing
and tubing is displayed in dog-house.
11. Flow check all drilling breaks.
12. Slip and cut drill/casing line as recommended.
13. Record slow circulating pump pressure at every bit change/ mud
weight change/ every shift change/200 m of drilling.
14. Carry out safety drills.
15. Use drill pipe wiper during POOH after initial safe pull out.
16. POOH wet in case of pressure loss and expected mud cut in string.
17. Trip tank must be properly connected with suitable volume
measurement system. The shift in charge is the FPR (First Person
Responsible) to ensure that trip sheet is filled for all trip as per drilling
practices.
18. Always keep hole full and monitor pipe displacement during POOH
with trip tank and trip sheets.
19. Keep a Full Open Safety Valve (FOSV) always on the rig floor in open
position with required x-overs during all drilling operations.
20. Record, up-weight, down-weight, rotating weight of drill string and
off- bottom torque.
21. Record tight spot intervals encountered during pipe connections and
trips.
22. Monitor shakers for signs in change of cuttings.
23. Monitor pit levels for mud loss/gain.
24. After every phase of drilling, a schematic of BOP stack indicating
distance from rotary should be displayed in dog house to ensure
distance of all rams and annular BOP from rig floor.
25. Ensure schematic diagram of choke, kill manifold and MGS in rig
floor.
26. Ensure schematic diagram of flow path hard/ soft shut in procedure
and positions (Open/ Close) of choke and manual valves in up and
down stream in rig floor.(Refer to Well Control Chapter 11)
27. Ensure Mud Logging Unit is installed and calibrated.
28. Ensure SCADA system is connected and enabled.
29. Ensure that required number of drill collars and HWDP are available
for the next phase in advance.
30. Pressure tally to be maintained for BHA & after every 500 m lowering
and at shoe.
31. P/o & check string if there is any unexplained pump pressure
reduction of more than 100 psi at constant SPM after due checking of
the surface equipment.
32. Observe for minimum 10 minutes to check the static condition of the
well prior to pull out.
33. In slim hole (6’’ and Lower) pump out is recommended.
34. All tubular / Handling Tools/ X-overs/ BHA component before run in
hole must be measured including all dimensions and diagram of the
same must be available in driller’s cabin.
35. Equivalent thread connections:
4-1/2” IF=NC 50; 4” IF=NC 46; 3-1/2” IF=NC 38;
2-7/8” IF=NC31; 2-3/8” IF=NC 26
c) Drilling 26” hole section:
Preparation:
1. Record clear distance from Rotary Table to bottom of Cellar Pit.
2. Confirm 20” Casing and casing handling equipment are on location.
3. Ensure proper diameter of return flow line from conductor to shale
shaker is installed.
List of Handling Tools:

SN Items No required
1 26’’ Bit 02
2 26” Bit Breaker & bit Gauge 01
3 Float valve for bit sub 01
4 Baffle Plate 01
5 Circlip nose plier 01
6 Nozzle gauge 01
7 5” Drill Pipe Elevator (250/350 t) 02
8 6 ½"Drill Collar Elevator (150 t) 02
9 8” Drill Collar Elevator(150 t) 02
10 9 ½" Drill Collar Elevator(150 t) 02
11 5” Drill Pipe Slip 02
12 6 ½" Drill Collar Slip 02
13 8” Drill Collar Slip 02
14 9 ½" Drill Collar Slip 02
15 Bit sub (7 ⅝” RBox X 7 ⅝” RBox) 02
16 Bit sub (6 ⅝”RBox X 7 ⅝” R Box) 02
17 X-over (6 ⅝” RBox X 7 ⅝” RPin) 02
18 X-over (4 ½"IFBox X 7 ⅝” RPin) 02
19 X-over (4½" IFBox X 6 ⅝” RPin) 02
20 X-over (4” IFBox X 6 ⅝” RPin 02
21 X-over (4½"IFBox X 4” IFPin) 02
22 Kelly saver sub (4½"IF Box X IF Pin) 02
23 Drill pipe/ Drill collar dope 02 Buckets
24 26” Stabilizer 03 (1 NBS +
2 SS)
25 Drill pipe wiper 02
26 Steel Measuring tape 02
Sequence of Operations:
1. Make up 26” bit and BHA for spudding. After drilling two singles
make up string stabilizer at 18m (60 ft).
2. Install float valve with baffle plate.
3. RIH with the 26” BHA inside the 30” Conductor.
4. Use a lower flow rate when drilling around 30” shoe to avoid wash out
of the shoe. In case of severe seepage, discharge is recommended to
maintain at lowest.
5. While drilling first 50 m below false conductor, conduct controlled
drilling with only one pump or at 60-75% of recommended flow rate.
6. The flow rate then should be increased to recommended flow rate to
drill the next 30m and maintained as per chart given in Chapter on
Drilling Hydraulics for the rest of the section.
7. Drill ahead to phase target depth with control drilling to avoid annulus
loading.
8. Viscous sweeps of sufficient volume should be frequently used for
drilling this section and monitor the volume of cuttings coming out to
confirm proper hole cleaning.
9. After reaching phase TD, sweep hole with 10 m3 Hi-Vis pill of 150 sec
viscosity and circulate to clean the hole.
10. Perform wiper trip to 30” casing shoe. POOH
11. Make a round trip with 2 string stabilizers at 9m (30ft) and 18 m (60 ft)
then make a round trip with 3 stabilizers – NBS at 0 m, SS at 9 m (30ft)
& 18 m (60 ft) respectively.
12. Ream if necessary. Check for fill and circulate hole clean.
13. Wash down last single to avoid plugging of nozzle.
14. Sweep hole with 10m3 Hi-Vis pill of 150 sec and circulate clean with
recommended flow rate.
15. Circulate and condition mud. As a general practice place fresh mud of
0.05 SG higher density in well before pulling out for casing.
16. POOH to run 20” casing.
Note: In case 17 ½’’ pilot hole is drilled first, the hole should be
enlarged with 26’’ hole opener in second run.
d) Drilling 17 ½” hole section:
Preparation:
1. Ensure all required tools and material are available on the rig.
1 17 ½”Bit 02
2 17 ½” Bit Breaker 01
3 Float valve for bit sub 01
4 Baffle Plate 01
5 Circlip nose plier for nozzles 01
6 Nozzle gauge 01
8 6 ½”Drill Collar Elevator (150 t) 02
11 6 ½”Drill Collar Slip 02
13 Cross-over (4 ½”IFBox X 6 ⅝” Reg Pin) 02
14 Cross-over (4” IFBox X 6 ⅝”Reg Pin) 02
15 Cross-over (4½”IFBox X 4” IF Pin) 02
16 Kelly saver sub (4 ½”IFBox X 4 ½” IF Pin) 02
18 17 ½” Stabilizer 03 (1 NBS +
2 SS)
Sequence of Drilling Operations:

1. Install well head & BOP as per guidelines in chapter on Wellhead
Installation and Well Control.
2. Test BOP and choke & kill manifold.
3. Make up 17 ½”BHA as per well program (keep baffle plate in place).
4. RIH with 17 ½”bit and tag cement top.
5. Test casing to 500 psi or as per specific requirement of well maximum
of 80% of burst rating of casing / well head rating whichever is lowest.
6. Drill through cement and shoe with 2-3 T WOB and 50 to 60 RPM
7. Wash down to bottom of 26” hole and drill ahead 3 m fresh hole.
8. Circulate hole clean till mud is conditioned.
9. Optimum Flow rate as per land mark software calculation to keep the
hole clean depending on well profile i.e Depth/ Inclination, and
rheology of mud.
10. Pull string inside 20” casing shoe.
11. Carry out LOT/ PIT and record max allowable Mud Weight.
(Note: LOT in exploratory well and PIT in development well)
12. Change BHA as per requirement. For vertical well, use 18 m (60ft)
pendulum assembly.
13. Resume drilling.
14. Perform drill off tests to optimize RPM/WOB combination.
15. Optimize flow rate once BHA is 15m below 20” casing shoe provided
losses are not observed.
16. Drill ahead to 17 ½” phase target depth.
17. Optimize flow rate (Refer to Chapter on Drilling Hydraulics) and
drilling parameters to maximize ROP.
18. Monitor shakers for signs in change and volume of cuttings.
19. Monitor pit levels for mud loss/gain.
1. Make wiper trips preferably after 24 hours/ 300 m of drilling or as the
well demands. Record tight spots. Do not pull into the tight spot.
20. Drill to Phase Target Depth and drop TOTCO tool, if required.
21. On reaching Phase Target Depth /Target Depth, circulate bottoms up
with full discharge until the shakers are clean.(However exact
discharge may be calculated as per landmark software).
22. Make wiper trip to the 20" shoe. POOH
23. Run back to bottom and ream down last 03 singles. Check for fill.
24. Circulate until hole is clean and mud is conditioned
25. POOH for logging/ casing as planned.
26. During logging, monitor the well through trip tank.
27. When logging is complete, make a round trip as per BHA in next point.
28. Make a round trip with 2 string stabilizers at 9m (30ft) and 18 m (60
ft) then make a round trip with 3 stabilizers – NBS at 0 m, SS at 9 m
(30ft)
& 18 m (60 ft) respectively.
29. Wash down last 03 singles. Check for fill and clear the same.
30. Circulate and condition mud for casing lowering.
31. On the trip out once bit is inside 20” casing, mud pumps should be
checked to ensure their reliability during the cement displacement.
32. Change pipe ram size to casing size.
33. Rig up casing handling tools for lowering 13 ⅜" casing.
e) Drilling 12 ¼”hole section:
Preparation:
1. Keep compatible Well head test plug ready. Check test plug seals.
2. Keep drilling jar ready if planned.
3. Ensure coring equipment is available at the drill site, if planned.
4. Change liners of mud pump as per requirement.
5. Keep FOSV and IBOP with required X/O ready in open position on rig
floor.
6. Record PIT, LOT, MAASP, casing burst pressures etc. and display
properly.
7. Ensure distance of all rams and annular BOP from rotary is displayed
in doghouse.
8. Schematic diagram of choke and kill manifold, MGS and positions of
choke and manual valves should be displayed.
9. On exploratory location ensure Mud Logging Unit is installed and
calibrated.
10. Ensure SCADA system is fully functional and calibrated. Sensors
meant for transmitting various data are functioning.
11. Ensure well shut-in procedures are displayed in the dog house (refer
Chapter on Well Control).
1 12 ¼” Bit (TCR/ PDC) As planned
2 12 ¼” Bit Breaker (TCR / PDC) 01 each
3 Circlip nose pliers for nozzles 01
4 Nozzle gauge 01
6 6 ½”Drill Collar Elevator (150 t) 02
10
10
9 6 ½” Drill Collar Slip 02
11 Bit sub (6 ⅝” RB X 6 ⅝” RB) 02
12 X-over (4 ½”IFB X 6 ⅝” RP) 02
13 X-over (4” IFB X 6 ⅝” RP) 02
14 X-over (4 ½” IFB X 4” IFP) 02
15 Kelly saver sub (4½”IFB X IFP) 02
17 12¼” String Stabilizer 03
18 12¼” Near Bit Stabilizer 01
20 Core bit 01
21 Core barrel with handling tools 02
22 Safety clamp 01
24 Test Plug (13 5/8’’) 01

2. Function and pressure test of all rams of BOP stake, all valves of
choke and kill manifold, IBOP, FOSV and surface equipment as per
standard lay down procedure. (Refer to Well Control Chapter)
3. RIH with 12¼”bit with TOTCO ring (baffle plate) and BHA as per
program. After drilling two singles make up string stabilizer at 18m
(60 ft), if the well is vertical.
4. Tag float collar and test 13 ⅜” casing to 70% of burst rating.

Consider Well head??
5. Drill Float Collar and upto top of the Shoe. Conduct CIT. Drill shoe
and conduct SIT.
6. Drill through cement and shoe with 2-3 T WOB and 50-60 RPM.
7. Wash down to bottom of 17½”hole and drill 3-5m fresh hole.
8. Circulate and condition mud.
9. Pull out string inside shoe and conduct LOT.
(LOT in exploratory well and PIT in development well)
10. Drill further down 20-30 m.
11. Perform drill off tests to optimize RPM and WOB.
1
12. Maintain annular velocity and flow rate as per simulation.
13. Drill ahead to phase TD.
a. Check drag with pump off on every connection to analyze
any down hole problem.
b. Record all drilling parameters every 30 minutes
c. Monitor shakers for signs in change and volume of cuttings.
Monitor Pit level.
d. If losses occur, refer to Chapter on Drilling Fluid
Management for LCM pill formulations.
14. Make wiper trips preferably after 24 hours/ 300 m of drilling or as the
well demands. Record tight spots. Do not pull into the tight spot.
15. Circulate and condition mud once on bottom.
16. While drilling lift Kelly after every ½ hr. or 1m (whichever is earlier)
to observe well behavior.
17. Before pulling out for logging ensure mud is properly conditioned.
18. POOH for logging.
19. During logging, monitor well on trip tank. After 24 hrs of TLC,
preferably circulate the well through circulation port if available.
20. Once logging is over, probe the well with two stabilizer (30’&60’) if
the well is vertical.
21. Wash /ream down last 03 singles/ 01 STD.
23. Make wiper trip. Wash down last 3 singles.
24. Circulate and condition mud for casing lowering.
25. POOH to run casing.
26. While POOH and once inside 13 ⅜” casing shoe, mud pumps should
be checked to ensure reliability during cement displacement
27. Change pipe ram to casing ram.
28. Rig up handling tools for lowering 9 ⅝ ” casing.
f) Drilling 8 ½” hole section:
Preparation:
1. Change liners of mud pump, as per requirement.
2. Keep compatible well head test plug ready and Check test plug seals.
3. Keep drilling jar ready, if planned.
4. Keep FOSV and IBOP with required X/O ready in open position on
rig floor.
properly.
in doghouse.
choke and manual valves should be displayed.
8. On exploratory location ensure Mud Logging Unit is installed and
calibrated.
9. Ensure SCADA system is fully functional and calibrated. Sensors
meant for transmitting various data are functioning.
10. Ensure activation balls/darts (e.g. for PBL circulating subs, core barrel
etc.) are of correct size and will pass through BHA components and
kept in locker in the dog house.
11. Ensure coring equipment is available on site, if planned.

1 8 ½”Bit (TCR/ PDC) As planned
2 8 ½” Bit Breaker (TCR/ PDC) 01each
3 Circlip nose plier for nozzles 01
4 Nozzle gauge 01
6 6 ½” Drill Collar Elevator (150 t) 02
8 6 ½” Drill Collar Slip with safety clamp 02
9 Bit sub (4½”IFB X 4½”RB) 02
10 Bit sub (4” IFB X 4½”RB) 02
11 Cross-over (4½” IFB X 4 ½’’ IFP) 02
12 Cross-over (4½” IFB X 4” IFP) 02
13 Kelly saver sub (4½” IFB X 4 ½’’IFP) 02
14 Drill pipe/ Drill collar dope 02
15 8 ½”String Stabilizer 03
16 8 ½”Near Bit Stabilizer 01
18 Core bit 01
19 Core barrel with handling tools 02
20 Safety clamp 01

1. Lay down 8” drill collars.
2. Function and pressure test of all rams of BOP stake, all valves of
3. RIH with 8 ½”bit with TOTCO ring (baffle plate) and BHA as per
program. After drilling two singles make up string stabilizer at 18m
(60 ft.), if the well is vertical. (Common point)
4. Tag float collar and test 9⅝” casing to 70% of burst rating. Consider
Well head??
5. Before drilling the shoe, BOP drill must be performed.
6. Drill Float Collar and top of the Shoe. Conduct CIT. drill shoe and
conduct SIT.
7. Drill through cement and shoe with 2-3 T WOB and 50-60 RPM
8. Wash down to bottom of 12¼”hole and drill 3-5m fresh hole.
10. Pull out string inside casing shoe and conduct LOT.
15. Check drag with pump off on every connection to analyze any down
hole problem.
16. If losses occur, refer to Chapter on Drilling Fluid Management for
LCM pill formulations.
17. Make wiper trips preferably after 24 hours/ 300 m of drilling or as
the well demands. Record tight spots. Do not pull into the tight spot.
18. Drill ahead to Phase TD.

a. Record all drilling parameters every 30 minutes.
b. Monitor shakers for change in shape and volume of cuttings
and pit levels for mud loss/gain.
c. Flow check all drilling breaks and report same in DPR.
d. Monitor connection gas and trip gas and report in DPR.
e. Prior to a connection, circulate & ream drilled portion.
f. Record on bottom and off bottom string weights.
g. If losses occur, refer to Chapter on Drilling Fluid
19. Make wiper trip. Report tight spots. Do not pull into tight spot.
20. Circulate and condition mud on bottom.
21. POOH for logging and rack pipe stands keeping in view of logging
requirement.
preferably circulate the well through circulation port, if available.
23. After logging, probe the well with clean out BHA.
24. Check for fill and ream if necessary.
25. Circulate and condition mud. Always keep the string in rotation and
reciprocation to remove cutting.
26. Make wiper trip.
27. Circulate and condition mud with simulated discharge.
28. Keep optimum pulling out and running in speed in open hole
depending on well condition to avoid swabbing and surging.
29. During running in last 3 single should always be washed down.
30. POOH to run casing/ liner and Lay down stabilizers.
31. While POOH and once inside casing shoe, both mud pumps should be
checked to ensure reliability during cement displacement

33. Rig up handling tools for 7”/5 ½”casing lowering.
g) Drilling 6” Hole Section
Preparation:
1. Change liners of mud pump, as per requirement.
2. Keep compatible well head test plug ready and Check test plug seals.
3. Keep drilling jar ready, if planned.
4. Keep FOSV and IBOP with required X/O ready in open position on
rig floor.
properly.
choke and manual valves should be displayed
in doghouse.
8. Ensure well shut-in procedures are displayed in the driller’s
cabin. 9. Ensure Mud Logging Unit is installed and calibrated.
10. Ensure SCADA system is connected and enabled.
11. Ensure activation balls/darts (e.g. for PBL circulating subs) are of
correct size and will pass through BHA components and kept in the
driller’s cabin.

SN Items Nos.
1. 6’’ Bit (TCR & PDC) As planned
2. 6’’ Bit Breaker (TCR & PDC) 01each
3. Circlip nose pliers for nozzles 01
4. Nozzle and Bit gauge 01 each
5. 3 ½”Drill Pipe Elevator 02
6. 3½”or 4 ¾”Drill Collar Elevator 02
7. 5” Drill Pipe Elevator 02
8. 3 ½”Drill Pipe Slip 02
9. 5” Drill Pipe Slip 02
10. 4 ¾”Drill Collar Elevator 02
11. Bit sub (3½”IFB X 3½”RB) 02
12. Cross-over (4 ½”IFB X 3½”IFP) 02
13. Kelly saver sub (4½”IFB X 4½”IFP) 02
14. Drill pipe/ Drill collar dope 02
15. Steel Measuring tape 02
16. 3 ½” Drill pipe wiper 02
17. 5” Drill pipe wiper 02
18. Safety clamp 01

1. Lay down 6 ½” drill collars
2. Function and pressure test of all rams of BOP stack, all valves of
3. RIH with 6” bit and BHA as per plan.
4. Tag float collar and test casing to 70% of burst rating and
considering well head and BOP pressure rating.
5. Before drilling shoe, BOP drill must be performed.
6. Drill Float Collar and top of the Shoe. Conduct CIT. drill shoe and
conduct SIT.
7. Drill through cement and shoe with 2-3 T WOB and 50-60 RPM.
8. Wash down to bottom and drill 3 m fresh hole.
10. Pull out string inside casing shoe and conduct LOT.
15. Check drag with pump off on every connection to analyze any down
hole problem.
16. If losses occur, refer to Chapter on Drilling Fluid Management for
LCM pill formulations.
17. Make wiper trips preferably after 24 hours/ 300 m of drilling or as
the well demands. Record tight spots. Do not pull into the tight spot.
18. Drill ahead to Phase TD.
a. Record all drilling parameters every 30 minutes.
b. Monitor shakers for change in shape and volume of cuttings
and pit levels for mud loss/gain.
c. Flow check all drilling breaks and report same in DPR.
d. Monitor connection gas and trip gas and report in DPR.
e. Prior to a connection, circulate & ream drilled portion.
f. Record on bottom and off bottom string weights.
g. If losses occur, refer to Chapter on Drilling Fluid
19. Make wiper trip with pump on. Report tight spots. Do not pull
into tight spot.
20. Circulate and condition mud on bottom.
21. POOH with pump on in open hole for logging and rack pipe stands
keeping in view of logging requirement.
preferably circulate the well through circulation port, if available.
23. After logging, probe the well with clean out BHA.
24. Check for fill and ream if necessary.
25. Circulate and condition mud. Always keep the string in rotation and
reciprocation to remove cutting.
26. Circulate and condition mud with simulated discharge.
27. Keep optimum pulling out and running in speed in open hole
depending on well condition to avoid swabbing and surging.
28. During running in last 3 single should always be washed down.
29. POOH to run casing/ liner and Lay down stabilizers.
30. While POOH and once inside casing shoe, both mud pumps should
be checked to ensure reliability during cement displacement.
32. Rig up handling tools for casing lowering.
h) Casing Integrity Test (CIT):

After casing cementation, casing is pressure tested prior to further drilling.
Casing test before drilling float collar:

The sequence of operations to test casing are as follows:
- RIH and tag cement top
- Establish circulation
- Clear cement up to float collar
- Circulate and condition mud
- Test casing to 70% of the burst rating of the casing and considering
well head and BOP test pressure whichever is minimum.
- Test duration is 5 minutes.
- Test is considered OK, if drop in pressure is not more than 5 %.
Drilling of cement, float Collar and shoe:
- Drill cement with 2-3T WOB and approx.50-60 rotary rpm
- Drill float collar and clear up to shoe.
- Repeat casing test as above.
- If OK, drill shoe and further 0.50m. Fresh formation should not be
drilled.
- Circulate cuttings out of the well.
Casing Shoe Integrity Test (SIT):

This test is conducted to determine competence of cement job around the shoe.
- Pull the drill string in the casing.
- Close pipe ram BOP and FOSV.
- Connect cementing unit with kill line.
- Flush BOP stack and kill & choke lines.
- Close HCR valve on choke line
- Conduct shoe integrity test to anticipated LOT value.
 Shoe test pressure is sum of surface pressure and hydrostatic
pressure of drilling fluid.
- Pump steadily at the rate of 50-100 liter per minute till test pressure is
reached.
- Plot the increase in surface pressure against volume pumped.
- If the shoe is holding, the plot will be linear.
- Hold the required test pressure for 15 min. The shoe is considered OK
if the pressure does not fall more than 10% of the test pressure during
this time.
- Release the pressure and measure the volume of fluid recovered.
Compare pumped volume with return volume which should be almost
equal.
- Open FOSV.
- In case, shoe does not hold up to the required pressure, squeeze
cement and repeat all the procedures for testing shoe.
i) Leak-off Test (LOT):
LOT is carried out to determine the competency of the formation. The

procedure for LOT is as follows:
- Drill 3-5 meters of fresh formation from last phase drilled depth.
- Circulate & condition mud till it is homogenous.
- Pull out string inside shoe.
- Make up FOSV. Pick up String on block.
- Connect the cementing unit through kill line and close choke line.
Flush the line and observe return.
- Open both the outlet valves of previous casing head housing.
- Close the pipe ram BOP & FOSV.
- Start pumping mud in the well at a controlled rate of ¼ bbl/min (About
40 litre/min)
- Note down pressure without stopping the pump after pumping each
incremental volume of ¼ bbl (40 litre)
- Initially pressure increases proportionally after pumping each
incremental volume
- Plot pressure rise against volume pumped on a graph simultaneously
otherwise this may sometime lead to over pumping and formation
breakdown.
- Draw a trend line with a minimum of 2 readings on graph paper to
predict pressure rise vs. volume pumped.
- As soon as any deviation in pressure rise from trend line is observed,
stop pump. Record volume pumped and leak off surface pressure.
- Hydrostatic pressure due to mud column is calculated at the depth
where leak-off is being performed as under.
PH=Hydrostatic Pressure with present mud (Kg/cm2) =D * MW/10
Where,
D = True Vertical Depth (TVD) in metre
MW= Mud weight of test drilling fluid in gm/cc
Ps=Surface pressure at which formation pressure does not increase
linearly any more (formation leaks) (kg/cm2)
EMW from LOT value (gm/cc) = [10 (Ps + PH)]/D
- After the test is completed, bleed off the pressure in the line.
- The volume of returned mud should be almost equal to the volume
of pumped mud.
Note:
- In exploratory well, LOT should be conducted.
- In development well, Pressure Integrity Test (PIT) to the expected
maximum mud weight value for the next phase.
20
LOT
1400
1200
1000
Surface pressure LOT
800
600 Pressure (psi)
400
200
0
0 200 400 600
VVoolluummee (Litres)
1
j) Extended LOT:
A LOT is a pumping pressure test carried out immediately below
newly set casing in a borehole. It is similar to other pumping
pressure tests known as the pressure integrity test, formation integrity
test, or casing- shoe integrity test. Each of these tests has a different
target pumping pressure. The LOT is done to assess the “fracture
gradient” of the formation (i.e., the maximum borehole pressure
that can be applied without mud loss) and to determine optimal
drilling parameters such as mud density. The LOT procedures are
simple but XLOT (extended LOT) is a slightly complex test with
extended pressurizing procedures, to estimate the magnitude of
minimum in situ horizontal stress, mainly for the practical purpose of
determining borehole stability during drilling operations.
To carry out LOT or XLOT after setting casing and cementing, a short
length (3-5 meters) of extra open hole is drilled below the casing shoe.
The casing shoe is then pressurized by drilling fluid pumped through
drill pipe from a cementing unit pump. The pressure at the casing shoe
is equal to the sum of the hydrostatic pressure of the drilling fluid
column and the Unit pumping pressure.
Initially, pumping fluid into the borehole results in volumetric
compression of the drilling mud column and elastic expansion of the
casing string plus rock around the borehole. As the pressure in the
borehole increases, the leak-off pressure (LOP) is reached when the
relationship between pressure increase and volume of fluid pumped
deviates from linear. This occurs when fluid begins to diffuse into the
formation at a more rapid rate as the rock begins to dilate. A LOT test
finishes immediately after LOP is reached.
An XLOT is an extended version of a LOT, similar to the hydraulic
fracturing test used for stress measurement. During an XLOT, pumping
continues beyond the LOP point until the pressure peaks at formation
breakdown pressure (FBP). This creates a new fracture in the borehole
wall. Pumping is then continued for a few more minutes, or until
several hundred liters of fluid have been injected, to ensure stable
fracture propagation into the undisturbed rock formation.
The pumping pressure then falls and stabilizes to an approximately
constant level, which is called the fracture propagation pressure (FPP),
time allowed for is about 5-6 minutes for getting 3-4 points on graph.
Then stop pumping (known as “shut-in”). The instantaneous shut-in
pressure (ISIP) is defined as the point where the steep pressure
decrease after shut-in, deviates from a straight line. After ISIP
pressure levels off in 8-10 minutes.
After ISIP from our perspective, the most important pressure parameter
is the fracture closure pressure (FCP), which occurs when the newly
created fractures closes again. FCP is determined by the intersection of
two tangents to the pressure versus mud volume curve. The value of
FCP represents the minimum principal stress, because the stress in
the formation and the pressure of fluid that remains in the
fractures have reached a state of mechanical equilibrium.
From XLOT data it is found that both FCP and ISIP provide better
estimates of minimum principal stress than LOP. In addition, ISIP is
visually easier to determine than FCP. To end the test, the valve on rig
floor is opened, and some of the fluid in the borehole flows back into
the fluid tank (known as “bleed-off”).
To confirm the pressure values obtained from the initial XLOT, a
second pressurization cycle is warranted. Because a fracture has been
created by the first execution of XLOT, in the second cycle the
pressure at the time of re-opening of the fracture corresponds
approximately to the FPP of the first cycle. In general, it is advisable
to conduct additional pressurization cycles beyond the second cycle in
order to confirm that stable values of FCP and ISIP have been
obtained.
Procedure:
Procedure in detail:
1. In the first LOT cycle, drilling fluid is pumped into the borehole at
a constant flow rate (e.g.,0.25 to 0.5 bbl/min, or about 40 to 80
L/min); pumping stops before the expected LOP, and the well is
shut-in for 5–10 min. The pressure decline during the very early
stage of shut-in reflects the decay of viscous pressure losses in the
surface piping and drill pipe, and the pressure change during the
later stage of shut-in is controlled by the permeability of the
formation. If the pressure decline in the late stage of shut-in is
large and does not stabilize, the leak-off of fluid might be
attributed to the existence of natural fractures or to ineffective
cementing. If the casing shoe is too permeable, then the second
and third test cycles are unnecessary, as a reliable measure of
the minimum principal stress will not be possible.
2. In the second injection cycle, pumping continues for at least 1 min

beyond formation breakdown, and then the well is shut-in. If
formation breakdown is not achieved but pressure decreases during
pumping (indicating fracture propagation, perhaps from a pre-
existing fracture), then pumping should continue until the volume
of fluid injected reaches at least several barrels (e.g., 3 bbl, or
about 450 L) and the well is shut in.
3. The well then remains shut-in while pressure is monitored for at

least 10 min or until the pressure ceases to decay. The well is then
bled off.
4. To evaluate the pressure versus volume curve during bleed-off, flow-back
volume is monitored and measured. The curve shown above is an idealized
relation between pumping pressure and volume, and it indicates the total
amount of fluid lost into the formation (or through other system leaks)
during the test.
5. The third cycle repeats steps 2–4 and allows comparison of the pressure
parameters obtained during the second cycle.
6. Comparison of the pressure decline curves of the third and second cycles
provides information about the state of the borehole. For example, if the
pressure decline after shut-in during the third cycle is comparable to that
observed in earlier cycles, then the cement bond has not been damaged, and
with the test interval permeability has not been significantly affected.
7. If required, a fourth cycle of pumping can be undertaken to investigate

borehole integrity, including the extent of formation permeability during the
test. In this case, the casing shoe is again pressurized to the maximum
pressure of the first cycle. The well is then shut in, and the pressure and
fluid volume monitored. Comparison of the pressure build-up rate (pressure
versus volume) during injection and the pressure decline after shut-in
during this cycle with those of the first cycle will show whether or not
borehole integrity has been compromised.
There may be concern that the new fracture created during the XLOT has
affected casing-shoe integrity. In general, casing-shoe integrity is maintained
if appropriate drilling fluid has been used.
Calculation of minimum principal stress by using LOT–XLOT data depends
on the assumption that a new fracture is created in a plane perpendicular to the
minimum principal stress by the pumping pressure and that pre-existing
fracture(s), weakness(s), anisotropy, and heterogeneity of the formation have
no significant influences.
k) Recommended practices for tripping out:

2. Flow check well 5 minutes or as required. Keep string in motion
to avoid stuck up.
3. Line up well on trip tank and start trip tank pump. Trip Sheet
should be ready.
 Record hole fill volume for every 5 stands of drill pipe
 Record hole fill volume for every stand of drill collar
4. Before P/O, ensure availability of all X-Overs at rig floor.
5. Pump slug and P/O first few stands slowly, keep check on
channel for flow of mud. In case of tight spots pump-out/ back
ream the string.
6. Pull out of hole. Pipe speed is dependent on hole conditions,
swabbing effects.
7. After pulling out 5 stands, flow check again.
8. If well is not taking mud as per the trip sheet, flow check, run
back to bottom and condition the well before restarting POOH.
9. Install pipe wiper, if flow check is negative.
10. Change working joint periodically.
11. During P/O FOSV and X-Overs to be kept ready.
12. Regular trip drills to be carried out inside casing to ensure
proper and quick responses by drilling crews.
13. Flow check well at casing shoe and before pulling BHA into
BOP, and any other time if required.
14. Remove pipe wiper before pulling BHA out.
15. While tripping, keep the tool joint above slips as minimum as
possible to avoid bending of tubulars during making up/
breaking out tool joint. Use of both tong is recommended.
l) Recommended practices for tripping In:
1. Lower first stand with bit very carefully till it passes through
well head followed by BHA.
2. Fill string regularly if float is used.
3. Circulate at every 500m interval and at shoe. Compare the
pressure with the pressure tally.
4. Run into open hole slowly observing held up.
5. In case of held up, Pick up string up to free condition. Try to
clear the same with reciprocation and intermittent rotation with
pump on but do not push through tight spots.
6. Start circulation slowly and observe returns. Monitor stand pipe
pressure and increase SPM gradually to normal SPM.
7. Wash down last 1-2 stands as a practice wherever top drive is
available and at least last 3-4 singles where Kelly is used to
avoid hole pack-off and resume further operations.
m) Recommended practices for reaming:

1. Ream each pipe length drilled at full circulation rate and with 1-2 ton
WOB.
2. Ream with minimum weight and keep an eye on erratic rotary torque.
Do not release WOB till rotary torque becomes smooth and is no
more erratic.
3. Higher WOB with erratic torque may lead to severe back-torque
causing bit failure/ string back-off
4. Once rotary torque is normal, lower the string and ream further
5. When circulation is nearing bottoms up, check shale shaker for type
and volume of cuttings/ cavings coming out
6. Reaming is not recommended with PDC/ Diamond bits.
7. If excessive reaming is foreseen, POOH PDC/ diamond bit and ream
with roller bit
m) Recommended practices for back-reaming:

1. Back-reaming should be used as the last resort and with the same
flow rate that was used during drilling.
2. Back-ream for 5 m maximum, circulate cuttings clear of the BHA,
then try to pull through the obstruction without pumps or rotation.
3. During back-reaming, shut down the pumps quickly in the event of a
pack-off.
4. In the event of a pack-off, stop the pumps - go down with the pipe
(maintaining rotation) - re-establish circulation and circulate hole
clean.
5. Attempt to pull through troublesome zone again without pumps and
rotation.
6. Repeat the above process - with patience. The objective is to POOH
with the absolute minimum of back-reaming.
n) Recommended practices for wiper trips in deviated hole:

• Carry out short/wiper trips alternatively after 24 hrs or 250m or as per the
well requirement.
• Wash down last 1-2 stands as a practice wherever top drive is available and at
least last 3-4 singles where Kelly is used to avoid hole pack-off.
• Circulate at casing shoe for 1.5 cycles in wiper trips to remove all cuttings
from the annulus if pumping out due to tight pull is a frequent observation.
• Pump-out in tight portions if required back reaming may be done.

Tandem pill sweep to be given intermittently.
o) Recommended practices to clear pack-off:
To avoid possible pack-off:
1. To prevent annulus loading and consequent packing-off by ensuring

that recently drilled cuttings are well above the BHA length by
circulation especially when the ROP is more than 25-30 meters per
hour.
2. In case of pack off, stop pump. Continuous pumping will lead to
formation break down and stop all chances of establishing circulation.
3. Come up with running in hole and establish circulation and try to go
down while pulling out of hole.
4. Try to reciprocate the string, hydraulic hammering i.e., bleed the
trapped pressure and again pressurize 200-500psi to physically
dislodge the packed cuttings. Intermittently try establishing
circulation, but do not continue pumping to avoid fracture the
formation.
5. In case of persistent difficulty in pulling out of hole in-spite of all
practices, review the hole stability issues.
p) Recommended practices for surface seepages:

Seepages during drilling especially in top hole results in serious consequences
such as rig foundation sinking and toppling of rig in extreme cases.
The surface seepages may be due to unconsolidated formations at shallow
depths that allow seepage of mud under relatively lower pressures due to
negligible bearing strength of the sands at surface.
It may also be due to Artesian effect where water from high altitude flows into
around the well bore from adjoining mountain area.
It may also happen during drilling deeper horizons, if the annulus
barrier/ cementation at surface give up during course of drilling or due to
uncontrolled tripping and drilling operations.
At suspected locations, the false conductor should be driven to a depth of 25
meters or more as per soil/water table data as against normal depth of 3 to 6
meters from Ground Level.
Recommendations procedures:
Due to possibility of communication from behind 30” false conductor as
the same is not cemented around the annulus, the following measures are
suggested;
a) Spud and drill initial 50 m of 26” hole by controlled drilling with
low discharge preferably with Supercharger (only in Onshore),
slowly increase discharge for further drilling.
b) In case of severe seepage expected (based on past history), drill
pilot hole of 12 ¼’’ and enlarge it.
c) Intermittent high viscous sweeps are recommended.
d) Prolonged mud circulation should be avoided at any point.
30
e) Excessive mud circulation during idle period/ before pipe
connection should be avoided.
q) Coring:
In general, geological data are gathered from direct observation and analysis of
rock cuttings collected at surface during drilling.
However for better and detailed understanding of rock properties, a solid core
is cut from rock in the zone of interest.
Procedure for making up Core Barrel:

1. Hole should be free of junk prior to coring. As per GTO, Junk sub
should be used on a trip prior to coring bit run to ensure hole is junk
free.
2. Check gauge of pulled out bit before running core bit. If it is under
gauge, it is advised to run a new TCR bit again to probe the hole.
3. The most commonly used coring equipment in ONGC is :
a. Core bit size: 8-15/32” or 8-7/16”
b. Core barrel: 6-3/4”OD: Core size:4”; Core barrel length:
30’/60’
4. Ensure recommended make-up torque values of core barrel
connections are displayed at rig floor.
5. Safety joint ‘O’ ring should be checked before each run and replaced
if required. Oil should be applied on safety joint thread. Ensure
recommended make-up torque to be applied on safety joint.
6. Tighten all joints of inner barrel using chain tong only.
7. Check inner barrel shoe threads.
8. Check vertical play in bearing by resting inner barrel on outer barrel
with the help of a solid rod. It should be less than ¼”.Change bearing
if required.
9. Check swivel joints for free rotation.
10. Place core marker inside inner barrel.
11. Install core catcher on inner barrel. Check length of inner barrel shoe
lip from bottom of outer barrel sub with the help of the manufacturer
supplied gauge before the bit is made up (it is 3-23/32” in case of 6-
3/4” x 4” Christensen core barrel).
1
12. If the length of the inner barrel shoe lip below outer barrel is not as per
gauge, adjust the same by changing shims which otherwise may affect
the core recovery.
13. Ensure bit breaker is in proper condition.
14. Core head should be made up with outer barrel by hand rotation only
and power tong should be used only for final tightening upto
recommended torque.
15. Check core bit is free of ring out groove in the bottom face of bit.
16. Ensure the steel ball is not inside the core barrel, before laying down
core barrel take out steel ball from core barrel.
Procedure for coring:

1. Run core barrel carefully in open hole and do not push the core bit
through tight spots.
2. Drift drill string and drill collars during P/O before coring.
3. Use pipe wiper during RIH to ensure junks do not fall into well.
Remove wiper before making Kelly.
4. If excessive reaming is required, POOH core barrel and probe the hole.
5. Wash down last 10-15 m with max circulation and without rotation.
6. Circulate one foot off bottom for half an hour for clearing bottom
before starting coring operation.
7. Tag bottom.
8. Check the space out of the string is such that when on bottom the
maximum kelly length is above the rotary to ensure maximum
continuous coring prior to making a connection. Add 5’/10’/15’ drill
pipe pup joint for space out if available. Ensure that pup joints will not
be across the BOP stack during coring operations.
9. Make sure steel ball is of proper make and size. Break Kelly and drop
the steel ball.
10. Confirm seating of ball in core barrel with rise in pressure.
11. Record off bottom and on bottom pressure for a particular discharge.
The difference is the pressure drop across the bit face.
12. Record SCR.
13. Keep circulation rate around 16-19 litres/sec for coring which is
optimum for 6-3/4” Core Barrel.
14. Recommended circulation rate:
a. 12-1/4” hole: +/- 550 GPM
b. 8-1/2” hole: +/- 300 GPM
15. Start coring with 1-2 T WOB and 30/40 RPM.
16. Increase WOB (to 3-4 T, if required) and RPM (to 50-60) after 1foot
core is cut.
17. Cut 9 m core. No reaming after coring.
18. Stop rotation and circulation. Pull up 5 Ton string to break core. If
core does not break, hold pull and start circulation.
19. Pump slug and POOH without rotation.
20. After core breaks, pick up 3 m and then lower within 0.50 m off
bottom to confirm the core is broken.
21. In case more than 9 m core is required, make up new pipe connection
without using rotary. Start pump and run back to bottom without
rotation. Apply 3-4 T WOB to release core from core catcher and
engage core in bottom before starting rotary.
22. Core to required core point. Break core as in Point No-18.
23. Pull out core barrel if
a. If abnormal rise in stand pipe pressure is observed. If it is more
than the pressure drop across the bit face and cannot be
accounted for, barrel may be pulled out for inspection.
b. If appreciable decrease in penetration rate is observed.
c. If coring is not progressing at desired rate and erratic torque is
observed, pull out and check core bit.
24. Rest core barrel in slips. Install safety clamp around inner barrel and
make up lifting sub on core barrel.
25. Break out safety joint and pick up inner barrel.
26. Fit core barrel tong just above core catcher and remove core catcher
while inner barrel is just nearly touching the floor to avoid falling of
core.
27. Raise inner barrel and tap it so that core comes out of inner barrel.
28. Use core tong to remove core safely and without breaking till core
marker comes out of inner barrel.
29. Place core in boxes as per proper sequence.
30. After core recovery, place the core marker inside the inner barrel.
31. Break all core barrel joints, clean and apply grease/oil before laying
down.
32. Inner barrel should be coated with lubricant oil to avoid corrosion
before laying down.
Core bit
Core catcher
Bearing
2 Bottom
Hole
Assembly
BHA is the lowest part of the drill string and is required to impart necessary
weight on bit (WOB), hole stability, stiffness to drill string and for maintenance
of desired well profile to achieve target depth in most effective manner. BHA
consists of bit, bit sub, stabilizers, drill collars, heavy weight drill pipe
(HWDP), drilling jars along with cross over subs and required directional
drilling tools.
This chapter deals with

a) BHA design
b) Operational guidelines
c) Guidelines on WOB
d) Use of stabilizers
e) Critical points while making BHA for various hole sizes
f) BHA for various hole sizes
g) Drilling Jar
a) BHA Design
The bottom hole assembly specified in the drilling program is to be used in
each hole section. The following points should be considered while selecting
BHA components:
 HWDP stands are run between the drill collars and drill pipe to provide
more compressive length of BHA.
 Stiffness Ratio is ratio of section modulus of various sections of the
drill collars and drill pipe.
 Ensure that crossovers from large diameter drill collars to smaller drill
collars or drill pipe do not exceed a 2" reduction in size, or that the
stiffness ratio does not exceed 5.5 for a non-critical well or 3.5 for a
critical well.
 Bending Strength Ratio (BSR) is ratio of section modulus of box and
pin. Maintenance of BSR within recommended limits is very important
to prevent failure of string at the joints where size changeover is
beyond limits.
 Formula for calculating BSR
4 𝐷 − 𝑏4
𝜋⁄ 𝐷 −
𝑏4 4
BSR = ZB / ZP = 𝜋 32 4𝐷 4 = 4𝐷 4
𝑅 −𝑑 𝑅 −𝑑
⁄32 𝑅 𝑅
ZB-Box Section Modulus,
ZP-Pin Section
Modulus, D-OD of Pin
& Box,
d-ID of Bore,
b-Thread root dia. of Box threads at the end of Pin,
R-Thread root dia. of Pin threads ¾” from shoulder of pin.
 BSR between 2.50 and 2.75 are preferable for all BHA connections in
hard formations.
 BSR between 2.25 and 2.75 are preferable for softer formations.
 When lost circulation is expected, select components of BHA
considering lost circulation material requirements (nozzles, motors,
MWD,) to avoid plugging when pumping LCM.
 Spiral drill collars are preferred to minimize differential sticking.
 Straight welded blade stabilizers minimize swabbing in gumbo
sections. Stabilizers with a longer contact area increase wall support
area in soft formations. Stabilizers with a shorter contact area are
preferable in hard formations.
Long stabilizer Welded Blade Shorter Stabilizer
b) BHA Operational Guidelines:
 Making up new drill collar:

 Clean box and pin thread and apply dope on thread and
shoulder.
 Make up new drill collar using chain tong with drill collar in
floating condition (i.e. Do not release DC weight as it may
damage threads).
 Make up to recommended torque using both power tongs.
 Break drill collar and unscrew.
 Clean thread, check the condition of the threads and shoulder.
If it is OK then apply dope again.
 Repeat this step again.
 If condition of the threads / shoulder found not OK, replace
the same.
 The following points are very important for satisfactory drill collar
performance:
 Proper cleaning of thread and shoulder
 Proper lubrication of shoulders and threads
 Recommended make up torque
 Repairing minor damage on shoulder and thread
 Use thread protector while laying down, lifting and
transportation.
 Never make up drill collars or BHA using rotary.
 Don’t allow the pin of the Drill collar stand to rest on the shoulder of
the drill collar on the rotary during RI.
 After crack opening DC during POOH, open drill collars with chain
tongs and with a slight upward pull on the blocks to avoid galling. Do
not allow threads to jump after the collar is backed out.
 Keep changing working joints of drill string on every round trip.
 Ensure there are sufficient HWDP/Drill collar above and below
drilling jars.
 Keep drawings of all BHA components with dimensions like OD, ID
and lengths for selecting proper fishing tool at the time of
complication.
 According to the BHA program, stabilizer should be lowered with
required gauge. Gauge the stabilizer every trip out and replace sleeve/
stabilizer as required.
 Lift sub pins should be cleaned, inspected and lubricated on each trip.
If these pins have been damaged and go unnoticed, they will
eventually damage the box of BHA component.
c) Guidelines on WOB
 WOB is decided as per the hole size and lithology to be drilled.
 The maximum WOB that can be given for a particular BHA is limited
to 80% of the buoyant weight of BHA to keep neutral point within
BHA.
 Neutral point is the point of changeover where the string components
changes from compression to tension. Above neutral point Drill string
is always under tension and below Neutral point it is under
compression.
d) Use of stabilizers
 Single Stabilizer at 60 feet is called a pendulum assembly which will
help to maintain the hole vertical.
 A stiff assembly consists of minimum 3 stabilizers at 0 feet, 30 feet
and 60 feet above bit which is useful to drill a straight hole and/or to
probe hole prior to lowering casing in a crooked hole.
 A slick assembly (without any stabilizer) is to be used only in specific
conditions like cement / shoe track drilling, lost circulation etc.
e) Critical points while making BHA for various hole sizes:

Making-up tubular joint to recommended torque is of utmost
importance. Under-torquing and over-torquing are not recommended.
Recommended torque
Drill Pipe Make of drill pipe, drill collar and HWDP is given below in
up Torque
Nom Weight
Drill Grade Conn- Cla Tool Joint OD Torque
Pipe ppf Kg/m ection ss in mm Ft-lb Kg-m
Size
I 3⅜” 85.7 3500 485
2⅜” 6.65 9.89 E 2⅜”IF S 33/16 81 2500 346
NC26 ”
(EU) II 3⅛” 79.4 2000 277
III 3⅛” 79.4 2000 277
I 4¾” 120.6 9100 1261
3½” 13.3 19.8 E 3½”IF S 4 ½” 114.3 7300 1011
NC38 II 4 111.9 5800 804
(EU) 13/32”
III 4 110.3 4800 665
11/32”
I 6⅜” 161.9 18900 2618
E 4½”IF S 5⅞” 149.2 15800 2189
NC50 II 5 146.8 13300 1843
tables: (EU) 25/32”
5” 19.5 29.02 III 5 144.5 10800 1496
Drill Collar Make up Torque
11/16”
DC OD & ID 9½”* I 8”* 6½”
6½”*
165.1 258004-3/4”*
3570
G 3” 4½”IF S2-13/16”6 3/32” 2-13/16”
154.8 219002-1/4”3030
Connections 75/8 Reg
NC50 II6 5/8 5Reg 4150.6
IF 3-1/2 IF
18400 2071
Min make-up Kg-m 12,166 (EU) 7,32731/32” 3,069 1,380
torque Ft-lbs 88,000 III53,0005 22,200
146.8 150009,986 1953
25/32”
I 6⅝” 168.3 31800 4406
S 4½”IF S 6 5/16” 160.3 28400 3934
NC50 II 6⅛” 155.6 22900 3173
(EU) III 6” 152.4 19300 2674
3½” 26 38.69 3½”IF 4¾” 120.6 9900 1372
HWD
P
5” 50 71.41 4½”IF 6½” 165.1 29400 4073
HWD
P
40
g) Drilling Jar
Jarring is the process of transferring stored energy (drill pipe stretch) in the
drill string to kinetic energy. When the jar trips, the energy is released
providing sudden impact.
The two basic types of jars are mechanical and hydraulic
Mechanical jars
- Both up & down jarring system is mechanical
1
- Have preset trip load and detent is released at trip load.
- Is sensitive to load and not time
Hydro-mechanical
- Up jarring is hydraulic and down jarring system is mechanical
Hydraulic jars
- Uses oil to delay jar firing till desired stretch is achieved.
- Time delay is by forcing oil through small ports or a series of jets
& a detent mechanism.
- Delay in firing is dependent on load & time
- Both up & down jarring is hydraulic.
Pump Open Force/Jar extension force
Pump pressure will generate a force, which will try to open the tool
and thereby increase ease of opening jar and increase upward
impact and down jar impact will be reduced. The pump open force
is calculated by multiplying pressure drop across the bit by the
piston area of jar. The area is listed in the specification sheet of the
different jar.
Upward Jarring
Weight indicator to be set at =Normal Hook load when lifting the

string – BHA weight below jar – pump open force + Desired upward
blow.
Cock the jar from full open position
Weight indicator to be set at = Hook load while lowering the string–

BHA weight below jar - jar friction - pump open force
Downward Jarring
Weight indicator to be set at = Normal hook load when lowering the
string – BHA weight below jar – pump open force – desired
downward blow.
Re cock the jar from closed position
Weight indicator to be set at = Hook load while lifting the string–

BHA weight below jar + jar friction - pump open force
Reason for Jar failure

Jar not firing up
 String is stuck above jar.
 Insufficient time given for firing.
 Jar not cocked.
 Jar needs repair
Jar not firing down
 String is stuck above the jar.
 Effect of drag not taken into account.
 Sufficient time is not given for firing.
 A lot of pump pressure is applied while jarring (Pump open force
resisting downward movement).
 Jar needs repair.
General guidelines for jar operation.

 Leave 3-5 feet of Kelly above bushing to provide slack off length
to cock the jar.
 Avoid using jars at cross over point i.e. DC to jar to HWDP
 R/I slowly through tight spot to avoid down jar firing.
 In zones where differential sticking is anticipated locate jar
relatively high in the BHA.
3 Drilling Bits
Achieving the highest ROP with the minimal hole problems is the goal of every
drilling engineer. Formation drillability is one of the most important aspects for
planning and designing a new oil/gas well since the factors affecting the
drilling performance have complex relationships between Formation
Properties, Drilling Bit Design and Operational parameters. In view of high
operating cost of Drilling Rigs, if ROP can be enhanced by any means, it
will reduce open- hole formation exposure time & any complications
associated with it and eventually significant savings in Drilling Time &
Drilling Cost can be realized. And this is possible by choosing right type of
drill bit for the formation.
The Chapter covers the following topics on bits:

a) Basics about Drill bits,
b) Bit Operating Guidelines,
c) Optimizing Drilling Parameters,
d) Drill-off test procedure,
e) Do’s& Don’ts for TCR Bits & PDC Bit,
f) Bit Selection, IADC Roller & Fixed Cutter Drill Bit Classification
System
g) IADC Dull Bit Grading method.
h) New Generation Bits
a) Basics about Drill bits:
 Roller bits with long, sharp and widely spaced teeth are the first
choice for soft and sticky formations that are prone to Bit Balling. In
this case, ROP is high and drilling action is by gouging & scraping
the rock.
 Roller bits with short and closely spaced teeth/ inserts drill by
crushing & chipping action at deeper depths.
 Bits with Open Bearings are run at lower WOB and higher RPM as
compared to Journal Bearings.
 Bits with Journal Bearings need higher WOB and lower RPM as
compared to open Bearings.
 Bits with Sealed Bearings have a longer life than bits with non-sealed
Bearings.
 Ideally, minimum 2.0 and maximum 3.5 HSI (HHP/in2) should be
maintained for different types of bits. HSI of 2.0 for TCR (Steel
bodied bit) & up to 2.5 HSI for TCR Matrix bodied and 2.5 to 3.5
HSI is preferred for PDC bits considering discharge requirements.
 Hard-facing and gauge protection are good choice for hard and
abrasive formations with alternating layers of shales and sandstone.
 PDC Bits are fixed cutter design and drill the rock by shearing action.
 PDC Bits work on low WOB and higher RPM.
b) Bit Operating Guidelines:
 Replace nozzles as per simulated hydraulic program.

 Measure nozzle size with gauge before lowering bit and ensure
nozzles are clear of debris.
 Use proper size bit breaker plate.
 Do not use worn out bit breaker to avoid bit jamming in it.
 Make up the bit to recommended torque.
 During make up release weight of Drill collar stand gradually over
the bit to avoid damage to the pin.
 Hoist & lower bit slowly through BOPs and wellhead stack.
 Lower the bit slowly at liner hanger tops and in open hole.
Bit Breaking (Commence Drilling with a New Bit):
1. Wash down last 3 singles to bottom.

2. Approach bottom with full circulation and low RPM to prevent
plugging of nozzles.
3. Tag bottom with low WOB and low RPM.
4. If torque is normal, gradually increase RPM first and then WOB in
steps to recommended parameters.
5. If abnormal torque is observed while breaking in bit, stop drilling.
Pick up string and go down with rotation and circulation repeatedly
till drilling torque becomes normal. Thereafter, start drilling.
6. If torque remains abnormal even after repeated attempts, pull out
the bit as there may be junk at bottom.
c) Optimizing Drilling Parameters:
Drill-off Test optimizes WOB & RPM and maximizes ROP based on
manufacturer’s recommended range of RPM & WOB for the particular
formation to be drilled.
Drill-off tests should be carried out:
1. At the start of the new bit runs.
2. On encountering a new formation with significant reduction in ROP.
d) Drill-off test procedure:

1. Start test with low RPM and WOB.
2. Start with minimum recommended WOB as per manufacturer.
3.Drill ahead and record the time till WOB drops by 2 T.
4. Record length of kelly drilled in step-3 and calculate ROP in m/hr.
5. Now increase WOB in increments of 2 T and record drilling time till

WOB drops by 2 T.
6. Step-5 may be repeated 2 or 3 more incremental values.
7.Now select the ROP with the best WOB.
8. Maintain this WOB constant and repeat the above procedure by
choosing 50 rpm and then varying RPM values in increments of 10 in
soft formations and 5 in hard formations.
9. Select the RPM with best ROP.
10. Select the optimum WOB and RPM.
e) Do’s& Don’ts for Roller Bits:

Do’s :
 Use lifting plug for handling the bit with crane to avoid thread damage.
 Make up small size bit initially by hand to avoid cross threading.
 Make up bit to recommended torque.
 A wooden plank or rubber sheet should be placed below insert bit
while making up.
 Use proper size bit breaker.
 Rollers of non-sealed bearing bit should be made free before lowering
it into the well.
 Gauge the bit before lowering into the hole with ring gauge and record
it.
 Remove rotary bowls / split bushings before PO bit through rotary table
 Cover the rotary table opening with cover plate before cleaning of bit.
 Grading of pulled out bit should be done carefully and ring gauge
should be used to measure gauge wear of pulled out bit.
 Preferably, Junk sub should be run on the last Milled tooth bit prior to
insert bit run and most importantly, always run junk sub on last bit
prior to PDC bit run to collect broken/lost teeth/inserts.
Don’t s :
 Do not make up the bit in reverse rotation and with jerk.
 Do not try to free the roller of the sealed bearing bit before lowering.
 Do not try to push the bit through tight spots.
 Do not tag the bottom with a jerk.
 Do not give excessive WOB while reaming.
 Do not load new bit immediately with normal WOB while resuming
drilling.
Do’s and Don’ts for PDC Bit

Do’ s:
 Junk sub should be run on the last roller bit to collect broken/ lost
inserts if the next run is PDC or Core bit.
 A wooden plank or rubber sheet should be placed below the PDC bit
while making up.
 Ensure that there is no junk in the hole prior to lowering PDC bit.
 Initially rotate the PDC bit at 50-60 RPM, with full discharge for 5-10
minutes. This will pump up junk or loose formation off bottom through
the junk slots on bit.
Don’t s:
 Do not run PDC bit if the previous pulled out bit is found under gauge
and/or with broken teeth/inserts.
 Do not ream long sections of the hole because the bit is not stable off
bottom. PDC breakage may occur near the gauge point.
 Do not try to push PDC bit through tight spots.
 Do not allow the PDC bit to vibrate or bounce on formation being
drilled. Optimize WOB and RPM to reduce vibration or bit bouncing.
f) Bit Selection:
Guidelines for bit selection are as follows:
 Bit selection generally calls for the most aggressive ROP and suited
for anticipated lithology.
 Soft formation mill teeth bit is suitable for surface hole drilling.
 Sealed journal bearing bit is recommended for drilling entire soft
surface section in one run.
 Sealed journal bearing bit is recommended for drilling at deeper
depths with high WOB and less RPM.
 In deeper hole sections requiring multiple bit runs, new bit should be
selected based on Dull Bit Grading of pulled out bit.
 Offset well bit records may be used to know the performance of bits
used previously in the corresponding formations.
 Worldwide ‘Rock Compressive Strength based Bit Selection’ is being
done nowadays by leading Bit Manufacturers with the help of
Proprietary Software.
Pin thread for drilling bits
ROTARY SIZE OF BIT (INCH)
CONNECTION
3-3/4” 4-1/8” 4-3/8”
2-3/8”REG 3-7/8” 4 ¼” 4-1/2 “
4-5/8” 4-7/8”
2-7/8”REG 4-3/4” 5”
5-1/8” 6” 65/8”
3-1/2”REG 5-3/8” 6-1/6” 6-3/4”
5-5/8” 6-1/4” 7”
5-3/4” 6-3/8” 7-3/8”
5-7/8” 6-1/2
7-1/2” 8-1/8” 8-3/4”
4-1/2”REG 7-5/8” 8-3/8” 9”
7-3/4” 8-1/2” 9-3/8”
7-7/8” 8-5/8”
9-1/2” 11-5/8” 15”
9-5/8” 11-3/4” 16”
6-5/8”REG 9-3/4” 12” 17”
9-7/8” 12-1/4” 17-1/2”
10-5/8” 13-1/2” 18-1/2”
11” 13-3/4”
11-1/2” 14-3/4”
14-1/2” 17” 22”
7-5/8”REG 14-3/4” 17-1/2” 23”
15” 18-1/2” 24”
16” 20” 26”
18-5/8” 23” 27”
8-5/8”REG 20” 24” AND
22” 26” LARGER
Make up torque for drilling bit
Bit Make-up torque
thread (daN.m) (ft.lb)
2-3/8 Reg 400–480 3,000–3,500
2-7/8 Reg 600–750 4,500–5,500
3-1/2Reg 950–1,200 7,000–9,000
4-1/2Reg 1,600–2,200 12,000–16,000
6-5/8 Reg 3,800–4,300 28,000–32,000
7-5/8 Reg 4,600–5,400 34,000–40,000
8-5/8 Reg 5,400–8,100 40,000–60,000
IADC Roller Bit Classification System:
 First Digit: Cutting Structure Series:

Eight categories or “Series” numbers 1 to 8describe general formation
characteristics.
a. Series 1, 2 and 3 refer to steel tooth (milled tooth) bits.
b. Series 4, 5, 6, 7 and 8 refer to insert (tungsten carbide) bits.
Within the steel tooth and insert group, series numbers increases as the
formation becomes harder and more abrasive.
 Second Digit: Cutting Structure Types:

Each Series is divided into 4 “Types” or degrees of hardness from 1 to
4:
 Type 1 refers to bits designed for the softest formation in a
particular Series.
 Type 4 refers to the hardest formation within the Series.
 Third Digit: Bearing/Gauge:

Seven categories of bearing design and gauge protection are defined as
“Bearing/Gauge”.
 1= standard roller bearing
 2= roller bearing, air-cooled
 3= roller bearing, gauge-protected
 4= sealed roller bearing
50
 5= sealed roller bearing, gauge-protected
50
 6= sealed friction bearing
 7= sealed friction bearing, gauge-protected.
 8 & 9= Categories reserved for future use.
 Fourth Digit: Additional Features:

A= air application
B= special bearing seal
C= center jet
D= deviation control
E= extended jets
G= gauge/body protection
H= horizontal/steering
J= jet deflection application
L= lug pads
M = motor application
S= standard steel tooth model
T= two cone bits
W= enhanced cutting structure
X = predominantly chisel insert
Y = conical tooth insert
IADC Fixed Cutter Drill Bit Classification System:
 First Character:
The first character specifies body construction:
 M = matrix body construction
 S = steel body construction
 Second Character:
The second character tells density of cutters on bit and ranges from
 PDC bits: 1 to 4 for in increasing order of no of cutters
- 1 = 30 or fewer ½” cutters
- 2 = 30 to 40 ½ in cutters
1
- 3 = 40 to 50 ½ in cutters
- 4 = 50 or more ½ in cutters
Note: Cutters larger than ½” and smaller than ½” are converted to ½”
equivalent size.
 6 to 8 for surface bits using diamond-type cutters in increasing
order of no of cutters.
- 6 = diamond sizes larger than 3 SPC*
- 7 = from 3 SPC to 7 SPC*
- 8 = diamond size smaller than 7 SPC*
*SPC= Stones (Pieces of diamonds) per carat
 0, 5 and 9 are reserved for future use.
 Third Character:
The third character represents digits 1 to 4 about the size of PDC cutter on this
type of bit, or
 1: Cutter size larger than 24 mm dia
 2 : Cutter size 14 to 24 mm dia
 3: Cutter size 9 to 14 mm dia
 4: Cutter dia 8 mm or less
Note: One bit may have different size of compacts
 Fourth Character:
The fourth character (digits 1 to 4) gives an idea of profileof the bit based on
overall length of the cutting face of the bit.
 1 = Fishtail PDC bit or flat TSP and natural diamond bit
 2 = Short bit profile
 3 = Medium bit profile
 4 = Long bit profile
For example, a long flanked “turbine style” bit would be categorized as 4.
Examples:
 Code S323: This is a (S) Steel body PDC bit with a cutters density (3) of 40
to 50 cutters and a size (2) (14 to 24mm) for the cutters. The profile (3) is a
medium profile.
 Code M713: This is a (M) Matrix body Surface-Set bit using diamond-type
cutter with a density/size (7) of 3 to 7 stones per carat of (1) natural
diamonds. The profile (3) is medium longer.
g) IADC Dull Bit Grading:
All pulled out bit should be graded for wear and damage according to the
IADC Dull Bit Grading System.
The dull grading system applies both to roller bits and fixed cutter bits.
Cutting structure Bearing Gauge Other Reason

Inner Outer Dull Loca seals Dull pulled
charact -tion charact- out
-eristic eristics
Col-1 Col-2 Col-3 Col-4 Col-5 Col-6 Col-7 Col-8
Column-1 and 2:
Inner cutting structure (inner is 2/3rdof the bit body from centre point)
Outer cutting structure (outer remaining 1/3rdof bit body beyond inner body)
In the columns 1 and 2 a linear scale from 0 to 8 is used to describe the

wear condition of the cutting structure according to the following:
Column-3
Steel toothand
bits:7:
 0 = No loss of tooth height
 8 = total loss of tooth height
Insert bits:
 0 = No lost, worn and/or broken inserts
 8 = All inserts lost, worn and/or broken
Fixed cutter bits:
 0 = no lost, worn and/or broken cutting structure
 8 = All of cutting structure lost, worn and/or broken.
 Write only cutting structure (Cone and cutters) related codes in Column
-3. All other problems may be indicated in Column-7.
Code Problem Code Problem

BC* Broken Cone LN Lost Nozzle
BF Bond Failure LT Lost Teeth/Cutter
BT Broken Teeth/Cutters OC Off Center Wear
BU Balled Up Bit PB Pinched Bit
CC* Cracked Cone PN Plugged Nozzle
CD* Cone Damage RG Rounded Gauge
CI Cone Interference RO Ring Out
CR Cored SD Shirttail Damage
CT Chipped Teeth/Cutters SS Self-Sharpening Wear
ER Erosion TR Tracking
FC Flat Crested Wear WO Washed Out Bit
HC Heat Checking WT Worn Teeth/Cutters
JD Junk Damage NO No Dull Characteristics
LC* Lost Cone
Show cone # or #’s under Column-3
Column-4: Location:
Roller cone Bit Fixed cutter Bit
Code Location Code Location Code Location Code Location
N Nose row #1 Cone#1 C Cone S Shoulder
M Middle #2 Cone#2 N Nose G Gauge

row
G Gage row #3 Cone#3 T Taper A All rows
A All rows All
Cones
Column-5: Bearings/Seals:
1
Non-sealed bearings: Sealed bearings
Linear scale estimating bearing life on 0-8
scale is used
0=No life used E=Effective seals
8=All life used N=Not able to grade
F=Failed seals
X= Fixed cutter bit
Loose cones, stuck cones and bearing exposure caused by shirttail wear
are all indicators of bearing wear.
Column-6– Gauge Condition:
Code Remarks
I Pulled out bit is in Gauge
1/16 Under gauge up to 1/16”
2/16 Under gauge 1/16” to 1/8”
3/16 Under gauge 1/8” to 3/16”
Degree of under gauge can be measured using a standard gauge ring of
steel with a known ID with ring touching two cones. Measurement of under
gauge is calculated from the gap between the third cone and inside of the ring.
 Under gauge for roller bit(In 1/16th of an inch)=
Gap measured (Inch) x 2/3
 Under gauge for PDC bit(In 1/16th of an inch)
= Gap measured (Inch)
Coumn-8– Reason for Pulling out bit or Terminating Bit Run:
Code Reason to pull out Code Reason to pull out
BHA Change BHA HR Hours On Bit
CM Condition Mud LIH Left In Hole
CP Core Point LOG Run Logs
DMF Down hole Motor Failure PP Pump Pressure
DP Drill Plug PR Penetration Rate
DSF Drill String Failure RIG Rig Repair
DST Drill Stem Test TD Total /Casing Depth

DTF Down hole Tool Failure TQ Torque
FM Formation Change TR Weather Conditions
HP Hole Problems TW Twist Off
New Generation Bits

StingBlade Conical Baker Hughes Halliburton
Diamond Element Kymera Hybrid MegaForce Bit
Bit Drill Bit
1. Stinger's unique 1. Rolling torque 1. Select Cutter

conical management PDC
geometry: with dual-action technology:
Innovative Conical cutting Enables the bit
Diamond structures: to stay sharper
Elements provide Increased ROP for long
Higher potential with more producing more
Concentrated Point efficient power meterage at
Loading capable of utilization, Better higher ROP
failing high directional control,
2. Premium
compressive rock lower and more Hydraulics:
2. Improved impact consistent drilling Micro Nozzle
resistance : offer torque & reduced optimize fluid
improved impact torsion vibration flow across the bit
resistance when and axial vibration face
drilling through 2. Balanced 3. Multi Level Force
inter-bedded downhole Balancing:
formations or dynamics: Provides
when hard Enhanced stability, maximum bit
inclusions such as bit life, and drilling stability and
chert & efficiency, system cutting structure
conglomerates. reliability, efficiency during
3. Stability: The advanced roller transitional
center location of cone bit bearing drilling
the Stinger conical and seal package 4. Premium
diamond in the thus maximizing Tungsten
bit enhances its seal reliability and Carbide
stability to provides longer bit Material: Helps
mitigate whirl and life to reduce erosion
other artifacts and wear on PDC
4. RockStorm PDC bit bodies
Technology: 5. Optimal Shank
These all-in-one Length: Reduces
cutters provide bit length for
ultimate wear directional
resistance and control
ultimate impact
resistance in the
same
PDC cutter.
Courtesy: Baker Hughes, Halliburton,

Drilling
4
Hydraulics
Hydraulics means flow of drilling fluid in drill string and annular space
between drill string and hole/casing. Hydraulics deals with Annular velocity,
Critical velocity, ECD, Pressure Losses, Hydraulic Horse Power/Sq. inch (HSI)
and impact force which affect hole cleaning and ROP. Hydraulics of drilling
fluid is of vital importance and serves many purposes in the well. Proper
hydraulics and hole cleaning are important for improving ROP and minimizing
well complications.
The hydraulics has following effects on the well:
1. Remove cuttings from the well
2. Cool & clean the bit
3. Increase penetration rate
4. Influences sizing of surface equipment such as mud pumps
5. Minimize hole erosion due to the mud's washing action during
Pipe movement
This chapter deals with

a) General Guidelines
b) Hydraulics in vertical hole
c) Hydraulics and Hole Cleaning in Intermediate & High
Angle Sections
c) Hole Cleaning and Monitoring
d) Remedial Hole Cleaning Practices
e) Cleanup Cycle
a) General Guidelines:
 In soft and unconsolidated formations especially at shallow depth, limit
jet velocity to minimize hole erosion and wash-out.
 In high angle holes, higher flow rate and turbulence helps in better
cutting lifting and hole cleaning.
 Run bit with preferably large size nozzle in expected loss circulation
zones to circulate out LCM.
 Utilize 6 5/8” or 5 ½” Drill pipes to maximum extent to reduce pressure
losses in high angle wells.
b) Hydraulics in vertical hole
Landmark hydraulics program gives correct nozzle combination and circulation
rate for a particular condition and improves bottom hole cleaning and ROP. It
is also important to utilize the maximum of available pump hydraulic horse
power at the bit.
Annular Velocity
Upward velocity of mud in the annulus against drill pipe is called
annular velocity. Drilled cuttings are heavy and travel upward initially but tend
to fall thereafter. This downward velocity of cuttings is called slip velocity. The
role of annular velocity is to transport these cuttings out of the hole. Generally,
annular velocity is kept about/around more than twice the slip velocity.
Table-1 gives the range of annular velocities for different sizes of
holes. Normally selection of annular velocity will be the first step in hydraulic
program.
Va, Annular velocity of mud
Vs, Slip velocity of particle
Table-1: Annular Velocities for different hole sizes
Size of Annular Velocity

the hole Feet per minute Meters per min.
(in inch)
4-3/4 140-220 42-66
6 140-200 42-60
8-1/2 120-180 36-54
12-1/4 70-110 21-33
17-1/2 60-100 18-30
26 30-50 9-15
Annular velocity should be maintained in the recommended range for
effective removal of cuttings. If annular velocity falls below the minimum
value, then cuttings fall back to the bottom of the hole and the bit keeps on
regrinding these cuttings. This results in poor ROP.
There is maximum annular velocity limit to avoid hole erosion
problem as enlarged hole may lead to many other problems later on.
Circulation Rate
The circulation rate depends upon:
1. Hole size :
Larger hole size needs higher circulation rate as ROP is more and a lot
of cuttings are generated. Smaller size hole needs less circulation rates as ROP
is less and lesser amounts of cuttings are generated.
2. Annular velocity:
Higher annular velocity gives higher circulation rate and vice versa.
If one pump fails and mud pump discharge of another pump is
insufficient to give minimum annular velocity, then it is advisable to stop
drilling and repair pump first after safety PO.
Normally tables give annular velocity against drill pipe annulus as in
most cases drill pipe body OD is same for all the pipes in hole.
Nozzles:
Nozzle size is normally given in whole numbers like 6, 7, 8, 9, 10, 11,
12, 13, 14, 15, 16, 18, 20, 22, 24 etc. Size ‘20’ means nozzle diameter of
20/32”. Sometimes nozzle size is also given in mm.
Normally wide variation in nozzle sizes in a bit is not preferred. For
example, 13-13-14 nozzles will be preferable to 12-12-16 nozzles.
Pump Output:
In ONGC, mostly 7” liner is used in the first phase of drilling with
Oilwell A-1700-PT/National 12-P-160 pumps till 12-1/4” hole and replaced
with 6-1/2” liners in the later phase.
Calculated triplex pump output, liter/ stroke = 0.0386 * D2 * H

where D = Liner bore or internal diameter, inch
60
H = Stroke length of piston, inch
Pump Efficiency:
Pumps are mechanical equipment and do not work at 100 %
efficiency. Use of strainer in suction line and super charger pumps increases
pump discharge efficiency to the order of 97 % can be realized. Actual pump
discharge is less than calculated discharge.
Actual pump output = Calculated pump output * Efficiency
Pump Operating Pressure
Normally pumps are rated at 3000 psi or 5000 psi. Oilwell A-1700-PT
pump is rated at 5,000 psi (350 kg/scm2). But 6-1/2” and 7” liners have
pressure ratings of 3,370 psi (237 kg/cm2) and 2,915 psi (205 kg/cm2)
respectively. Further, a margin of about 250 psi (~18 kg/cm2) is allowed to
avoid any accident. So, normally maximum pump operating pressure will be
liner rating minus 250 psi (~18 kg/cm2).
However if rotary hose condition or any other equipment dictates lower

pressure rating, then that will be maximum pressure rating.Mud pump safety
valve should be set according to liner rating
Pump pressure losses:

Standpipe pressure gauge gives total pressure losses in the system. Standpipe
gauge pressure or total pressure loss is sum of pressure losses in surface
equipment, drill pipe bore, drill collar bore, bit nozzles, mud motor if present,
drill collar and drill pipe annulus.
1
Remarks:
1. In shallow depths, circulating pressure loss is less as compared to bit
pressure loss.
2. In deeper depths, circulating pressure loss increases significantly.
3. Pressure loss is directly proportional to depth.
4. In deep wells, a simulated value of discharge derived from the software
take care of system pressure losses Vs minimum discharge.
Pressure loss in surface equipment

This includes pressure loss in standpipe lines, rotary hoses, swivel and
Kelly. This is a small fraction of total pressure loss. Sharp and abrupt bends
leads to higher pressure losses and erosion. Bends should be 45 or 90 degree
and smooth. Surface equipment is divided into four categories as follows:
Table: Friction factor for Pressure loss in surface equipment
Type Fric Standpipe Rotary hose Swivel Kelly

of tion
Length, ft
Length, ft
Length, ft
ID, inch
ID, inch
ID, inch
Length, ft
equip fact
inchID,
ment or
1 1.00 40 3 45 2 4 2 40 2-1/4
2 0.36 40 3-1/2 55 2-1/2 5 2-1/4 40 3-1/4
3 0.22 45 4 55 3 5 2-1/4 40 3-1/4
4 0.19 45 4 55 3 5 3 40 4
Pressure loss in drill pipe bore

Drill pipe length keeps on increasing as drilling progresses. So pressure loss
keeps on increasing with depth.
Pressure losses in drill collar bore

Pressure losses inside drill collar bore are quite high as compared to
drill pipe as drill collar ID is much less as compared to drill pipe. ID of main
body of 5”, 19.5 ppf drill pipe is 4.27” while ID of 8” drill collar is 2-13/16”.
Number of drill collar should be used as minimum as possible to avoid
unnecessary high-pressure losses. Drill collar bore pressure loss for the
complete bit run will remain the same if discharge is not changed.
Pressure loss in drill pipe annulus

Pressure loss in drill pipe annulus is quite small and can be neglected
in large size holes of 17-1/2” and 12-1/4”. But this should be considered in
smaller hole sizes like 8-1/2” and 6” hole sizes.
Pressure loss in drill collar annulus

Pressure loss in drill collar annulus is quite small and can be neglected
in large size holes of 17-1/2” and 12-1/4”. But this can be considered in
smaller hole sizes of 8-1/2” and 6” hole sizes.
Pressure loss in bit nozzles
Pressure loss in bit nozzles is the major part of total pressure loss.
Nozzle size is selected to optimize hydraulics. Hydraulics optimization leads to
improvement in ROP.
Hydraulics Optimization:
Hydraulics optimization takes place when pressure loss in bit is
between 50 to 65 % of total system pressure loss. For optimizing
hydraulics, pump pressure should be as high as possible but subject to the
maximum operating pressure.
There are two theories of optimization:
1. Maximum BHHP Theory:

Maximum Bit Hydraulic Horse Power theory gives about 65 % of total
pressure loss in the bit. Nozzle size is smaller and pump pressure is high.
Higher jet velocity gives better ROP in top-hole soft formation.
2. M a x i m u m I m p a c t T h e o r y :
At deeper depth, higher jet velocity does not help in improving ROP.
Moreover, it may not be possible to have 65 % pressure loss in bit as loss in
drill string also increases significantly. When bit is drilling, excessive
hydrostatic pressure of mud column does not allow cuttings to dislodge.
Impact force dislodges these cuttings.
Now Maximum Impact force optimization is more important than
maximum BHHP. This theory gives higher discharge, bigger nozzle size and
less pump pressure. Pressure loss in bit is around 50 % in this theory to
optimize impact force. There is less wear and tear of mud pumps.
Effect of mud weight on pump pressure:

Pump pressure with increase in mud weight and vice versa.
New pump pressure

= Old pump pressure * New mud weight / Old mud weight
Effect of pump discharge on pump pressure:
Pump pressure changes with pump discharge as follows:
New pump pressure

= Old pump pressure * (New discharge / Old discharge) 2
Effect of drill string bore on pump pressure:
Pump pressure changes with string bore as follows:
New pump pressure
2
= Old pump pressure * (Old bore, inch/ New bore, inch)
Hydraulics Optimization Criterion :

The three criterion for hydraulics optimization are as follows:
1. Pressure loss in bit nozzles in 50 -65 % of total pressure loss
2. Jet velocity is in the range of 100 -168 m/sec
3. HSI (Bit Hydraulic Horse Power per square inch of hole size)
is in the range of 2 -5
Reynolds Number and Flow Profiles:

Reynolds number is a dimensionless number that relates the velocity
to the ratio of inertia force and viscous force (viscosity).
Reynolds number, R n = 928 ρ V an /60 µ
Where D= Hydraulic diameter (inch)=D h -D p
Dh=Diameter of hole (inch)
Dp=Pipe OD (inch)
µ=Viscosity (cps)
ρ=Mud weight (ppg)
V an ==Annular velocity (ft/min)= 24.5 Q/(D h 2 -D p 2 )
Q=Circulation rate (gpm)
 Reynolds number < 2000, flow is laminar.

 Flow is in transition for Reynolds number 2000 -4000
 Turbulent for Reynolds number>4000.
The lower transition range of Reynolds number is called the Critical

Reynolds Number, ie 2000. If the actual Reynolds Number is less
than Critical Reynolds Number (=2000), the flow is laminar,
otherwise, it is turbulent.
Pressure losses are more in case of turbulent flow. Normally flow
inside drill string and against drill collar annulus is turbulent and
laminar against drill pipe annulus.
Hydraulics calculations:
Bingham Plastic, Power Law and Modified Power Law mathematical
models are used for pressure loss calculations by Hydraulics
software. These models give different pressure loss values.
However, the following equations provided in FPS and MKS system
can be used for pressure loss calculations and hydraulics
optimization on the rig.
FPS System:
1. Annular velocity
V an = 24.5 Q/(D h 2 -D p 2 )
2. Surface equipment pressure losses
∆P= C ρ (Q/100) 1 . 86 = 1.90 x 10 - 4 C ρ Q 1 . 86
3. Drill stem bore pressure losses
∆P= 0.000061 ρLQ 1 . 86 /d 4 . 86
4. Jet nozzle pressure losses
∆P= ρQ 2 / 10858 A n 2
5. Annular pressure losses
∆P= [(1.4327 x 10 - 7 ) ρLV 2 ]/[D h -D p ]
6. Jet velocity
V n =0.320086 Q/A n
7. Jet impact force
I f =0.000516ρQV n
8. Hydraulic Horsepower
HHP=PQ/1714
9. Bit HHP=∆P bit Q/1714
10. HSI=Bit HHP/Area of hole (square inch)
Nomenclature:
C= Coefficient of Friction whose value can be found
in Table: Friction factor for Pressure loss in surface
equipment given above
Q=Circulation rate (gpm)
Dp=Pipe OD (inch)
V an ==Annular velocity ( ft/min)
ρ=Mud weight (ppg)
C=Friction factor
P=Pressure (psi)
L=Length of component (ft)
A n = Area of nozzle (Square inch)
∆P=Pressure drop (psi)
V n =Jet velocity (ft/sec)
I f =Jet impact force (lb f )
HHP=Hydraulic Horsepower (hp)
d=Pipe bore or ID(inch)
MKS System:
1. Annular velocity
V an = 1.973 Q/ (D h 2 -D p 2 )
2. Surface equipment pressure losses
∆P= 9.40 x 10 - 6 C ρ Q 1 . 86
3. Drill stem bore pressure losses
∆P= 9.87 x 10 - 6 ρLQ 1 . 86 /d 4 . 86
4. Jet nozzle pressure losses
∆P= 3.77 x 10 - 6 ρ ρQ 2 /A n 2
5. Annular pressure losses
∆P= [(2.97x 10 - 6 ) ρLV 2 ]/[D h -D p ]
6. Jet velocity
V n =0.0258 Q/A n
7. Jet impact force
I f =0.001695ρQV n
8. Hydraulic Horsepower
HHP=0.00219 PQ/1714
9. Bit HHP=0.00219 ∆P bit Q/1714
10. HSI=Bit HHP/Area of hole (square inch)
Nomenclature:
C= Coefficient of Friction whose value can be found
in Table: Friction factor for Pressure loss in surface
equipment given above
Q=Circulation rate (lpm)
Dp=Pipe OD (inch)
V=Annular velocity (m/min)
ρ=Mud weight (gm/cc)
C=Friction factor
P=Pressure (kg/cm 2 )
L=Length of component (m)
A n = Area of nozzle (Square inch)
∆P=Pressure drop (kg/cm 2 )
V n =Jet velocity (m/sec)
I f =Jet impact force (kg f )
HHP=Hydraulic Horsepower (hp)
d=Inside diameter (inch)
c) Hydraulics & Hole Cleaning in Intermediate & High Angle

Sections
Following procedures are recommended for the deviated portion of the
wellbore where problems due to accumulation of cuttings beds are suspected:
 Circulate at simulated flow rate for high angle wells with rotation and
reciprocation prior to start a trip.
 Maintain maximum pipe rotation, which can directly contribute to
hole- cleaning. While using MWD, maintain 50-55 RPM.
 String rotation aids in hole cleaning significantly in high angle holes
minimum at 55 rpm and up to 120 rpm based on directional assembly
in use to stir-up & remove cutting bed
 Rotate string at (maximum permissible rpm in accordance to the bent
angle) periodically to clean the hole if large section of hole was drilled
under sliding mode or with mud motor.
 In the deviated section, POOH slowly with close watch on weight
indicator.
 If excess drag is indicated (half of buoyant BHA weight), stop pulling
out and circulate at least one bottoms up at the maximum allowable
rotation and flow rate.
 If hole condition is bad and continuous drag is observed during POOH
in high angle hole section, the following action is recommended:
 If top drive is not available:
Pump out one single at a time at the maximum allowable flow
rate while pulling at 1-2 minutes per single. Continue till hole
becomes free of cuttings. Pump out of the hole preferably to
casing shoe.
 If a top drive is available:
Pump out of the hole preferably to casing shoe at the
maximum allowable flow rate while pulling out at 3-6 minutes
per stand.
 Once string is inside casing, circulate at least one bottoms-up at the
maximum allowable flow rate or hole is clean
 POOH without pumping.
 Prevent annulus loading and consequent packing-off by ensuring that
recently drilled cuttings are well above the BHA length by circulation
especially when the ROP is more than 25-30 meters per hour.
 Pumping-out with back reaming is an accepted procedure in high angle
wells. However, the best way to deal with the cutting beds is to first
try normal pull out, if necessary pump-out at simulated GPM and
finally pump-out with back reaming if needed. The important point is
that, if back reaming is resorted then the string is to be pulled all the
way by back reaming only to shoe to avoid cutting bed packing-off.
For effective hole cleaning in directional wells with more than 350 angle, the
recommended flow rates are as follows:
Table: Recommended Discharge for High angle wells

Hole size Min pump discharge ssible
gpm lpm gpm
17-1/2”-16” 1,100 4200 1,200-1,400 -
12-1/4” 800-1,000 3,000-3,800 1,000-1,100 -5,300
8-1/2” 450 1,700 500-550 4,200
-
6” 250 950 300 2,100
115
0
Following table can be used to calculate actual bottoms up strokes in deviated
wells for ensuring effective well cleaning:
Table: Minimum no of circulations to clean well in High angle wells

Inclination of Well Section Length Factor (= No of circulations)
(Degrees) 17-1/2” 12-1/4” 8-1/2” 6”
0 - 10 1.5 1.3 1.3 1.3
10 - 30 1.7 1.4 1.4 1.4
30 - 60 2.5 1.8 1.6 1.5
60 - 90 3.0 2.0 1.7 1.6
d) Hole Cleaning and Monitoring:

 Flow rate – Maximize flow rate as per well plan
 RPM – Maximize within system limitations like surface
limitations, vibrations, ECD, down hole tools, etc.
 ROP– Maximize based on Torque & Drag monitoring and
hole cleaning.
e) Remedial Hole Cleaning Practices:

 Control ROP until hole cleaning improves.
 If the hole still does not clean up, stop drilling and perform
a cleanup cycle.
 If hole cleaning continues to be a problem, other options
may include i.e. sweeps, wiper trip, back reaming, change
in mud weight and rheology.
f) Cleanup Cycle:
The following procedure may be used to clean up the hole
prior to tripping out or for remedial purposes when drilling:
 Circulate minimum 2.5–3.0 times bottoms up and until
shale shakers are clean.
 Monitor the quantity of cuttings coming over the shakers
every 15 minutes.
 Maintain rpm and flow rate at their maximum level.
 Monitor relative changes in Torque &Drag. Improvement
70
is expected as the hole cleans up.
70
 Generally 2 distinct waves of cuttings over the shakers will
occur during the cleanup cycle (second peak generally
comes at 1.0-1.5 times Bottoms up after the first peak).
 When well inclination is 50-600, annular velocity should be

twice as compared to a vertical well.
Minimum no of circulations to clean well in High angle wells
Inclination of Well Section Length Factor (= No of circulations)

(Degrees) 17-1/2” 12-1/4” 8-1/2” 6”
0 - 10 1.5 1.3 1.3 1.3
10 - 30 1.7 1.4 1.4 1.4
30 - 60 2.5 1.8 1.6 1.5
60 - 90 3.0 2.0 1.7 1.6
1
5 Drilling
Fluid
Management
Drilling fluid is a critical part of the drilling process. Drilling fluid

provides the primary well control through its hydrostatic head and
provides the most important hole cleaning function. It is also needed to
realize the twin objectives of minimizing the drilling cost through
control of Non-Productive Time (NPT) due to down-hole
complications and maximizing the productivity of the well by control
of formation damage during drilling.
Functions of Drilling Fluid:

1. Hole cleaning:
a) Transport drilled cuttings and caving to the surface.
b) Suspend drilled cuttings and caving in the annulus when circulation
is stopped.
2. Primary Well Control: Control formation pressure.
3. Lubricity: Cool and lubricate the bit and drill string.
4. Hole stability:
a) Stabilize the down hole formation through inhibition, cake formation
etc.
b) Support the wall of the well bore.
5. Hydraulic Horse Power (HHP): Deliver hydraulic energy upon the
formation beneath the bit.
6. Data transmission: Provide a suitable medium for transmitting data
from down hole tools like MWD, LWD etc.
Types of Drilling Fluid:
Drilling muds are divided into two general types: water-based drilling
muds and oil-based drilling muds. Each type needs
special additives which are discussed in this chapter. The type of fluid
base used depends on drilling and formation needs.
Drilling Fluid Selection Criteria:
The drilling fluid is an ultimate carrier of success of the well, whether well is
drilled for production or data acquisition.
Wellbore instability is a common problem while drilling through shale, usually
attributed to inadequate density and/or composition of the drilling fluid.
The factors involved in selection of drilling fluid for a well can be summarized
as below:
a) Well depth
b) Temperature profile of well
c) Lithology profile of well
d) Expected maximum pore pressure to be encountered during drilling
e) Expected well bore complications
f) Type of influx expected
g) Other contamination type expected like various type of salts
h) Drilling fluid density requirement based on offset well records
i) Zone of the well to be drilled, like Reservoir / Non reservoir
j) Environmental Issues
k) Techno-economic issues
Selection Matrix of Drilling Fluid:
Sl Hole Size/ Recommended Drilling Fluid options Remarks

section
Litho**
1 23”-26”/Top Pre hydrated Bentonite Gel (5-8% w/v.) In case of
Hole 2. Pre hydrated Bentonite Gel (10% w/v.) + minor losses
Un- seawater (1:1) + 1.5-2 % w/v CMC-HV 15-20 ppb fine
consolidated ( for offshore) LCM can be
formation, 3. Pre hydrated Bentonite Gel (10% w/v.) + used to control
clay seawater (1:1) + 0.3-0.5 % w/v XC the losses.
& Silt polymer ( for offshore )
4. Pre hydrated Bentonite Gel (4-5% w/v.)
+ 1.5-2 % w/v CMC-HV /0.3-0.5 % w/v
2 XC polymer.
17 ½” section/ 1. Gel-Polymer + Drilling Detergent:1- **In presence
clay-clay 1.5% (w/v) in pill form, pH: 9.0-9.5 of shale
stone/ 2. Gel-Polymer ( 3-5% - Lignite (or formation KCl
immature shale CFD: 1.5-2.0% )+ Drilling Detergent:1- to be added
interlarded 1.5% (w/v) in pill form, pH: 9.5-10.5
with sand Gel-Polymer ( 3-5% - Lignite or CFD
stone layers :1.5-2.0% ) +1-2% KCl.**+ Drilling
Detergent:1-1.5% (w/v) in pill form, pH:
9.5-10.5
3 12 ¼” 1. Gel- KCl- PHPA- Polyol- Polymer – *1If MW
section/ NIFA. *1 requirement is
majorly shale >1.50 and temp
with Gel - KCl- Polyamine - Polymer –NIFA*1 >120ºC.
interlarded Gel- lignite- CFD system-NIFA*1 *2 if temp in
with silt 4. Gel -lignite -resinex -HPHT F/L reducer between ( 120-
,Siltstone clay, 165ºC) / MW
- Barite system*2 1.50-2.10 )
claystone,
sand/ 5. Gel -lignite -resinex -HPHT F/L reducer *3 temp (
sandstone – Mn3O4 system*
3 max-170 ºC/
MW-2.30
6. Formate based Drilling Fluid*4. *4.HPWBM
(Sodium Formate / Potassium for faster
Formate) drilling/Eco-
SOBM (70:30 O/W ratio) friendly/better
ECD
management
and shale
inhibition in
high angled
wells.
4 8 ½”
(non-reservoir
section) shale
with Technical
interbedded parameters will
with silt The drilling fluid selection will be same as be changed as
,Siltstone clay, chosen in 12 ¼” section. per
claystone, requirement.
sand/
sandstone
5 8 ½” Conventional NDDF (MW 1.06-1.10)
reservoir HGS System (MW 0.75-0.90)
section - Micro bubble System (MW 0.60 -0.75)
Lime Stone/ 4. High density formate brine based NDDF
Sand stone ( MW upto 1.55)
6 6” Drain Hole The drilling fluid selection will be same as

Horizontal / chosen in 8 ½” reservoir section.
deviated /Open
Hole
This chapter covers the following aspects of drilling fluid:
(A) Pre-requisite for Drilling Fluid Management

(B) Preparation of Drilling Fluid Tanks/ Circulating System
(C) Preparation/Maintenance of
i. Gel Drilling Fluid System
ii. KCL-PHPA Drilling Fluids
iii. KCl-Polyamine-Polymer Drilling Fluid
iv. Non-Damaging Drilling Fluid
v. Hollow Glass Sphere (HGS) Drilling Fluid
vi. Formate based Drilling Fluid
vii. Micro-bubble Drilling Fluid
viii. Mix Metal Complex based drilling fluid
ix. KOH-K Lignite drilling fluid system
x. HPHT Drilling Fluid
(D) Standard Methods of Testing and Control of Water Base Drilling Fluid
Parameters
(E) Low Toxic Mineral Oil/ SOBM
(F) Guidelines for Drilling
i. Clay Formations
ii. Shale Formations
iii. Pay Zone/ Reservoir Section
iv. Coal Section
(G) Hole Cleaning.
(H) Recommended Drilling Fluid Practices
(I) Bore Hole Instability
(J) Stuck Pipe
(K) Lost Circulation
(L) Guidelines for Operating Solid Control Equipment like Decanting
Centrifuge, Maintenance & Troubleshooting of De-sanders & De-silters
(M) Gas/ Water Influx Detection and Control
(N) Well Conditioning for Logging/ Casing Operation
Appendix:
i. Recommended drilling fluid properties in different hole sizes
ii. Stacking & handling of Drilling Fluid chemicals,
iii. Key safety precautions
iv. Emergency First-Aid procedures.
v. Abbreviation
(A) Pre-requisite for Drilling Fluid Management:

For effective drilling fluid management, the followings are essential pre-
requisites:
1. Geo-Technical Order (GTO) with lithological sequences (Sand, Clay,
Shale and Reservoir), temperature & Pressure data, caving, Drilling
Fluid loss and oil/ gas show zones.
2. Availability of all solids control equipment viz. shale shaker, desander,
desilter/Drilling Fluid cleaner, centrifuge (if available).
3. Handling equipment such as hoppers, agitators, jet shearing device,
guns and tanks with proper isolation and dump valves.
4. Drilling fluid testing equipment such as mud balance, Marsh funnel,
API fluid loss kit, Retort kit, Rheometer, pH meter, sand content kit,
MBC kit, labs centrifuge etc.
5. Chemical testing kits for salinity, KCl, PHPA, Ca++/Mg++, alkalinity
determination.
6. Additional chemical testing kits for SOBM and emulsion testing kit
7. Ensure that the technical water is tested for chemical composition.
8. Minimum 100 MT Baryte stock may be maintained in exploratory wells
at rig to meet any well control exigencies.
(B) Preparation of Drilling Fluid Tanks/ Circulatory System:

It is necessary to check and prepare the tanks and the circulatory system
of the rig before spudding a well. The following may be ensured:
1. Active and all other tanks are placed in order and inter connected.
2. All valves are functioning properly and have no leakage.
3. Agitators in the tanks are functioning properly.
4. Active pit is properly connected to incoming water line and mud pumps.
5. Flow line is of sufficient diameter to handle maximum discharge of
drilling fluid without overflow and with sufficient margin for gas influx/
expansion.
6. Bell nipple is properly aligned with the return flow line having proper
slope to possum belly at shale shaker and without leakages.
7. Ensure provision of minimum of 2” diesel line to slug pit.
8. Settling pits and other tanks of the circulatory systems are properly
lined up with no leakage.
9. Solid control equipment like shale shaker, desander, desilter, mud
cleaner and centrifuge are properly installed and functional. There
should be no leakages from the gland packings.
10. All motors to be properly protected from drilling fluid & water.
11.Degasser is properly installed and tested.
12. Both hoppers are functional and lined up.
13. Flow between different compartments of settling tank and to
intermediate tank is in over flow mode. Interconnection valves at bottom
to be kept closed to allow solids settle down.
14. Place Baryte platforms close to hopper.
15. Sensors for measurement of pit volume, flow rate, gas show,
fluid density etc. are installed properly.
Preparation of Gel in Mud Tanks:
1. Check salinity and calcium content of technical water. Chloride as NaCl
should be less than 1000 mg/l and Calcium less than 50 mg/l.
2. Clean the Drilling Fluid tanks thoroughly by flushing with drill water.
3. Take sufficient quantity of water in the Drilling Fluid tank.
4. Mix bentonite powder through hopper using water of active pit. The rate
of addition of dry bentonite powder is controlled to avoid choking of
hopper nozzle. Normally 7-8% (w/v) bentonite powder is sufficient to
achieve desired viscosity. However, thick gels of 10% or more bentonite
may also be prepared for keeping as reserve Drilling Fluid in other
tanks.
5. Check pH value of the gel under preparation and maintain in the range
9- 10 by adding required quantity of caustic soda.
6. Keep the gel for hydration for 6-8 hours with agitators running during
period of hydration.
7. Avoid contamination of drill water with salt, lime and cement etc., to get
proper hydration of bentonite.
(C) Preparation Maintenance of
a) Gel Drilling Fluid System

The bentonite gel is used for spudding the well (for drilling the hole for
Surface Casing/top hole). Normally, this drilling fluid is maintained only
with pH control and dilution. The well is drilled to a depth of 200/ 300 m
or more. The surface casing is lowered and cemented to isolate fresh
water sands. While drilling cement inside casing, cement contamination
causes viscosity hump in the Drilling Fluid system. The fluid is pre-
treated with soda ash (0.1-0.2 %-w/v) and citric acid to control pH and
viscosity hump. Minor treatment with thinner may be required to
smoothen the fluid flow.
Drilling Fluid Composition: 4-5% (w/v) Pre Hydrated Bentonite Gel
(PHBS) + 0.2-0.3 %( w/v) of XC Polymer/ 1.0-1.5% CMC-HVG (w/v).
This will provide an optimum rheology for lifting the cuttings in larger
hole diameter.
Conversion of Top Hole Drilling Fluid to Treated Drilling Fluid
System: Gel-Polymer
After drilling top hole section, before opening problematic shale section,
the bentonite gel based drilling fluid is converted to Gel Polymer
Drilling Fluid using specialty chemicals to control rheological and
filtration properties as follows:
1. Before conversion of Drilling Fluid System, the concentration of Clay/
Bentonite should be brought down to 2.0-3.0% (w/v) or Cation
Exchange Capacity (CEC) value within range of 1.5-2.0 meq.
2. Treat the Drilling Fluid with 0.5% (w/v) CMC-LVG with continuous
dilution to maintain rheology in order.
3. Add 0.2-0.3 % (w/v) XC-Polymer along with continuous dilution and 0.5
% (w/v) PAC-LVG to maintain desired fluid loss around 10 cc.
With this continuous treatment during drilling, the gel polymer system is
conditioned to the desired parameters by the end of the section for
logging and casing operations.
Note: Alternately, based on formation suitability/ specific well
requirement KCl-PHPA/ SOBM system may be used for top hole
drilling.
b) KCl-PHPA Drilling Fluids:

The ingredients of polymer Drilling Fluid are mixed in following order:
 Mix required dose of Biocide in technical water.
 Add KCl as per design for shale inhibition.
 Add PHPA for encapsulation. (0.3-0.4%; w/v)
 Add PAC (LVG) for fluid loss control (0.5–1.0%; w/v)
 Add XC-Polymer for viscosity and Low Shear Rate Viscosity (LSRV).
(0.3 – 0.5%; w/v)
 Add weighing material (Lime Stone Powder/ Barite) for increasing mud
weight.
 If weighing material is not used then mix 6% (w/v) micronized calcium
carbonate (MCC) for bridging purpose.
 All the polymers should be mixed very slowly to avoid hopper choking
and preferably through jet shearing device for proper shearing.
Particularly PHPA should be added slowly with sufficient shearing to
avoid the formation of fish eyes (lumps).
 Mix lubricants and Polyol (Grade-I/II depending on temperature) as per
requirement.
 Add maintenance dosages of these Drilling Fluid additives (in premix
form) at regular intervals to ensure that properties of drilling fluid
remain within the limits set in GTO/plan.
Guidelines for Running Partially Hydrolyzed Poly Acrylamide

(PHPA) Drilling Fluid:
The following guidelines for running PHPA Drilling Fluid are based on
careful analysis and field experience.
 Ensure that the rig has adequate solid control equipments. If the solid
control equipments are inadequate, then massive dilution will be
required for control of solids. Low gravity solids should be maintained
below 5% by volume.
 Maintain at least 1 lb/ bbl [2.9 Kg / m3] active PHPA in the Drilling
Fluid system as determined by a material balance calculation. The
PHPA depletes from the system as it coats on the solids and the well
bore. PHPA is to be added slowly or preferably as premix (in water) in
the system for replenishing its concentration as fresh formation is
being drilled. For 12¼” hole section 50-75 Kg and 8 ½” section 25-50
Kgs of PHPA is to be added for each 100 M3 drilling depending on
formation reactivity and as experienced in drilling operation. There are
several methods to test for PHPA concentration in the Drilling Fluid.
The best way to ensure sufficient PHPA in the system is to add
additional quantity of PHPA for every unit volume of dilution.
 To maintain active system, prepare a premix in separate pit containing
all ingredients and add to active Drilling Fluid system. Product
concentrations in the premix can be adjusted if necessary to increase
product concentration in the active system. The premix should be
sheared at high shear rates prior to adding to the active system. It is a
normal practice to maintain about 2% higher KCl in the premix to
compensate loss of Potassium ion in the drilling fluid system. Usually
about 20-40 m3 of premix addition per day may be required to
maintain fluid loss, inhibition, LSRV of the total Drilling Fluid system
in the desired range. The premix technique will minimize temporary
viscosity fluctuations and will also facilitate material balance
calculation.
 When mixing new Drilling Fluid, use a shearing device to eliminate
viscosity hump problems. Alternatively, if the initial viscosity is too
80
high, mix only 50% (w/v) of the required PHPA. Balance quantity
of PHPA can be added to the system as soon as circulation
commences.
 PHPA Drilling Fluids are sensitive to high pH, especially in the presence
of high calcium levels. For this reason, it is not recommended to drill
cement with this, unless the Drilling Fluid system is to be discarded after
drilling. If it is unavoidable to drill cement with a PHPA system, the
system should be pretreated preferably with citric acid or sodium
bicarbonate to knock out calcium ion and to control pH. If cement
contamination occurs, dump excessively contaminated patch of Drilling
Fluid and replenish PHPA concentration.
 The calcium ion concentration in PHPA Drilling Fluid should not be
more than 400 mg/L. Higher calcium ion levels will interfere with the
PHPA polymer. Avoid excessive treatment with soda ash to remove
calcium as this could lead to self-induced carbonate contamination in
the Drilling Fluid.
 Maintain pH in the 8.5 - 9.0 range. At higher pH, PHPA degrades to
release Ammonia.
 PHPA Drilling Fluids can be run at any salinity from fresh water to salt
saturation. They are particularly effective in seawater. For greater
inhibition, sodium chloride at a chloride ion concentration of 125,000
mg/L (ppm) has been quite effective in many areas. PHPA should be
pre- hydrated in fresh water for maximum yield prior to adding to the
active system.
 If insufficient yield value or initial gel strength is obtained from the
initial Drilling Fluid formulation, Xanthan gum can be used at 0.25
lb/bbl [0.7 Kg/m3] for the required low shear rate viscosity.
 When adding Baryte, it is recommended to add about 0.25 to 0.5 lb/bbl
[0.7 to 1.4 Kg/m3] of polymeric deflocculant (in the premix) to
minimize viscosity fluctuations in the active system.
 Another effective technique to enhance the inhibitive quality of PHPA
Drilling Fluids is to use Sulphonated asphalt in concentrations of 6 to 8
lb/bbl [17 to 23 Kg/m3] to seal shale micro-fractures.
 If viscosity increases are noted with increasing drill solids, take steps to
reduce drill solids through increased use of solid control equipment or
dilution and increase the PHPA concentration in the active system.
 Measuring HPHT fluid loss at 212-2500F [100-1200C], utilize PAC
1
polymer at 1 to 2 lb/bbl [2.9 to5.7 Kg/m3].
2
 Observe the drill cuttings across the shale shaker. If the cuttings stick
together when squeezed, additional PHPA polymer may be required.
Ideally, the cuttings should have a glossy appearance and have a slippery
feel.
 Observe the cuttings size distribution at the shale shaker/ flow line.
They should be coarse with a minimum amount of fine particles. If
shaker screen blinding occurs with the PHPA Drilling Fluid, use a
shearing device while pre-hydrating the PHPA or switch to the next
coarser screen size.
 When drilling with PHPA Drilling Fluid, tight hole may be encountered
as a result of gauged hole or drill cuttings smeared to the well bore. This
phenomenon often occurs only in the newly drilled section and clears up
after the first trip through the drilled section. If tight hole across the
same section persists on consecutive trips, investigate other causes.
 Although PHPA Drilling Fluid stabilizes well bores, unconsolidated
sands and mechanically weak shale will still be susceptible to hydraulic
and mechanical erosion. In such areas, maintain proper yield value, use
lowest optimum bit /annular hydraulics.
Solids Control in PHPA based Drilling Fluids:

The success of PHPA drilling fluid depends mainly on two key factors:
1. Maintenance of adequate quantity of polymer i.e. PHPA at all times in
the drilling fluid because below a critical polymer concentration there is
an unacceptable rise in viscosity mainly due to high yields and gels. So,
it is advisable to always maintain sufficient concentration of PHPA in
the drilling fluid system.
2. The second key factor is maintenance of good control over the low
gravity solids. This in turn requires the following solid control
equipment on the rig in proper working condition to prepare and
maintain high specific gravity KCl-PHPA Polymer drilling fluid:
 Shale Shakers capable of handling sufficient mesh screens.
 Linear Motion Mud Cleaner capable of handling large volumes of high
specific gravity KCl-PHPA Polymer drilling fluid.
 A Centrifuge of adequate capacity to handle high specific gravity KCl-
PHPA Polymer drilling fluid.
c) KCl-Polyamine-Polymer Drilling Fluid:
For reducing the dose of KCl, Polyamine can be added. Field results
validate the 2.0-2.5% (w/v) dose of Polyamine with half of the
prescribed dose of KCl performs, better than alone KCl or Polyamine.
The mixing of additives should be in following order:
 Mix required dose of Biocide in technical water.

 Add KCl as per design.
 Add Polyamine (2.0-2.5%; w/v)
 Add PAC (LVG) for fluid loss control (1.0–1.5%; w/v)
 Add XC-Polymer for viscosity and Low Shear Rate Viscosity (LSRV).
(0.3 – 0.5%; w/v)
 Add 6% (w/v) Micronized calcium carbonate (MCC) for bridging
purpose
 Add weighing material (Lime Stone Powder/ Barite) for increasing mud
weight.
 Maintenance and Solid control in this drilling fluid will be same as KCl-
PHPA drilling fluid.
d) Non-damaging Drilling Fluid:

Non-damaging Drilling Fluid (NDDF) is the drilling fluid to be used in
all drain hole drilling to minimize formation damage and maximize
productivity. NDDF drilling fluid is also used as testing fluid for pay
zone/ reservoir section. The components used in its preparation are eco-
friendly and biodegradable. The mud cake formed by NDDF can be
removed by mild acids/ mud cake removing formulations.
General formulation for its preparation:
 Technical water + 5.0% (w/v) KCl + 0.45-0.5% (w/v) XC polymer + 3 -
4 % (w/v) PGS+ 6.0% (w/v) Micronized CaCO3 + 0.1% (w/v)
formaldehyde (biocide).
Maintenance of NDDF is similar to KCl-PHPA polymer fluid as
described above. Particle size of the micronized calcium carbonate in
NDDF needs to be designed based on 1/3rd of average pore throat
diameter of the pay zone being drilled.
 When NDDF is used for pay zone drilling in conventional wells other
than drain holes, with cased hole completion, for improved performance
efficiency 2-4% (w/v) Sulphonated Asphalt, 3-4% (w/v) Polyol Gd II (at
high temperature~120°C) and antioxidant 0.1% (w/v) for thermal
stability) may be added to the NDDF system.
 Even though starch which is easily biodegradable is chosen for NDDF,
alternatively for maintaining optimum filtration loss, 0.3 to 0.5% PAC -
LV or PAC-R (Regular) may be used.
e) Hollow Glass Sphere (HGS) Drilling Fluid (0.64 – 0.80 SG / 5.3-6.6

ppg):
 HGS (Hollow Glass Spheres) is used as a density reducing agent in

drilling fluids to prepare lighter weight drilling fluids.
 The material is stable, incompressible and virtually insoluble in water or
oil.
 It has a high strength to weight ratio which ensures survivals in high
pressure down hole conditions. Density of HGS varies from 0.28 g/cc
(2.3ppg) to 0.42g/cc (3.5 ppg) depending on its pressure resistance.
 Its particle size ranges between 15 microns to 135 microns.
 These are unicellular hollow spheres, a composition of Pyrex-like soda-
lime-borosilicate glass.
 The practice of using HGS to reduce the density of drilling fluids has
become more important due to increasing demand of sub hydrostatic
pressure management with high performance low density fluids.
 The composition of drilling fluid is similar to NDDF formulation
described under Point no. viii.
 Drilling fluid density of 0.78 g/cc (6.5 ppg) and 0.66 g/cc (5.5 ppg) can
be achieved by using 12-13% (w/v) and 20% (w/v) doses of HGS4K28
respectively. HGS Gd-IV provides the drilling fluid density 0.90 g/cc
(7.5 ppg) and 0.80 g/cc (6.6 ppg) at doses 10% (w/v) and 20% (w/v)
respectively.
Maintenance of Hollow Glass Sphere (HGS) Drilling Fluid:

 Breakage of HGS more often leads to high density of drilling fluid. As a
remedial measure a continuous run of centrifuge and mud cleaner is
required during drilling and circulation.
 Premix of polymer and HGS in water, should be kept in mixing to
control the continuous rise of density and to maintain optimum
concentration of polymers.
Handling of Hollow Glass Sphere:
 Avoid handling practices that cause dust formation.Observe
occupational exposure limits and minimize the risk of inhalation of
dust.
 Store in tightly closed original container in a dry, cool and well-
ventilated place. While mixing of HGS in drilling fluid, wear safety
goggles, hand gloves, apron and face must be covered with
protective helmet. Mixing to be done in well ventilated place and
in the same direction of wind.
 Eye contact: Direct contact with eyes may cause temporary
mechanical irritation. Signs and symptoms may include pain,
redness. Wash eyes with plenty of potable/sterilized water.
 Skin contact: Direct contact with skin may cause irritation. Signs and
symptoms may include redness, pain and itching.
 Inhalation: Above recommended exposure levels may cause
respiratory track irritation including cough.
 Ingestion: No harmful effects expected in amounts likely to be
ingested by accident. May cause discomfort if swallowed.
In all the cases, consult the Medic for proper treatment.
f) Formate base drilling fluid:

For drilling pay zones with more than hydrostatic pressure, the NDDF is
prepared with Sodium Formate brine 1.33 SG (11.1 ppg max) and
Potassium Formate brine 1.57 SG (13.1 ppg max).
The main benefit in formate fluids is the use of solid free drilling fluid at
higher density even up to 2.1 SG (17.5 ppg) in case of Cesium formate.
The composition for formate based drilling fluid:

 Technical water + 0.3-0.45% (w/v) XC polymer + 3.0% (w/v) PGS +
6.0% (w/v) MCC + 20-30% (w/v) Sodium Formate (or as per density
requirement) + Potassium Formate (as per density requirement).
Note: Since, availability of Cesium formate for density > 1.55 SG (12.9
ppg) is very limited and the chemical is expensive too. Therefore, other
density material like Tri Manganese Tetra Oxide (Mn3O4) may be used
in Potassium Formate brine to achieve density up to 2.30 g/cc (19.2
ppg)
g) Micro bubble Drilling Fluid:

Micro bubble drilling fluids are used for drilling depleted reservoirs, loss
prone section, with alternate sand and shale or fractured lime stone
formations.
To prepare micro bubble drilling fluid, a blend of two different
surfactants is mixed in technical water/Sea water along with foam
stabilizers for creating stable micro-bubbles of sufficient low shear rate
viscosity (LSRV). A co-surfactant is also added to form a stabilized
foam system. This Drilling Fluid system works up to 110°C with good
Rheology profile including LSRV. HPHT fluid loss measurements
indicate good sealing properties of this system.
Mixing sequence & procedure:

 Take technical water/drill water half the volume of desired quantity of
drilling fluid, as the volume of the drilling fluid formed is doubled.
For example: If 100 M3 (~630 bbl) of drilling fluid is required, then
initial volume of water should be 50 M3 (~315 bbl ).
 The drilling fluid should be prepared in two parts in separate tanks:
 First half i.e. Part-I say 25 M3 (~158bbl) in present example of the
initial volume of water taken, should be used to mix polymers. Run the
gunning lines and shearing devices in mixing tanks. (refer table-Part-1)
 Remaining additives should be mixed in Second half i.e. Part-II say 25
M3 (~158 bbl) in present example as per mixing sequence. Run the
gunning lines and shearing devices in mixing tanks.( refer table-Part-II )
 The percentage of additives is to be taken with respect to total volume of
water i.e. 50 M3 (~315 bbl) as per above example.
 Later, both the parts (Part-I and Part-II) should be mixed until a
homogenous mixture is obtained.
Part-I (Mixing of Additives)
S.N. Additives Dose%(w/v) Mixing time (min)
1 Water As per
requirement
2 Biocide 0.2 10
3 Sodium Bi 15
0.25 – 0.30
Carbonate
4 XC Polymer 0.7 Add slowly (each chemical in 30-
5 Poly Anionic 1.0-1.2 40 min time for each chemical) to
Cellulose –(RG) prevent fish-eye/ lump formation.
Circulate for 20 min.* through
mixing pump / jet shearing
device.
*If the additives do not mix properly within stipulated time, additional
time can be given till proper mixing.
 Mixing of chemicals to be done through hopper.
 Gunning lines and shear devices must be in operation during additive
mixing.
Part-II Mixing of additives
S.N. Additives Dose%(w/v) Mixing time (min)
Water As per
1 -
requirement
Liquid Poly Vinyl 2.5-3.0 30 min.* agitation and
2 Alcohol (20%) recycle through mixing
pump/ jet shearing device.
3 Stearic Acid 0.3-0.4 40
4 Oleic Acid 0.1-0.2 15
5 Magnesium Oxide 0.3-0.4 15
Cocamido Propyl 0.4-0.6
6 20
Betaine
Surfactant (Non- 0.4-0.8
7 20
ionic)
8 Polyol Gr-II 0.5-0.6 10
If the additives do not mix properly within stipulated time,

additional time can be given till proper mixing.
 The maintenance dose of polymers/ formate should be given as a premix

with water.
h) Mixed Metal Complex (MMO/MMH) drilling fluid:
This drilling fluid is recommended for drilling the loss prone formations
having Bottom Hole Temperature (BHT) upto 120°C.
Following are the advantages of Mix Metal drilling fluid:
1. High shear thinning drilling fluid (PV:YP range 1:4 to 1:6) with low
Plastic viscosity.
2. High yield value resulting in better cutting lifting.
3. It seals-off the high permeability area (loss zone) and stabilizes the
formation by preventing further fluid loss, results in better well bore
stability.
Formulation for Mixed Metal Complex Drilling Fluid:

3.5-4% (w/v) pre-hydrated bentonite suspension (PHBS) + 0.1% (w/v)
Soda Ash+ Sodium Hydroxide (to maintain pH between 10.5 to 11.0) +
1.0-1.5% (w/v) Mixed Metal Complex + 2.5-3.5% (w/v) Pre-gelatinized
Starch + 5.0-6.0% (w/v) Micronized Calcium Carbonate + 0.5-1.0%
(w/v) Sulphonated Asphalt -Rheology Modifier.
Mixing Procedure:
 Thoroughly clean all the tanks to avoid Cement contamination for
drilling fluid preparation. Three mud tanks are initially required for
drilling fluid preparation.
 Prepare 10% (w/v) Bentonite Gel in tank#1 as described at point no (ii).
 Divide the tank #1 volume of bentonite gel in two tanks equally, say #1
& #2.
 Top up both the gel tanks (#1 & #2) with water.
 Fill tank #3 half with water.
 Mix 0.1% (w/v) Soda Ash, 10% (w/v) PGS, & 3%(w/v) Mixed Metal
Complex in tank#3 and maintain the pH of this suspension 10.5-11.0.
 Thoroughly mix the contents of tank#3 using hopper, gunning line and
shear pumps.
 Interconnect all three tanks, viz. #1, #2 & #3 and intermix by running
hopper, gunning line and shear pumps.
 This way all three tanks will make a homogeneous system of drilling
fluid.
 Mix it thoroughly. Top up all the three tanks with water. Mix it
thoroughly.
 Record Rheology.
 In order to resume drilling PV/YP ratio should be 1:6.
 During circulation/drilling 6% (w/v) MCC is to be added as a bridging
material.
Maintenance of Mix Metal Complex Drilling fluid:
Make new bentonite gel 3.5-4.0% (w/v) in one tank and mix 1.5 % (w/v)
mixed metal complex suspension + 3.5% (w/v) PGS. Maintain the pH
10- 10.5.This suspension is to be used for maintenance of running
drilling fluid system.
i) KOH-K Lignite drilling fluid system:

 This drilling fluid is a clay based dispersive system that can work up to
165°C.
 It can tolerate high solid and salt contaminations and has low cost
maintenance.
 Because of High pH the bacterial growth is suppressed.
 Density of drilling fluid can be reached up to 2.2 g/cc (18.3 ppg)
Mixing Procedure:
The drilling fluid should be prepared in two separate tanks:
1. Mixing of K-Lignite (4% w/v) along with KOH (4:1): For making
this, mix total quantity of KOH and K-Lignite in water as per ratio
given above. This is to be left overnight for activation of lignite in tank-
1.
2. Also keep ready the mixture of lignite having same composition as
above in tank-3, for further use during drilling for treatment.
3. Pre hydrated bentonite gel (3.0-3.5% w/v) should be prepared in tank-2
(full volume) using technical water/drill water as in practice. Additives
at
S.N. 2, 3 & 4 should be added to this gel system in the following order
Composition and Mixing Sequence
S.N. Additives Doses%(w/v) Tentative

mixing time
(min)
1 PHBS (3.0-3.5%) As per requirement -
2 XC Polymer 0.25 30.0
3 Poly Anionic Cellulose 0.4 30.0
(LVG)
4 Drilling Detergent 0.5 10.0
5 K Lignite-KOH (4:1) (4:1) 30.0
solution from tank-1
6 Resinated Lignite 1.0-1.5 20.0
7 Polyol Gr II 3.0 10.0
8 Non-Invasive Fluid 2.0-2.5 10.0
Additive (NIFA)
9 EP Lube 0.5 5.0
10 Barite As per requirement 20.0
Interconnect Tank l & Tank 2, intermix through hopper 60 min
/ gunning line etc. thoroughly and add chemicals at additional
S.N. 6, 7, 8, 9&10 in time line as suggested. mixing
*If additives are not mixed properly within stipulated time, additional
time can be given. Mixing of chemicals to be done through hopper.
Depending on availability, Gunning lines and shear devices should also
be run during additive mixing.
Note:
90
i. In final composition of drilling fluid CEC should be kept in between
2.5-3.5 meq (milli equivalent) before change over the drilling fluid to
well and pH >9.5.
ii. Before exposing shale section, add 3-4% (w/v) Sulphonated Asphalt,
0.5-1.0% (w/v) HPEP Lube (v/v) and 2.0-2.5% (w/v) NIFA in Hi-Vis
pill form .
iii. High viscosity pill (Vis > 120 sec) must-be ready for regular sweeps
during drilling.
iv. Low Viscosity-high density pill with Vis <35 sec; Density 0.05 g/cc
(0.42 ppg) higher than the running density of system must-be ready
for tandem sweeps during drilling.
j) HPHT drilling fluid:

The HPHT drilling fluid is recommended for formations having Bottom
Hole Temperature (BHT) in the range of 150°C to 230°C.The drilling
fluid properties must be maintained as under:
1. Plastic viscosity should be as low as possible to minimize ECD.
2. The yield value should be sufficient to prevent sag but not so high as to
cause gelation resulting in high surge & swab pressures.
3. Fluid loss should be as low as reasonably possible to prevent formation
damage and risk of differential sticking.
4. Rheological properties should not change over time under static or
dynamic conditions. It should be stable and tolerant to contaminants.
General Formulation for HPHT Drilling Fluid:

2% (w/v) pre-hydrated bentonite suspension (PHBS) + KOH (to
maintain pH 9.0 to 9.5) + 5–7% (w/v) KCl ( or as recommended) + 2.0-
2.5% (w/v) HT fluid loss additive + 0.5-1.0% (w/v) HT deflocculant +
0.6% (w/v) PAC(LV) + 1.5-2.0% (w/v) Resinated lignite +2.0-3.0%
(w/v) SA +0.1% (w/v) Sodium Sulphite + Baryte as per density
requirement
(0.5-1.0% (w/v) EP Lube/ graphite flakes may be added for better
lubrication).
1
Guidelines:
Before drilling a HPHT phase, convert the drilling fluid of previous
phase to HPHT system or prepare fresh HPHT drilling fluid. Salient
points are as follows:
1. HPHT drilling fluid has high volume fraction of solids (due to high mud
weight). Therefore, clay/ LGS content should be as low as possible.
2. Maintain Methyl Blue Capacity (MBC) value equivalent to 3-5 ppb
active clay content to avoid excessive viscosity and gelation.
3. For preparation of fresh drilling fluid, 1.5-2.0% w/v PHB should be used.
4. Sepiolite clay performs better at high temperature and can be used in
place of bentonite, if available.
5. Use high quality Baryte (4.2 SG/ 34.98 ppg) with particle size in the
range 10-75 microns and free from any clay or impurities.
6. Density materials of higher specific gravity like Micronized Hematite or
Tri manganese tetra oxide may be used to reduce solid content.
7. Additives like PHPA, PAC cannot withstand high temperature (above
150°C) so their use may be avoided.
8. Lignite, Resinated lignite and sulphonated asphalt can be used along
with HPHT chemicals to control fluid loss & rheology.
9. pH should be maintained between 9.5 to 10.0.
10. HPHT fluid loss reducing polymers should be mixed during circulation
to avoid any pumping problem.
11. HPHT deflocculant should be mixed very slowly in small quantity as per
requirement.
12. Where flow line temperature is very high (> 900C), use of mud cooler is
recommended for safety of crew and to maintain proper ambient
temperature around Drilling Fluid tank area. Use of mud coolers can also
reduce consumption of mud pump expendables in HPHT wells.
(D) Standard methods of testing and control of water base drilling fluid
parameters:
 Mud Weight:
Mud balance is graduated in different units in the scale of Specific
Gravity (0.72 – 2.88) and pounds/gallon (ppg) (6-24).
Procedure:
Fill Drilling Fluid in cup and place the lid. Close the hole on lid with
finger & wash the cup thoroughly. Place the balance on the fulcrum and
adjust spirit bubble on the leveler with sliding weight. Read the value.
Balance can be calibrated by unscrewing the screw at the end of the bar
& adding or removing lead shots.
Mud Weight Control:

In case of rise in specific gravity:
Every section of the hole is drilled with a certain desirable specific
gravity range based on the pore pressure and fracture pressure
values of the formation exposed in that section of the hole. Besides
control of pressured and highly dipping formations also sometimes
require higher values of specific gravity of drilling fluid. If however the
specific gravity of drilling fluid rises above the desired values, the
main cause is accumulation or build up low gravity solids which must
be curtailed and thrown out to keep the specific gravity of the drilling
fluid in check.
Following step wise procedure is recommended for trouble shooting this
event.
 Check the type of formation being drilled, if it is sand, silt, or compact
shales then the specific gravity build up is due to inefficient application
of solids control equipment.
 Check the shale shaker for efficiency and screen size ensure proper size
screens are installed. Preferably 60 or 80 mesh at the bottom if the
prevalent flow rates permit the same.
 Make sure that integrity of screens is intact & they are not torn. If torn
replace them immediately.
 Do not bypass shale shakers to avoid Drilling Fluid wastage in case of
high flow rates; instead enhance their efficiency by their proper servicing
and maintenance.
 Always ensure thorough and regular cleaning of shaker screens for its
optimum efficiency.
 Check the desander’s cones for their efficiency. This can be done by
checking the desirable pressure (2.5 kg/cm2 ~35 psi) developed on the
head of hydro cyclones. If there is leakage get it rectified immediately.
 Ensure that cones are in good condition and they are not mud cut.
 Ensure that the nozzle size of desander is proper. This can be checked
by inserting finger through the nozzle while desander is running. If a
distinct force is experienced by the finger tending to suck it in, the
nozzle size of the desander is correct. This force is developed due to
central portion created in an efficient vortex of a hydro cyclone.
 Watch the discharge of cones; it must be a spray discharge. If any time
rope discharge is observed get the cone checked and corrected
immediately. Rope discharge means inefficient operation of hydro
cyclone (desander & desilter).
 During round trip, clean and service the cones of desander & desilter for
their efficient operation in next cycle.
 Measure the specific gravity of under flow i.e. discharge of cones. This
shall give an idea of efficient running of desander.
 Follow all the above guidelines for proper operation, maintenance and
servicing of the desilter also.
 Run both desander and desilter simultaneously to remove the undesirable
low gravity solids up to silt range. This shall certainly reduce the
specific gravity of drilling fluid and it may come within the desirable
range.
 Once the specific gravity has come within desirable range maintain it at
that level by prudent alternate operation of desander and desilter and
efficient use of shale shaker.
 Use Linear Motion shale shaker and Linear Motion Mud cleaner if
available, for most efficient solids control results.
 In case the formation being drilled is soft clay, the rise in specific gravity
is due to particles finer than silt range and a good number of them may
fall in colloidal size range. The only option for their control and weight
reduction is by centrifuge or dilution with base liquid i.e. water or brine
as the case may be hence dilute with water at an optimal rate
commensurate with rate of drilling (ROP) to nullify the effect of clay
solids getting mixed in the system.
 For every cubic meter of water being added. Add desired quantities of
caustic soda for maintaining pH, fluid loss control additive, and other
specialty additives composed in the prevalent Drilling Fluid so that their
percentage dosages are maintained.
 Once the specific gravity reaches desirable value minimize water or base
fluid addition along with other chemicals and additives, to a level to
maintain specific gravity at that desired level.
In case of fall in specific gravity:

 If it occurs, an immediate remedial action must be initiated before the
control on the formation is lost and the well becomes active. The
following steps are recommended to trouble shoot this problem.
 Check if there was an inadvertent mixing of water or low gravity fluid

in the active circulatory system of drilling fluid. It may be due to a
leaking tap or valve failure allowing transfer of water or low gravity
fluid like reserve bentonite gel in the active system. If such is the case
rectify the cause of dilution of drilling fluid immediately.
 Measure the present specific gravity of the drilling fluid and add
calculated amount of weighting material i.e. Baryte over one or two
cycles, homogenously till the fluid specific gravity reaches back again
to the desired value.
 In case the fall in specific gravity is due to undesirably low viscosity of

the drilling fluid (YP<6), which is unable to suspend Baryte in the
system, then build up viscosity immediately by adding highly viscous
bentonite suspension/ viscous gel/ XC polymer till it is able to suspend
Baryte again for desired specific gravity.
 Add more Baryte to compensate for the added low specific gravity,
high viscosity gel.
 Funnel Viscosity:
Funnel viscometer is used to measure funnel viscosity. It consists of a
Marsh funnel and a mug. Funnel is conical in shape, 12 inches long,
diameter at top of 6 inches &fitted with 10 mesh screen. Lower end has
2 inches long tube with an orifice of 3/16 inches.
Procedure:
Fill Drilling Fluid in the funnel by closing the orifice at bottom. Allow
the Drilling Fluid to drain from the funnel into the mug up to the
marked point (1 quart or 946 cc)& measure the time taken in sec.
Report funnel viscosity in sec.
Viscosity Control:
KCl-PHPA Drilling Fluid:
This is one of the most common problems encountered during operations
and needs proper diagnosis after careful analysis of the causes of the
problem.
The rheological behavior of PHPA Drilling Fluid is controlled largely by
viscosifying effect of high molecular weight polyacryl polymers. The
key to the maintenance of PHPA Drilling Fluid is to ensure that the clay
solids and barite minimally add to the Drilling Fluid viscosity. This is
achieved by keeping the clay content within a specified range (by
keeping MBC 4.0- 5.0 ppb) and an excess of polymer is available.
At low concentration of polymers, the polymer chains bridge clay

particles resulting in a yield point increase. At high concentrations,
however, enough polymer chains are adsorbed on clay surfaces to leave
few free surface sites for a single polymer chain to bridge two particles.
The surface saturation results in steric stabilization reduced bridging
flocculation and a reduced yield point.
Many failures of the PHPA Drilling Fluid systems have resulted from
not keeping enough PHPA in the Drilling Fluid during
incorporation of drilled solids or addition of barites. Without sufficient
polymer, the influx of new free surface area (drilled solids or barite)
into a stable Drilling Fluid of desired viscosity causes adsorbed
polymers to redistribute so that
bridging flocculation occurs. The Drilling Fluid viscosity increases,
sometimes drastically. Often, the Drilling Fluid is then diluted or even
dispersed. PHPA Drilling Fluids that become too viscous initially.
Addition of PHPA should be done preferably in premix form to avoid
further viscosity increase. Material balance is calculated daily and
polymer additions are adjusted to ensure that 1 ppb active PHPA is
maintained preferably in the Drilling Fluid system at all times to
account for PHPA loss and degradation. Actual % of PHPA content
is to be analyzed regularly to support material balance.
Drilling Fluid viscosity could become excessive after adding PHPA,

when:
(1) Adding PHPA to the Drilling Fluid too quickly.

(2) Adding premixed PHPA without shearing the premix first.
(3) Adding PHPA to a system with a high mud weight or a high
concentration of filtration control materials where free water has been
depleted.
HPHT Drilling Fluid:

In the case, the rise in viscosity is due to partial thermal degradation of
deflocculant in the dispersed system along with reaction of clay with
caustic soda at this temperature (>1500C or more).Replenish
deflocculant after every 2-3 cycles so that it never falls below
minimum required levels. Drilled solids (LGS) should be kept
below 5.0% to keep the viscosity in range.
 Filtration Loss Control:
If fluid loss value exceeds the desired limits:

In relatively deeper sections of the hole, a prudent fluid loss control
regime is necessary to avoid uncontrolled flow of drilling fluid’s liquid
phase to formation pores and channels. This requirement becomes even
more important when permeable sand stone sections are drilled. If fluid
loss values of the drilling fluid goes above the desired limits and
permeable formations are exposed, the risk of a differential stuck up gets
greatly enhanced due to formation of a thick fluffy filter cake against the
formation face of the well bore. It is therefore, essential to keep the fluid
loss value within desirable limits and for that following steps are
recommended:
- If the fluid loss values exceed desirable limit, check the type of cake
deposited on the filter paper. Also check if there was a spurt loss when
the fluid loss was measured using API filter press. Normally both spurt
loss and a fluffy cake shall be observed.
- Check the Drilling Fluid rheological parameter, if the viscosity, yield
point and gels are within the desired limit, add fluid loss control additive
over a cycle so as gets its homogenized mixing with the drilling fluid.
- Let the Drilling Fluid be conditioned for one more cycle after addition of
fluid loss additive.
- After that measure API fluid loss again and record the drop in fluid loss
value, spurt loss if any and quality of mud cake.
- If the new fluid loss value falls within desirable range and there is no
spurt loss and cake has become thin & tough in appearance, the desired
percentage of Fluid loss additive is achieved in the system.
- Maintain this desired dosage by regular intermittent treatment of the
fluid loss additive depending upon the rate of drilling and rate of
dilution of drilling fluid with water/ pre-mix / bentonite gel.
- If the new fluid loss value does not fall within desirable range, continue
addition of fluid loss additive as per above procedure till the desired
value of API fluid loss is achieved.
- If the rise in fluid loss value of the drilling fluid is associated with
concurrent rise in viscosity, yield point and gels, the drilling fluid is
flocculated. Add sufficient quantity of deflocculant/pre-mix till viscosity
/ Rheological parameter fall within desirable limits
 Filtrate / Drilling Fluid analysis:
Filtrate Alkalinity (Pf & Mf) & Drilling Fluid Alkalinity (Pm):
The analysis gives concentrations of hydroxyl/carbonate/bicarbonate
ions.
Reagents required:
i) N/50 H2SO4
ii) Phenolphthalein indicator
iii) Methyl orange indicator
 Procedure:
Filtrate Alkalinity (Pf & Mf):
 Take 1 ml of filtrate
 Add 2-3 drops of Phenolphthalein indicator
 Titrate with N/50 H2SO4.
 End point - Color changes from pink to colorless
 Pf = ml of N/50 H2SO4
 To the above solution, add 2-3 drops of Methyl orange indicator and
titrate with N/50 H2SO4
 End point - Colour changes from yellow to pink.
 Mf = total nos. of cc of N/50 H2SO4
Drilling Fluid Alkalinity (Pm):

 Take 1 ml of Drilling Fluid with syringe.
 Add 25 ml distilled water and 2-3 drops of Phenolphthalein indicator.
 Titrate with N/50 H2SO4.
 End point - Colour changes from pink to colourless.
 Pm = ml of N/50 H2SO4
 Salinity:
Reagents required:
(i) 0.05N AgNO3
(ii) K2CrO4 solution
Procedure:
1. Take 1 ml of filtrate,
2. Add 2-3 drops of K2 CrO4 solution and titrate with 0.05N AgNO3
3. End point - Colour changes from yellow to brick red due to
precipitation of Ag2CrO4
Calculation:
Salinity as NaCl (gm. /lit)
= 0.05 x ml of AgNO3 x 58.5 / ml of filtrate
 KCl Determination (NaClO4 method):
Reagents required:
NaClO4 solution (150g/100ml Distilled Water)
Standard solution of NaClO4
Procedure:
Take 7 ml of filtrate, add 3 ml of NaClO4 solution and slowly invert the
centrifuge tube to mix the contents very gradually. Centrifuge for 1 min
at1800rpm. Read volume of precipitate. Determine % KCl from standard
graph given below for illustration. (Prepare standard graph with different
concentration of standard solution of KCl for actual measurement).
%KCL
12
10
% 8
K 6
C
4
2
00 0.5 1 1.5
ML PPT
 PHPA Determination:
Reagents required:
(i) SnCl 4 solution (20 g/100ml Distilled Water)
(ii) Standard PHPA solutions
Procedure:
1
Take 7 ml of filtrate, add 3 ml of SnCl4 solution and centrifuge for 1 min
at 1800rpm. Read volume of precipitate & determine PHPA percentage
from standard graph given below for illustration. (Prepare standard
graph with different concentration of standard solution of SnCl4 for
actual measurement).
 Total Hardness, Calcium & Magnesium determination:
Reagents required:
1. 0.01M EDTA solution
2. Erichrome black-T indicator
3. Solochrome dark blue or Calcon indicator
4. Ammonia buffer pH-10.0
5. 4N KOH buffer pH >12
Procedure:
 Take 1 ml of filtrate and add 10 ml of hypochlorite solution.
 Boil for 10 min to oxidize organic matter.
 Cool.
 Add 50 ml Distilled Water, 2 ml of buffer pH-10 and Erichrome black-T
indicator.
 Titrate with 0.01M EDTA solution.
 End point - Colour changes from wine red to blue.
 Record ml of 0.01M EDTA solution = V1
 Take 1 ml of filtrate and add 10 ml of hypochlorite solution.
 Boil for 10 min to oxidize organic matter.
 Allow to cool.
 Add 50 ml Distilled Water, 2 ml of buffer pH > 12 and Calcon indicator.
 Titrate with 0.01M EDTA solution.
 End point - Colour changes from red to sky blue.
 Record ml of 0.01M EDTA solution = V2.
Calculations:
Total Hardness (ppm)(As CaCO3) = 0.01 x 100 x V1 x 1000 Ca+
+ (ppm) = 0.01 x 40 x V2x 1000
Mg++ (ppm) = 0.01 x 24x (V1 -V2)x 1000
 Sand Content:
Sand content kit has a glass tube, a funnel & a cylindrical part fitted with
74 micron screen.
Procedure:
 Fill the Drilling Fluid in the tube to the mark ‘Mud to here’.
 Add water up to the mark ‘Water to here’.
 Shake & pour the contents of the tube over screen.
 Wash the solids by pouring water over the screen.
 Place the funnel over cylindrical part and invert it into the clean glass
tube.
 Pour water to transfer the contents into the tube.
Read the volume of sand (% V/V).
 Methylene Blue Capacity (MBC)/Cation Exchange Capacity (CEC):
Reagents Required:
1. Methylene blue solution (3.74 g /litre)
2. H2O2 solution (3%)
3. 5N H2SO4
Procedure:
 Take 1 ml of Drilling Fluid through syringe and add 10 ml Distilled
Water, 15 ml of H2O2 solution (3%) and 0.5 ml of 5N H2SO4.
 Boil gently for 10 min.
 Allow to cool.
 Dilute to 50 ml by Distilled Water and titrate with Methylene blue
solution in 0.5 ml increments & taking a drop of the suspension on filter
paper.
 At the end point, excess of Methylene blue elutes forming a Halo.
Calculation:
MBC (cc) = ml of titrant solution / ml of Drilling Fluid
Bentonite / clay (lbs/bbl) = 5 x MBC (cc)
Bentonite / clay (Kg/M3) = 2.853 x 5 x MBC
Bentonite (% w/v) = 1.4265 x MBC
 pH Measurement:
pH value is a very important parameter for performance of the drilling
fluid.
pH Strip Method:
Take an inch of the strip & place it on the surface of the Drilling Fluid for
~45 sec. Match the colour & report pH to the nearest 0.5 unit.
pH Meter Method:
This is more accurate method. Calibrate pH Meter with standard buffers.
Place the sample under pH Meter & measure stabilized value of pH.
Report the value to the nearest 0.1 unit
 Oil Water Retort Kit Analysis (Solid analysis):

The equipment used is called Oil Water Retort Kit. It has a sample cup of
10 ml capacity, a condenser and a heating system placed in insulator of
steel container. The contents are heated, evaporated and then condensed
liquid collected in graduated 10 ml cylinder. The solids are left behind in
sample cup.
Procedure:
 Take out retort assembly out of the insulator and remove Drilling Fluid
chamber or cup.
 Fill Drilling Fluid chamber with Drilling Fluid.
 Fit the assembly after applying silicone grease over the thread.
 Heat the assembly in the retort.
 Collect volume of liquid in the cylinder.
Calculations:
Find out the value of S from the relation:
A x 100 = (B x 1.0) + (C x S) + (D x 0.8)
Where
A = SG of Drilling Fluid
B = % of water by volume
C = % of solids by volume
D = % of oil by volume
S = SG of solids
C (4.2 – S)
% by volume of LGS = ------------------
(4.2 – 2.6)
% by volume of Baryte = C - % by volume of LGS

(E) Low Toxic Mineral Oil/ SOBM
i. Mixing Procedure, Testing & maintenance:
Take required quantity of Base oil (LTMO/Synthetic Oil) and mix
additives in following order with vigorous agitation:
 Add primary and secondary emulsifiers.
 Add lime in excess.
 Add required amount of brine
 Add organophilic clay/ viscosifier.
 Add filtration control additives.
 Mix and agitate for extended period to ensure good emulsion
formulation, especially immediately after adding brine. A well
emulsified SOBM should present a glossy mirroring finish.
 Add weighing agents.
 The addition of components in their proper sequence is essential because
initial mixing will optimize the performance of each product.
 Mixing time may vary depending on the amount of shear either at the rig
or mud plant.
 Organophilic clay/viscosifier requires considerable shear to develop full
viscosity.
Tentative concentration of additives in LTMO
S.N. Chemical Concentration.

1 Primary Emulsifier 2.00-2.25 % w/v
2 Secondary emulsifier 0.60% w/v
3 Organophilic clay 3-4%w/v
4 Fluid loss agent 2-3% w/v
5 Lime 3-4% w/v
Testing & Maintenance of Oil Based Mud (OBM):

Besides general tests carried out for Water base drilling Fluid, some
special tests are carried out for Oil based Drilling Fluid. These are:
 Alkalinity (OBM):
Determine the whole-Drilling Fluid alkalinity and lime content of an oil-
based Drilling Fluid (OBM).
Equipment & Solution:

 500-ml Erlenmeyer flask with a rubber stopper or a pint jar with a lid.
 3-ml disposable syringe
 50-ml graduated cylinder
 250-ml graduated cylinder
 Two 1-ml pipettes
 Two 5-ml pipettes
 Base fluid
 Distilled water
 Phenolphthalein indicator solution
 0.1N (N/10) sulfuric acid solution
 0.1N (N/10) sodium hydroxide
Procedure:
1. Collect a drilling fluid sample.
2. Measure 100 ml. of base fluid into the Erlenmeyer flask.
3. Add 1.0 ml of the fluid sample to the Erlenmeyer flask using the syringe.
4. Stopper the flask and shake vigorously.
5. Add 200 ml of distilled water and 10 to 15 drops of phenolphthalein
indicator solution to the flask.
6. Stopper the flask and shake vigorously for a minimum of two minutes.
7. Allow the phases to separate.
 If pink color develops and remains, go to Step 8.
 If pink color does not develop, Alkalinity is zero. Go to Step 16.
8. Add 3 ml of sulfuric acid solution to the flask using the 5-ml pipette.
9. Stopper the flask and shake vigorously.
10. Allow the phases to separate.
 If the solution remains pink, go to Step 11.
 If the solution turns colorless, go to Step 12.
11. Continue to add sulfuric acid solution in 3-ml increments with shaking
until the pink color disappears.
12. Record the volume of sulfuric acid used in ml.
13. Back titrate with sodium hydroxide using the 1-ml pipette until the pink
color first reappears and remains.
14. Record the volume of sodium hydroxide used in ml.
15. Calculate alkalinity.
 Alkalinity = ml N/10 sulfuric acid - ml N/10 sodium hydroxide
16. Calculate excess lime pounds per barrel of Drilling Fluid.
 Excess lime, lb/bbl = 1.3 × alkalinity
Calculation of Lime content:

Lime lb/bbl = 0.026 (Pm - Pm x Fw)
Lime Kg/M3 = 0.742 (Pm - Pm x Fw)
Where Fw =Volume fraction of water
 Filtrate: HPHT:
Equipment
 Baroid 500mL HPHT filter press
 Filter paper
 30-minute interval timer
 Thermometer up to 500°F (260°C)
 25- or 50-mL graduated cylinder
 High-speed mixer
 Gas supply (CO or nitrogen)
Procedure:
1. Collect a fluid sample.
2. Preheat the heating jacket to 10°F (6°C) above the desired test
temperature.
3. Close the bottom valve stem on the filter cell and pour a stirred, fluid
sample into the cell.
4. Place the filter paper in the cell.
5. Place the cap on the cell, tighten all set screws, and close the valve
stem on the cap.
6. Place the cell in the heating jacket with the cell cap on the bottom.
Rotate the cell until it locks.
7. Put a thermometer in the cell thermometer well.
8. Connect the pressure unit to the top valve stem and lock the unit in
place.
9. Connect the pressure receiver to the bottom valve stem and lock the
receiver in place.
10. Apply 600 psi (4,140 kPa) on the top and 100 psi (690
kPa) on the bottom.
11. Open the top valve stem and maintain this pressure until the
desired test temperature is reached.
12. Open the bottom valve when the cell reaches the
desired test temperature.
13. Adjust the pressure immediately on the top and bottom
regulators. Use the following specifications as a guide:
Temperature and Pressure on Top & Bottom Regulator

(as per API guidelines)
Temperature Top regulator Bottom regulator

Up to 3000F (1490C) 600 100
300-4000F (149-2040C) 700 200
0 0
400-500 F (204-260 C) 800 300
14. Filter for 30 minutes while maintaining the temperature at ± 5°F (±

3°C) of the test temperature and maintaining the pressure. Collect filtrate
by draining in to a graduated cylinder.
15. Close the top and bottom valve stems.
16. Release the pressure off the top regulator and disconnect the pressure
system.
17. Back off the T-screw on the bottom regulator.
18. Drain the filtrate cautiously from the receiver into a graduated cylinder.
19. Wait a few seconds for the filtrate to drain to the bottom of the receiver.
20. Tighten the T-screw slowly to flush any filtrate remaining in the
receiver into the graduated cylinder.
21. Release the pressure off the bottom regulator and disconnect the pressure
system.
22. Remove the cell from the heating jacket and allow the cell to cool.
23. Hold the filter cell with the cap down and loosen the filter cell's valve
stem to release pressure.
24. Close the valve stem when all the pressure has been released.
25. Hold the filter cell with the cap up and loosen the valve stem.
26. Loosen the set screws and remove the cap.
27. Remove and measure the filter cake to the nearest 1/32 inch (1.0 mm).
28. Record the HPHT filtrate as two times the filtrate volume collected.
 Electrical stability:
Equipment
 Fann 23D / OFITE electrical stability tester
 12-mesh screen or Marsh funnel
 Thermometer: 32 to 220°F (0 to 104°C)
 Heating cup
Procedure:
1. Collect a drilling fluid sample.
2. Pour the sample through the 12-mesh screen or Marsh funnel.
3. Use the heating cup to adjust the temperature of the fluid to 120°F (49°C).
4. Immerse the probe in the sample with the tester turned off. Ensure the
fluid covers the electrode surfaces.
5. Stir the sample with the probe for 15 to 30 seconds.
6. Turn the electrical stability tester on and press the Test button to start the
test.
7. Record the voltage when the values in the display stabilize.
 Retort Analysis:
Equipment
 Complete retort kit-50 ml capacity
 Volumetric receiver
 Fine steel wool
 High temperature lubricant
 Pipe cleaners
 Putty knife or spatula with blade
Procedure:
1. Collect a fluid sample and cool it to approximately 80°F (27°C).
2. Pack the upper retort chamber with very fine steel wool.
3. Lubricate the threads on the sample cup and condenser with a light
coating of lubricating/anti-seize compound.
4. Fill the retort sample cup with gas-free Drilling Fluid.
5. Place the lid on the retort cup; rotate the lid slowly.
6. Wipe off any excess Drilling Fluid and screw the retort sample cup into
the upper retort chamber.
7. Place the retort in the insulator block and put the insulator cover in place.
8. Place the volumetric receiver under the drain of the condenser.
9. Heat the sample until the liquid stops coming out through the condenser
drain tube, or until the pilot light goes out on the thermostatically
controlled units.
10. Remove the volumetric receiver and examine the liquid recovered. It
should be free from solids/ emulsion bands.
11. Allow the volumetric receiver to cool to approximately 80°F (27°C).
12. Read and record the volumes of oil, or synthetic and water in the
volumetric receiver.
13. Calculate % by volume of the liquid and solid components of the fluid.
a) % by volume water = ml water × 10

b) % by volume oil/synthetic = ml oil/synthetic ×10
c) % by volume total solids = 100 – (% by volume water) – (% by volume
oil/synthetic)
14. Calculate the oil: water (OWR) ratio or synthetic: water (SWR) ratio if
the fluid is oil based or Synthetic Drilling Fluid.
Oil Fraction= 100 X Oil/ synthetic % v/v

Oil/synthetic % v/v + water% v/v
Water fraction = 100 – (oil/synthetic fraction)
OWR = oil fraction: water fraction
SWR = synthetic fraction: water fraction
ii. Troubleshooting:
Problem: Insufficient Viscosity

Cause Treatment
Under treatment of viscosifier  Add organophilic clay
Lack of proper particle size  Add Gelling agent
distribution (Rheology modifier)
Low water content  Add water (brine)
New Drilling Fluid, lack of shear  Shear through bit or shear
unit
Gas stripping  Increase mud weight
 Add wetting agent
 Add primary emulsifier &
lime
Problem: Excessive Viscosity

Cause Treatment
High water content (saltwater  Dilute with base oil
flow)  Add primary emulsifier and
lime
Incorporated drill solids  Centrifuge/solids control
1. High solids (% volume)  Use dilution
2. Fines solids problem  Centrifuge/solids control
3. Water-wet solids  Use dilution
 Add wetting agent and
primary emulsifier
High-temperature  Add wetting agent and
instability primary emulsifier
 Increase Oil content
 Reduce solids content
1
Acid gases  Add lime
 Add primary emulsifier and
wetting agent
 Increase mud weight
Overtreatment  Dilute with base oil
Problem: Increase In HPHT Filtration

Cause Treatment
Weak emulsion  Add primary emulsifier
 Add lime
Lack of proper particle  Add Gilsonite, a naturally
size distribution occurring Asphalt
 Add Amine treated Lignite
 Add Oil base thinner
 Add weight material or bridging
agent
High-temperature  Add primary emulsifier and
instability wetting agent
 Add lime
 Add Gilsonite or Amine treated
Lignite
Problem: Water in HPHT Filtrate (If Undesirable)

Cause Treatment
Weak emulsion  Add primary emulsifier
 Add lime
High-temperature  Add primary emulsifier and
instability wetting agent
 Add lime
 Add Gilsonite or Amine treated
Lignite
Problem: Water-Wet Solids

Cause Treatment
Super-saturation  Add emulsifier and wetting agent
 Add water sparingly
Excessive solids  Use solids control and dilution
Under-treatment  Add primary emulsifier and
wetting agent
Problem: Shale Shaker Screen Blinding

Cause Treatment
Water wet solids  Add wetting agent
 Add primary emulsifier
Problem: Water Flow

Indicator Treatment
Decrease in O/W ratio (water  Increase mud weight
intrusion)
Decrease in mud weight  Increase mud weight
 Add primary emulsifier & wetting
agent
 Add lime
 Add base oil to adjust O/W ratio
 Add salt to adjust brine salinity
Problem: CO2 Contamination

Indicator Treatment
POM decrease  Increase mud weight
 Add lime
Rheology increase  Add primary emulsifier and

wetting agent
 Add oil for dilution
 Increase mud weight
 Add lime
Problem: Hydrogen Sulfide Contamination

Indicator Treatment
POM decrease  Increase mud weight
 Add lime
wetting agent
 Add zinc-based H2S scavenger
Foul odor  Increase mud weight
 Add lime
wetting agent
Mud turns black  Increase mud weight
 Add lime
wetting agent
 Add zinc hydrogen sulfide
scavenger
Drill pipe turns black  Increase mud weight
 Add lime
wetting agent
Problem: Lost Circulation

Cause Treatment
Overbalanced hydrostatic  Reduce mud weight (if possible)
pressure  Use LCM pills
 Set casing (Contingency)
Excessive annular pressure  Decrease rheology and gel
loss strengths
 Decrease circulation rates
Drilling Fluid turns black  Increase mud weight
 Add lime
wetting agent
 Add zinc H2S scavenger
Problem: Lost Circulation

Cause Treatment
Surge pressures  Decrease rheology and gel
strengths
Break gel at regular intervals while tripping in hole
Reduce tripping speed
Use LCM pills spotted in hole
(F) Guidelines for Drilling
i. Clay formation:
1. Drilling fluid should be pre-treated with soda ash (0.1-0.2% w/v) to
remove calcium ions while drilling float collar/ casing shoe to control
cement contamination in drilling fluid.
2. Gel-Polymer Drilling Fluid: It is the most preferred drilling fluid to
drill clay sections. Although gel/polymer drilling fluid is normally
prepared fresh, but existing bentonite spud Drilling Fluid or native
clay Drilling Fluid can also be converted by diluting the systems
and adding the appropriate fluid loss polymers.
3. Slower drilling rate in clay results in gain in viscosity with shoot up in
YP.
4. Use symptomatic doses of available thinner, dilution and water loss
control agent (CMC) towards relaxed fluid loss control of <16 cc.
5. Use drilling detergent (0.2% w/v) to prevent bit balling.
6. Shale shaker screen capable of handling circulating discharge should be
used (Preferably, 60-100 mesh).
7. Monitor active pit volume. Reserve tank should be kept full of Drilling
Fluid for seepage losses.
8. Run solid control equipment continuously.
9. Use maximum recommended discharge for proper hole cleaning & better
ROP.
10. LCM should be kept at drill site to cure loss problems whenever
encountered. This can be used either as System LCM (15-20 ppb) or as
Loss Control Pill according to severity.
 System LCM: Calcium Carbonate (Fine, Medium, Coarse grade)
 Granular LCM: Saw Dust, Mica flakes, Rice husk, Walnut shell,
Coconut shell etc.
11. Maintain viscosity, pH, W/L, Sand content, Specific gravity as per GTO
ii Shale Formations:
 Shale is the most frequently encountered Lithological segments in the
drilling of a well.
 To drill shale section, changeover to inhibitive Drilling Fluid system
(KCl-PHPA-Polyamine/ Choline Chloride-XCP-Polyol-Sulphonated
Asphalt).
 Inhibition is provided by additives like KCl, Choline Chloride,
Polyamines, PHPA and Polyol.
 Maintain mud weight as per requirement of the well / GTO.
 Never cut down mud weight from the initial mud weight with which
shale interval was opened.
 In case caving is observed at shale shaker; gradually increase the mud
weight to control caving. Hole should be swept with 5% (w/v)
sulphonated asphalt pills regularly to effectively seal the shale micro
fractures.
 Start shale drilling with low API water loss (4-6 ml).
 Maintain pH for polymer Drilling Fluid system in the range of 8.5-9.0.
 Run mud cleaner (Screen size 150-200 mesh) continuously throughout
drilling.
 Maintain plastic viscosity as low as possible (ALAP).
 Treat the Drilling Fluid with Sodium Sulphite (0.01% w/v) prior to trips
for oxygen scavenging especially in polymer Drilling Fluid.
 Maintain YP/PV ratio>1 for good hole cleaning.
 Add lubricant for providing lubricity.
 Ensure proper hole cleaning without turbulence against unstable shale
sections.
iii Pay Zone/ Reservoir Section:

 Change over to NDDF for drilling pay zone/ reservoir.
 Here the main objective is to avoid formation damage. Baryte and
Bentonite should not be used in NDDF.
 Micronized calcium carbonate (MCC) / Lime stone powder (LSP) is
used as bridging agent and also for providing specific gravity upto1.30
(10.8 ppg).
 For higher specific gravity, formate salts may be used (Sodium formate
~1.33 (11.1 ppg), Potassium formate~1.57 (13.1 ppg)
 Use Pre-gelatinized starch (PGS) as water loss control agent, KCl as clay
inhibitor, XCP as viscosifier and Biocide for controlling bacterial
degradation
 Add only bio-degradable lubricants like linseed oil (0.5% w/v).
 Maintain Drilling Fluid parameters with special attention on pH (8.5-9.0)
and water loss as per GTO.
 Run mud cleaner continuously to minimize entry of fine solids into
NDDF.
iv Coal Section:
 Coal is highly brittle and caving prone.
 Polymer Drilling Fluid system (KCl-PHPA-XCP) is useful in drilling
coal.
 High mud weights may not be of much use to stabilize coal formations
as they have inherent low fracture gradients.
 The recommended technique to drill coal is to controlled penetration rate.
 Good hole cleaning is essential. it may be necessary to increase cleaning
capacity of the Drilling Fluid by having YP/PV ratio up to 2 while
drilling coals. The properties can be restored to normal after the coal
section has been drilled.
 Alternatively, viscous asphalt sweeps can be used to enhance hole
cleaning.
 If pipe gets stuck in coal and circulation is possible, spotting caustic pill
around the coal may help to free the pipe.
 While coring with water based Drilling Fluid, low water loss and lower
jet velocity should be used. Avoid turbulence against coal section. To
stabilize fractured coals, sulphonated asphalt (3-4%) (w/v) and NIFA
(2.0-2.5%) (w/v) may be used.
(G) Hole Cleaning:
 Monitoring of Shale shaker:

1. The best way to monitor hole cleaning is by observing the volume and
shape of cuttings coming out at shale shaker.
2. Shale shaker may show excessive cuttings (more than normal size)
which may indicate that the well is caving.
3. Reduced volume of cuttings on shale shaker indicates poor hole cleaning
which means cuttings are floating in the annulus and not getting lifted to
the surface. It may lead to hole pack off.
4. If any of the above abnormalities are observed, corrective action needs
to be taken for proper hole cleaning.
5. Maintaining YP/PV ratio > 1 is an effective way for good hole cleaning.
Shear thinning properties must be imparted to the Drilling Fluid system
with addition of Xanthan gum. It increases YP/PV ratio.
6. A thumb rule for effective hole cleaning is to keep PV as low as possible
(ALAP).
7. Use high viscosity sweep for vertical wells. Funnel viscosity of the
viscous sweep should be >150 sec. Observe the surfacing of the pill for
additional cuttings and viscosity.
8. Use combination of low viscosity sweep followed by high viscosity and
high density sweeps for directional wells.
9. Use low Vis (<40 sec) and high density sweep in high angle well (>350).
Minimum volume of the sweep should be calculated for 150m of
annulus height. Weighted sweep should be 0.20SG (1.66 ppg) to
0.25SG (2.08 ppg) higher than the existing mud weight. When the
sweep is coming out of bit, circulation rate and rotation should be at
their maximum. The next sweep should be pumped only after the first
sweep has been circulated out of the well.
10. Approximately 5% w/v Sulphonated Asphalt is to be used for preparing
Asphalt sweep in case of severe caving in shale/ coal.
 Other Factors:
 Annular velocity is the other important factor in hole cleaning efficiency
in vertical as well as directional wells. This is to be maintained
according to requirement which varies from 100-200 feet/ minute.
 Pipe rotation (60-120 rpm) improves hole cleaning efficiency.
 Circulate out cuttings above the BHA prior to connection.
(H) Recommended Drilling Fluid Practices:

 All the solid control equipment should be in good working condition to
maintain sand and solid content of the drilling fluid in desired range.
 Ensure maximum GPM and RPM possible for high angle wells to
avoid cutting bed formation.
Recommended Discharge for High angle wells
Hole size Min. pump discharge ge, if
gpm lpm gpm lpm

17-1/2”- 1,100 4200 1,200-1,400 4,500-5,300
16”
12-1/4” 800-1,000 3,000-3,800 1,000-1,100 3,800-4,200
8-1/2” 450 1,700 500-550 1,900-2,100
6” 250 950 300 1150
 Rule of Thumb:
 Up to 300 well inclinations, 20 % more annular velocity is required as
compared to a vertical well.
 When well inclination is 50-600, annular velocity should be twice as
compared to a vertical well.
Minimum no of circulations to clean well in High angle wells
Section Length Factor (= No of circulations)

Hole size 17-1/2” 12-1/4” 8-1/2” 6”
Well
Inclination
(Degrees)
0 - 10 1.5 1.3 1.3 1.3
10 - 30 1.7 1.4 1.4 1.4
30 - 60 2.5 1.8 1.6 1.5
60 - 90 3.0 2.0 1.7 1.6
Requirement of Low Shear Rate Viscosity (LSRV) to Avoid Baryte

sag and Cutting Bed Formation:
1. Maintain Fann 3 rpm reading at least 12-15 and 6 rpm reading 1.1 times
hole diameter to avoid cutting bed formation, achieve better hole
cleaning and less torque and drag in high angle wells.
2. For more accurate LSRV, the following formula may be used
LSRV=2Q3 – Q6 where Q3 and Q6 are 3 and 6 rpm readings respectively.
3. LSRV should be maintained
- Equal to 0.4-0.8 times of well diameter in inches in normal condition
- Equal to well diameter in inches in critical situation.
4. If Brookfield viscometer is available, then measure LSRV at 0.3 rpm
using L-3 spindle and maintain LSRV at 20,000 to 50,000cp (reading on
Brook Field Viscometer) depending on well angle. Higher the hole
angle, more is the required LSRV value.
5. In deviated wells when angle is less than 450:

Sweeps with YP of 1.5-2.0 times that of running Drilling Fluid should
be pumped in laminar flow, preferably mixed with a fibrous
materials/polymers covering 60-90 m of annular height to clear cutting
beds.
6. When well inclination is more than 450:
Apart from conventional low vis (vis<40 sec) high weight (3-4 ppg
higher than mud weight in use) followed by high vis (vis>120 sec)
pill. The recommended volume of pill should be at least150m
annular height. Fibrous material (1.5-2.0 ppb) is also helpful in this pill.
The next sweep should be pumped only after the first sweep has been
circulated out of the well.
7. This high weight- low vis pill must be circulated out before any trip
for P/O with maximum rotation possible (at least 80 + rpm). Once
sweep is pumped; do not stop pumps till sweep is out of the hole.
Because of high density, fracture gradient must be taken into
consideration for volume selection of this pill.
8. In high angle well with a horizontal drift of 1,500 m or more; very high
torque and drag is expected. The above recommended sweeps of low
vis high weight pill should be used regularly.
(I) Borehole Instability (Caving– detection and control):

The following steps are recommended for proper detection and control
of caving while drilling:
1. Designing of drilling fluid specific gravity is generally done on the basis
of pore pressure data provided and Drilling Fluid system is chosen on
the
behavior of shale cuttings (dispersion characteristics of shale when
exposed to drilling fluids).
2. When drilling directional and horizontal wells in tectonic areas, dipping
weak bedded formations and depleted reservoirs; geo-mechanical studies
of the shale/ caving formations is essential for establishing the minimum
mud weight required to control caving as per collapse pressure data
calculated.
3. If geo-mechanical studies are not possible, then decision regarding
increasing mud weight may be taken during actual course of drilling
depending on presence of caving at shale shaker, tight pull and held up
during round trip and increase of torque etc.
4. Monitor cuttings at shaker; both in quantity and size while drilling
through caving prone shale sections especially during bottoms up.
5. Big pieces of formation cuttings in large quantities at the shale shaker
are indicative of caving.
6. Stop drilling ahead; circulate with a pill as discussed in hole cleaning
section to clean the annulus.
7. Simultaneously, condition drilling fluid with sufficient quantities of shale
stabilizer (KCl, Polyamine etc.), sulphonated asphalt and polyol.
Running Drilling Fluid may be loaded with 3-5% (w/v) Sulphonated
asphalt and intermittently used as sweep as well as placed at bottom
before pull out of hole.
8. Also ensure that sufficient quantities of all other chemicals are present in
the drilling fluid to ensure the best possible values of rheology and
filtration loss.
9. Follow good drilling practices

 Avoid pressure surges/ swabs during tripping
 Do not use rotary for opening joints in open hole.
10. If the caving are due to pressured shale, tectonically stressed and / or
highly dipping formations, raise the specific gravity of the drilling fluid
to counter balance these pressure.
1
11. 1.5-2.0 % (w/v) NIF (non- invasive drilling fluid additive) can be mixed
in the drilling fluid during drilling to strengthen the well bore.
12. In any case mud weight must not be decreased from running mud
weight in caving prone formations.
(J) Stuck-Up:
 Non-Weighted Spotting Fluid:
1. Immediate spotting without loss of time can ensure release of stuck pipe.
2. Placing of spotting pill by observing differential pressure as soon as pill
goes out of bit is the best method to ensure that pill is in place.
3. Before and after the stuck breaker pill (SBP), a balanced high viscous
high weight (1ppg higher than current mud weight) spacer pill should be
pumped to prevent mixing of SBP with Drilling Fluid.
4. 2-4% (w/v) Spotting fluid is mixed in HSD to prepare non-weighted
spotting fluid pill.
5. Size of the pill should be such that it covers the drill string annulus at
least up to the free point or alternately the whole BHA length including
HWDP. Add 25% extra volume for hole washout especially if hole has
been showing caving problems. However it must be made sure that
hydrostatic head under balance due to SBP pill does not allow formation
fluid to enter the well bore.
6. In some cases it has been observed that during soaking period of 6-8
hours, the pill starts to surface at the shale shaker. This makes the pill
ineffective. In such cases, pumping a balanced hi-vis pill before and
after spotting fluid is useful.
7. It is recommended to leave at least 50-100m more of SBP column inside
the drill string compared to the column height in the annulus and close
Lower Kelly cock. Every half an hour, 5 strokes should be pumped
through drill string into the annulus.
8. String should be kept under compression if bit is off bottom by a few
meters.
9. In case Drilling Fluid circulation exists, it is recommended to at least try
with three or four stuck breaker pills before going for other fishing
operations.
Preparation of Weighted Spotting Pill
 Clean out tank and fill with HSD. The volume shall be equal to 100 %
excess over the annular volume around the drill collars. Mix the pill in
accordance with the following procedure.
Formulation for preparing weighted spotting fluid (1M3)
SG/ppg
1.2/10.0 1.44/12.0 1.68/13.99 1.92/16.0 2.16/18.0
required
Spotting Fluid
80 80 80 80 80
(Weighted), litres
Water, litres 540 490 450 430 410
HSD, litres 295 270 245 135 110
Baryte, Kg 350 660 960 1280 1600
 Add Baryte until the desired weight is achieved.

 Normally, 8–10% (v/v) of weighted spotting fluid has been found
satisfactory.
 Weight of the pill should be the same or preferably 0.06–0.12 SG above
the weight of the Drilling Fluid system to minimize migration of the pill
through the static Drilling Fluid column.
 Care shall be taken to isolate oil-based spotting fluid and any
contaminated Drilling Fluid, when it is returned to the surface.
 Mud Acid Job To Release Stuck Up:

1. The mud acid job is suitable up to 1200C circulating temperature.
2. Rig up acid pumper, Water tanker, Acid tanker, Oil tanker and Fire
tender at site.
3. Make necessary connections.
4. Pump 5.0 M3 crude/ HSD + 2% spotting fluid non-weighted as spacer.
5. Prepare and pump 3.0 M3 (HCl-HF: 9:6) acid solution containing
 15% HCl (by diluting 1,500 liters of 28% HCl)
 60 liters of Acid Corrosion Inhibitor (ACI) grade II (2% v/v)
 90 liters Acetic acid (3% v/v)
 30 liters Surfactant (1% v/v)
 250 kg Ammonium Bi-fluoride (9.26% w/v)
6. Followed by, 5.0 M3 crude oil / HSD as spacer.
7. Place acid solution at the bottom with Drilling Fluid.
8. Pump acid solution into annulus in 500 liters batch. Wait for 10-15
minutes after pumping each batch.
9. Work on string during acid placement and soaking.
10. Pump out acid solution after soaking it for 90 minutes. Take necessary
safety precautions while handling out coming spent acid and do not mix
spent acid with active Drilling Fluid.
11. Above recipe (point 5) is for 3 M3 mud acid pill, for bigger or smaller
jobs quantities of the chemicals are to be adjusted accordingly.
(K) Lost Circulation:

Each case needs to be studied into the possible reasons and the well
design may be optimized and preventive measures such as planning for
suitable system LCM, controlled drilling, minimizing ECD etc. are to be
in place during planning stage itself.
1. Monitor Drilling Fluid returns at shale shaker.

2. Monitor active pit volumes closely and record all Drilling Fluid
additions and transfers.
3. Ensure there is no leakage in surface equipment and no surface losses.
4. In case of mud loss, analyze & identify the probable causes and depth of
loss zone. Incompetent formations are usually just below the casing seat
of the previous casing.
5. Record rate of loss in dynamic as well as static condition.
6. In case of mud loss, hole should be full of drilling fluid or water (if mud
is exhausted) to avoid well bore instability and influx of fluids from the
pressurized formations.
7. Prepare a pill with a blend of fibrous and granular bridging materials like
Mica flakes, Rice husk, Sawdust, Bagasse (fibrous sugar cane by-
product), granular walnut shell, Calcium Carbonate (Fine, Medium,
Coarse) etc. in a separate tank or otherwise Single sack LCM remedies
available can be used.
LCM Pill Composition
Dynamic LCM Pill LCM pill LCM pill Remarks

loss rate pill volume composition in composition
(L/min)/ conc. bbl / M3 pay zone for other than
bbl/hr pay zone
03-30/ 15-20 Of total System LCM Single sack All the pill
~1.5-11 ppb drilling (DF with NIFA LCM constituent
fluid and CaCO3 of (Indigenous/ s should
volume different Fracseal/ Stop pass by 80
particle size- loss) mesh
(Fine, or screen.
Medium, Mica/walnut
Coarse) shell/saw dust/
cotton
seed/rice husk
30-150/ 30 ppb In 50-80 Various -do- Can be
~11- 60 bbl / 7.5- grades-fine, placed
12 M3 medium & through
batches coarse CaCO3 PBL tool
in running drill or OEDP
Fluid
150- 45 ppb In 50-80 Various -do- Can be
1500/ bbl / 7.5- grades-fine, placed
~60-560 12 M3 medium & through
Fluid
>1500/ 60 ppb In 50-80 Various -do- Can be
~ >560 bbl / 7.5- grades-fine, placed
12 M3 medium & through
Fluid
8. Pump and place the pill slowly against the loss zone and pull out to
casing shoe.
9. Circulate 1 ½ string volume to avoid any choking of string.
10. Allow time (~4 hours) for healing of fracture by bridging materials in
the pill.
11. Circulate with slow SPM at casing shoe to consolidate the LCM Bridge
and record loss rates. If the loss is not controlled repeat the steps from 8-
11.
12. If loss is controlled, run back to bottom and resume controlled drilling
preferably at less than 10 m/hr.
13. Ensure that all further tripping and casing operations are carried out very
slowly and smoothly to avoid pressure surges which may otherwise
aggravate the problem.
14. In case above bridging material fails to seal the loss zone; other
advanced LCM material such as polymer cross-linked pills, high fluid
loss squeeze slurry such as Diaseal-M etc may be used. In other than
pay zones, Diesel Oil Bentonite (DOB plugs) or diesel oil bentonite
cement (DOBC plugs) may also be used.
15. If the above plugs also fail, pump appropriate quantity of specially
designed cement slurry to seal the loss zone.
Composition and Mixing Procedure of System LCM:

 In case of minor losses (05-30 bph), the system LCM of 15-20 ppb
(w/v) is to be mixed with the ongoing drilling fluid. Before adding
system LCM, the configuration of shale shaker screens and bit nozzles
should be in line to handle the LCM. It is better to drill this loss zone
section without nozzles.
 Single sack LCM or conventional LCM (Mica, Walnut and Sawdust) can
be used. Drilling should not be stopped and proper monitoring of losses
should be done.
 If losses are greater than 30 bph, depending upon the severity,
conventional LCM or single sack LCM can be used.
 High filtration squeeze:

 A high filtration squeeze is also used to combat severe losses in
fractured formations. The squeeze requires highly packed dehydrated
solids to seal the loss zone.
 The maximum pumpable density of high filtration slurry using calcium
carbonate is 14.0 ppg (1.68 SG).
High-filtration squeeze procedure:
 Spot the slurry against the loss zone
 Close BOP
 Squeeze the pill by hesitation method.\
 Gunk squeeze: Gunk Formulations:

The following mixtures will produce about 1.4 bbls of pumpable volume
for each 1 bbl of base oil (diesel) mixed. Recommendation would be to
only use the 1:2 cement ratios as this mixture sets firm to hard, will
support significant differential pressure, and will allow further operations
to continue for a significant period of time.
Bentonite to Oil
Add 400 lbs Bentonite to 1 bbl. base oil (or diesel)
Bentonite& Cement to Oil 1:1 ratio

Add 215 lbs Bentonite and 215 lbs cement to 1 bbl. base oil (or diesel)
Bentonite& Cement to Oil 1:2 ratio

Add 145 lbs Bentonite and 290 lbs cement to 1 bbl. base oil (or diesel)
1. Set mixture in the Drilling Fluid lab using a water bath. set the Bottom
Hole Static Temperature to determine the expected setting time for the
cement.
2. Position bit at casing shoe or 100 ft. above loss zone if the location is
definitely known.
3. Align cement unit pump to pump mud into the annulus and align rig
pump on the drill pipe to place the pill, simultaneously.
4. Do not open the PBL sub if there is one in the BHA.
5. Prepare 50 bbl. in a batch mixer or 100 bbl. in the slug pit.
6. Pump 50 bbl. drill water (the intension and expectation is for most of
this to get circulated above the drill pipe)
7. Pump 10 bbl. base oil (can use 5 to 7 bbl. in 5” or smaller DP)
8. Pump the Bentonite and cement slurry (use the same pump & flow path
as the base oil. The objective of the base oil is to flush all water from the
suction manifold and pump ahead of the gunk mixture to prevent
premature setting)
9. Pump 10 bbl. base oil (can use 5 to 7 bbl. in 5” or smaller DP)
10. Displace base oil to above the bit, close BOP.
11. With cement pumps, displace the gunk mixture out of the drill pipe at 4
bbl./min. simultaneously, begin pumping water based Drilling Fluid or
seawater down the annulus at 2 bbl./min.
12. When a pressure increase of 200 psi is noted, begin a “hesitation
squeeze” procedure by pumping 2 bbls down drill pipe and 1 bbl
down annulus. Shut the pumps down and wait for 10 minutes, Repeat
cycle until all of the bentonite-cement is displaced out of the drill pipe.
Ideally the pressure would increase to as much as 500 psi.
13. Open BOP, POOH 10 stands. Circulate minimum one cycle while
rotating the BHA.
14. Wait for the cement to set in the water bath, RIH and drill out the plug.
15. Increase flow rate to maximum flow rate required to drill and monitor
for losses. This would be considered a dynamic leak off test. A static
leak off test can also be done to provide more confidence.
16. If required repeat the job.
Advantages:
1. Will not set in the drill pipe, unless the base oil spacer is too short.
2. Have plenty of time to perform a hesitation squeeze to more effectively
seal the loss zone
3. Uses inexpensive materials available on the rig without special ordering.
4. Uses existing rig equipment
5. Can be pumped through drilling and MWD/LWD tools as it has no large
particle size solids.
Disadvantages:
1. Cannot be used in a potential reservoir zone as it causes extreme
formation damage which is permanent due to the Bentonite
2. High molecular weight polymers can be used as a substitute for the
Bentonite in reservoir intervals. This is less effective than Bentonite, but
it will break down with time and is therefore less damaging to a
reservoir.
Pump pill as follows:

 Pump base fluid as pre- flush to cover appprox.150 m length of drill
string.
 Pump gunk squeeze to cover approx. 2 times open hole volume.
 Pump base fluid as after flush to cover approx. 150 m length of drill
string.
 Displace the pill to the bit.
 Close BOP.
 Pump simultaneously from drill pipe and annulus in equal volume until
squeeze pill & spacer are displaced from the drill pipe.
 Maintain equal pressure on drill pipe and casing.
 Most important precaution: Before placement of gunk, the lab
composition is to be pilot tested on the rig to decide final composition
and pumping rate from drill pipe and annulus.
 Barite Plug:
It is used to control internal blow out and control loss/ activity
situations. pH should be maintained after addition of Sodium Acid Pyro
Phosphate (SAPP)/CLS but before addition of Barite. Recommended
height of plug is 100M.
Required Slurry composition per M3 of water

Specific CFD SAPP pH Baryte
Gravity (Kg) (Kg) (MT) Slurry
SG/ppg Yield
(M3)
1.8/ 15.0 2.0-2.5 1.2-2.0 9 1.4 1.33
2.0/16.7 2.5-3.0 1.5-2.5 9 1.9 1.45
2.2/18.3 3.0-3.5 2.0-3.0 9 2.52 1.60
2.4/20.0 3.5-4.0 3.0-4.0 9 3.27 1.78
2.6/21.7 >5.0 >5.0 9 4.2 2.0
(L) General Guidelines for Operation of Solid Control Equipment:
 Decanting Centrifuges:
 Do not operate the centrifuge without rotating assembly shroud and
belt guards fastened in place.
 Rotate the bowl by hand first to ensure “free” (no drag) movement.
 Do not operate if unusual noise or vibration develops.
 Lubricate bearings as per supplier’s recommendation (typically every 8
hours of operation).
 Allow the unit to attain desired rotational speed prior to starting the
feed pump.
 Do not overfeed (“crowd”) the centrifuge.
 Heavily weighted and viscous fluids require lower feed rates and higher
dilution rates.
 Ensure proper agitation is available at the centrifuge pump suction and
in the Barite return tank.
 Remember to turn off the dilution liquid after the centrifuge has been
shut down.
Symptoms of malfunctioning of centrifuge are:
i.Safety torque coupling frequently disengages.
ii.Unit packs-off rapidly.
iii.“Excessive” amount of weight material in the overflow.
iv.“Wet” solids discard from unit.
 Maintenance and Trouble Shooting of Desanders and Desilters:

(Improper operation and probable causes)
 No wet solids discharge at the apex (bottom)

 Bottom opening (apex) plugged: Turn unit off. Loosen bottom
adjustment. Push a rod up through the bottom opening to break up
dried or caked Drilling Fluid. If this is not successful, remove top of
hydrocyclone and take out object plugging apex. Make sure the
shale shaker is not bypassed. Re-adjust bottom and replace top of
hydro-cyclone.
 Feed pressure (head) too high: Adjust to proper head pressure, or
75±5 ft, using accurate pressure gauge.
 Avoid overuse of hydrocyclone: If drilling is very slow or if the unit

is running during a trip, removal can approach zero at the underflow
and unit should be shut down and run only periodically.
 Worn inlet nozzle, vortex finder or hydrocyclone ID: Remove
hydrocyclone and inspect for excessive wear. Replace hydrocyclone if
required.
 Hydrocyclone improperly installed: Remove and inspect
hydrocyclone and re-install according to manufacturers’ instructions.
 Flooding liquid out of apex bottom or Roping:
 Feed pressure (head) too low:

 Check pump suction for restrictions, inadequate liquid level for pump
suction or air entering suction.
 Check pump impeller blades for wear and proper size.
 Check pump discharge for correct manifold routing to only one hydro-
cyclone solids-control unit.
 Check condition of pump packing and alignment-clearance of pump
impeller.
 Be sure the pump suction compartment is bottom-equalized to overflow
discharge compartment downstream.
 Hydrocyclone inlet plugged resulting in inadequate feed pressure:
 Remove hydrocyclone and inspect.
 Remove any objects plugging inlet.
 If feed plugging occurs frequently, carefully inspect if shale-shaker is
bypassed or shaker screens are torn.
 Install a suction screen on the centrifugal pump.
 Vortex finder plugged, resulting in back-pressure on hydrocyclone.

 Remove hydrocyclone and inspect
 Remove any objects plugging inlet.
 If feed plugging occurs frequently, carefully inspect if shale-shaker is
bypassed or shaker screens are torn.
 Install a suction screen on the centrifugal pump.
 Hydrocyclones plugging
 Feed header (feeding hydrocyclone inlets) plugged.

 Stop feed pump.
1
 Remove blind Victaulic cap from the inlet header end and remove
obstruction.
 Replace the blind cap and restart pump after checking suction screen.
 Do not bypass shale shaker.
 Hydrocyclone overloaded (roping).
 More solids-control capacity needed.
 Solids removal system cannot handle excessive drilling rates and/or
solids loading.
 Inlet head fluctuating
a. Restricted pump suction.

- Check for plugging, gas-cut Drilling Fluid or foam at the pump suction.
- Inspect general condition of pump and piping.
(M) Gas/water influx-detection and control:

The following steps are recommended for detection and control of Gas
Influx during drilling operation:
 Check for increase in flow rate in the return line and Drilling Fluid
volume in active tank, an increase shall confirm influx.
 Keep a strict watch on specific gravity and viscosity of Drilling Fluid
while drilling through a permeable formation like sand stone, lime
stone etc.
 Measure specific gravity of out coming Drilling Fluid more frequently,
if gas influx is anticipated.
 A sudden rise in viscosity of the out coming drilling fluid with an
enhanced flow rate at the shale shaker indicates gas influx.
 Check if the pump rate is same or increased. Same pumping rate
reconfirms the gas influx.
 Immediately stop drilling ahead &start the degasser.
 Stop circulation
 Check self-flow.
 If well flowing, shut in pipe rams of Blow out preventer and
record shut in drill pipe pressure.
 Discuss and decide on well killing method with drilling
Engineer and follow the exact guidelines on kill mud weight requirement
in terms of specific gravity and volume of the kill Drilling Fluid
required.
 Calculate required kill mud weight and prepare kill Drilling
Fluid in the fastest possible time.
 Once the kill Drilling Fluid is ready, coordinate with the
drilling Engineer of the rig for its proper pumping and placement in the
well to kill the well.
 Once the high pressure gas influx is controlled by killing
operation, resume Drilling Fluid circulation with a higher specific
gravity (approx. safety margin 0.02 SG + Trip margin (0.03 SG)=0.05
SG/ 0.41 ppg)) which must be more than formation pressure (i.e. Pm new
> Pf)
 Continue circulation with new higher specific gravity drilling fluid for
one or two cycles, stop circulation intermittently and check for self-flow.
 If no self-flow or gas influx, resume normal drilling operation with new
higher specific gravity Drilling Fluid.
 It is mandatory to keep kill mud of maximum MW ready in the

reserve tank as indicated in the GTO for that section, while drilling
an exploratory well.
(N) Well Conditioning for Casing Cementation:

The following points are recommended from drilling fluid’s angle while
preparing a well for cementation job:
 Circulate and condition the drilling fluid after the casing pipe has been
lowered to the desired depth for 2-3 cycles.
 In the first cycle ensure that the casing open hole annulus gets cleared
off all debris / caving, or left over cuttings from the annulus by
suitable Drilling Fluid Rheology / hydraulic combination in new
annular geometry.
 In the next one or two cycles treat the drilling fluid with suitable
quantities of deflocculant / pre-mix and fluid loss control additive to
ensure that drilling fluid has low plastic viscosity and yield point values.
 Once the desired drilling fluid parameters are achieved, start
cementation without delay.
ii. Well Conditioning for Logging/ Casing Operation:

The following points must be taken in to consideration while preparing
well for logging operation.
 Pump 50 bbl low-vis- high weight pill followed by 50 bbl. high viscosity
pill. Circulate and condition the drilling fluid at simulated SPM. During
Circulation pipe must be in rotation & reciprocation to ensure that all
cuttings/ debris are out. Observe the shakers for the type
(cuttings/carvings/coal etc.) & quantity of Cuttings. If needed more sets
of pill can be sweep & circulate.
 The rheology should be optimum to keep the well bore intact.
 Treat the drilling fluid with proper lubricant to facilitate smooth
lowering of logging tools.
 Following pill composition in required volume of running drilling fluid
can be mixed & placed in open hole :
2.5-3.0% (w/v) sulphonated Asphalt (w/v) + 0.5-0.6 %( w/v) PAC-LV +
1.0-2.0 %( w/v) mud lubricant + 0.1-0.2% (w/v) XC polymer + 2.0-2.5%
(w/v) NIFA
iii. Well conditioning for Hermetical Test:

The following procedure to be followed while preparing well for
hermetical testing.
 Run in scraper. Circulate and condition the drilling fluid at least 2-3
cycles depending on the hole trajectory to ensure that all cuttings/ debris
are out.
 Displace Drilling Fluid with water having a 50 bbls (7.5 m3) spacer of
8- 10% pre-hydrated bentonite suspension to prevent Barite
contamination and settling.
 Conduct hermetical testing to desired pressure.
 Displace water with Drilling Fluid having a 50 bbls (7.5 m3) spacer of 8-
10% pre-hydrated bentonite suspension to prevent Barite contamination
and settling.
 Circulate and condition the drilling fluid at least 2-3 cycles depending on
the hole trajectory to ensure homogeneity and hole cleaning before
pulling out scraper.
 In case of any anticipated delay, scraper must not be allowed to stay at
bottom without intermittent circulation and reciprocation.
Note:
 In case the hermitical test is done in 2 stage displacement, the same
procedure as described above is to be followed for each stage.
 In High pressure wells with more than 1.5 SG Drilling Fluid,
hermetical test may be done with OEDP run without scraper in hole.
iv. Hydrogen Sulphide (H2S) Control:
Hydrogen Sulphide Hazards

 Hydrogen sulphide gas has an offensive, rotten-egg odour at low
concentrations and cannot be smelled at higher concentrations.
 This colourless, highly reactive acidic gas is hazardous to workers and
detrimental to drilling equipment, even at low concentrations.
 H2S is heavier than air and when released will accumulate in low-lying
areas. Closed compartments and storage tanks are particular hazards.
 H2S can even accumulate in the top portion of mud pits when there is
little wind or air movement.
 Lethal concentrations can accumulate above mud pits or in tanks even
when the concentration of H2S is so low that it might be considered
trivial.
 Whenever H2S is present or thought to be a possibility, all rig personnel
should be warned not to bend over, or reach down into, the mud pits.
 The gas is highly flammable and forms an explosive mixture with air.
Even short periods of exposure to hydrogen sulfide can kill or seriously
injure humans and can cause catastrophic failure of steel tubular.
 The maximum safe level for repeated worker exposure, the threshold
limit, is only 10 ppm H2S.
 The accepted industry standard is to wear respiratory protection for
concentrations greater than 10 ppm.
 The hazardous limit, or the concentration that may cause death, is 250
ppm/hr.
 Unconsciousness occurs after short-term exposure to a concentration of
500 ppm, then breathing stops and death occurs if the condition is not
quickly treated.
Hydrogen sulphide scavengers:

Following additives may be used for the removal of H2S
 H2S is soluble in both water and oil base drilling fluids.
 High alkalinity drilling fluids with excess lime are preferred for
buffering and pH neutralization.
 In solution, H2S gas ionizes depending on pH. H2S dominates in lower
pH range. At higher pH range H2S is ionized into less harmful hydrogen
sulfide (HS) and sulfide (S) ions.
 At pH of 11; 99.99% H2S is converted to HS and S ions.
 pH neutralization is reversible and if pH falls below 11, these HS and S
ions convert into H2S.
 At atmospheric pressure, even high pH fluids liberate H2S if sulfide
concentration is excessive.
 So, alkalinity alone should never be relied up on to control H2S and
detectable sulfide contamination should always be immediately treated
with scavenger chemicals.
 Zinc Oxide is most preferred for most cases and can be used in both oil
and water base drilling fluids. A 1 lb/bbl treatment can theoretically
remove 1100 mg/l sulfide but actual removal occurs in the range of 200-
800 mg/l.
 Basic Zinc Carbonate is a complex compound containing Zinc
Carbonate and Zinc hydroxide. Treatment of 1-lb/bbl can remove
about 500 mg/l sulfide.
 Iron Oxide is most effective at low pH, where H2S is the predominant.
Recommended dose is 10-20 lb/bbl . Because of pH sensitivity, it is
advisable to use a Zinc based scavenger in combination with Iron Oxide.
 Because these scavenger are high density chemicals so good rheology of
drilling fluid is essential to keep them in suspension.
 As a suspended solids, these scavenger chemicals can be removed by
solid control equipment.
APPENDIX
1. Recommended drilling fluid properties in different hole sizes
Properties Top Section Intermediate Final Section

Sections
Problems to be Hole cleaning & Reactive formations Formation
tackled seepage loss damage
Mud Weight Minimum to avoid Provide 10-20 Kg Same but as
mud loss. margin over pore low as
/collapse Pressure butrequired.
less than fracture Pr.
Plastic Viscosity As Low As Possible (ALAP)
Yield Value Just sufficient for hole cleaning and cutting removal. Most
optimum range:20-30 lbs/100ft2
Gel0 The most important parameter with respect to Hole Cleaning.
Optimum range 8-15 lbs/100ft2 based on Hole size.
Gel10 In general maximum 30 lbs/100 ft2 for most applications.
LSRV 1. Maintain Fann 3 rpm reading at least 12-15 and 6 rpm
reading 1.1 times hole diameter
2. LSRV=2Q3 – Q6 where Q3 and Q6 are 3 and 6 rpm
readings respectively.
3. LSRV=0.4-0.8 x well diameter” (Normal case)
LSRV=Well diameter” (Critical situation)
Water loss API No Control 6-12 4-6
Filter Cake Sufficient to As thin and compact as possible to
support well bore support well bore and control water
Solid Content Optimum % for drilling fluid system used with maximum
High Gravity Solids =(SG value -0.9) x 30
pH As per drilling fluid system used.
2. Stacking and Handling of Chemicals:
1. Never exceed the recommended weight limit when lifting the pallets of
chemicals by a lift. If shifting is required in a pallet whose weight is
more, then extra sacks should be transferred to another empty pallet
prior to lifting by fork lift.
2. Chemicals like Bentonite, Ethogel, CMC, PAC, PHPA, XC-Polymer etc.
are potentially slippery, when wet. Hence spillage of these chemicals in
the sack store and hopper area should be cleaned up at the earliest. Any
torn bags should be taken out and stacked separately for use at the first
opportunity.
3. Acid tanks when taken on board should be transferred with care and
covered with proper lids and never left uncovered. If slippage takes place
wash with plenty of water immediately and neutralize with lime, Soda or
Calcium carbonate.
4. Addition of caustic soda directly in to the hopper should never be done.
It should be preferably be added as an aqueous solution through
a tank wherever available. Canvas gloves are not sufficiently
protective specially when wet, for handling caustic soda. Use safety
goggles, rubber apron and PVC gloves while handling Caustic soda.
5. Use dust masks when adding chemicals like Bentonite, Barite, Cement,
FCLS and other such finely powdered chemicals.
6. Hopper area should be adequately ventilated and illuminated.
7. While diluting acids, never add water to concentrate acid in the
tanks. Splattering may take place. Always add the acid to water.
8. Some surfactants, defoamers, corrosion Inhibitors etc. can produce
irritation of the skin and the vapors can irritate the eyes. When handling
such chemicals, wear appropriate personal protective equipment like
gloves, aprons and goggles. If spilled on the skin wash the area with
plenty of water and soap and seek medical advice.
9. Eye washing stations should be provided with fresh potable water at all
places where drilling fluid handling is done, viz. drill floor, shale, shaker,
mud pit room, hopper/mixing area. Such a facility should also be
provided near the cementing unit.
III. Key Safety Precautions While Handling Chemicals:
 MSDS for all the chemicals on board or at rig should be available and
must be read / understood properly.
 Proper PPE must be used while handling the chemicals.
 Avoid contact, inhalation or ingestion of the chemical.
 In case of any of the above occurrence, emergency first aid procedures
should be immediately followed.
 The safe exposure limits for various chemical should be known in
advance.
 In case of release of toxic gas like Hydrogen Sulphide etc. escape in
opposite to wind direction or cross wind at height, so as to be away from
source of leakage. Chemicals for scavenging H2S must be available in
the stock such as Zinc Carbonate/ Ironite sponge for use at the site
especially in known H2S prone field or exploratory locations.
 The inventory for each chemical should be known in advance.
 In case of release of flammable chemicals, all ignition sources must be
removed.
 Any confined space entry where chemicals are handled must be done
with a valid work permit.
 Spillage of chemicals must be avoided. In case of any spillage, sweep
clean spilled substances, wash away remainder with large amount of
water.
 Extra personal protection – breathing apparatus set
IV. Emergency First- Aid Procedures:
Inhalation: Fresh air, half upright position and transport victim to a

Hospital.
Skin: Remove contaminated clothes, rinse skin with plenty of
Water or shower and send the victim to a doctor.
Eyes: First rinse with plenty of water of 15-20 minutes and then
Transport the victim to a doctor.
Ingestion: Rinse mouth, give plenty of water to drink then transport
Victim to a doctor.
Abbreviations:
PAC (LVG) – Poly Anionic Cellulose (Low Viscosity Grade)

PAC (RG) - Poly Anionic Cellulose (Regular Grade)
PHPA – Partially Hydrolyzed Poly Acrylamide
XC Polymer – Xanthan Cellulose Polymer
CMC (LVG) – Carboxy Methyl Cellulose (Low Viscosity Grade)
CMC (HVG) – Carboxy Methyl Cellulose (High Viscosity Grade)
KOH – Potassium hydroxide
KCl – Potassium Chloride
K Lignite – Potassium Lignite
PHBS – Pre Hydrated Bentonite Suspension
NIFA – Non Invasive Fluid Additive
CEC – Cation Exchange Capacity
MBC – Methylene Blue Capacity
CFD – Chrome Free Deflocullent
SAPP - Sodium Acid Pyro Phosphate
LSRV – Low Shear Rate Viscosity
SOBM – Synthetic Oil Base Mud
LTMO – Low Toxic Mineral Oil
PV – Plastic Viscosity (cp)
YP – Yield Point (lbs. /100 ft2)
6 Casing
Operations
The basic purpose of casing is to prevent the drilled section of well from
collapse, for zonal isolation, to prepare the well to sustain pressures from
formations to be drilled subsequently and for providing a conduit for taking
production. The casing operations elaborate the procedure to successfully run
and cement a string of casing/liner capable of meeting the specified pressure
test and geological objectives. In view of utmost importance of casing
operations in successful completion of each phase of the well, the following
procedures need to be adhered strictly.
This chapter covers the following aspects of casing operations:-

a) Casing Plan
b) Casing preparation at site
c) Hole preparation prior to casing lowering
d) Rigging up for lowering casing
e) Casing lowering Procedure
f) Casing Landing Practices
g) Phase wise checklist/ running procedures for all casings/ liners
a) Casing Plan:
The foremost requirement prior to casing lowering is the casing plan complete
with details of casing such as
 Casing specifications like grade, nominal weight, connections, depth
interval.
 Use of short casing pipe to be mentioned in the plan for validation
of depth through logging.
b) Casing preparation at site:
While receiving and unloading casing pipes at Drill Site, the following steps
are to be undertaken:-
1. Casings to be lowered last into the well are to be stacked first.
2. Place rafters (wooden plank) or thick casing line below each row of
1
casing pipes at three places.
2
3. Visually inspect pipes and reject pipes with damaged threads/ having
dents/ovality or any other damage.
4. Measure and prepare casing tally for casing pipe.
Note
: a) Marking may be done with different colour paint for casing of
different grades and ppf.
b) The measuring tape should not be damaged, should start from
0 marking.
c) For buttress thread casings, length should be measured from
the top of coupling to the base of triangle mark (▲) on the
pin end.
5. Prepare the tally of casing pipes of first row giving length, grade,
weight and type of connection.
6. Place subsequent casing pipes in rows one by one. Measure and
prepare the tally of all the casing pipes. Casing tally may be re-
checked by making reverse tally.
7. Clean pin and box end threads.
8. All Casing pipes should be go-gauged if threads are OK. Reject all the
pipes through which go-gauge cannot pass.
Note: Size of go-gauge should correspond to the drift diameter of
casing.
9. Re-install thread protector on the pin end of casing.
Note: Ensure that all the rows of the casing are properly secured at
both ends to prevent rolling.
10. Before making up, float shoe and float collar should be visually inspected
for any damage to body, threads and ball.
11. Check for correct NRV function for any leakage by carrying out water
integrity test.
12. Clean threads and apply casing dope and make up casing shoe with
the casing pipe up to the base of triangle (▲) for casing.
13. In case float collar is used, it should be made up with casing dope on
the second casing pipe (or as per plan). Shoe and float collar should be
made up in advance and kept ready.
14. No welding should be done on N-80, P-110 and above grade casings.
15. In case of larger size of casings i.e. 20” and above, weld shoe after
making V-cut on pipe.
c) Hole preparation prior to casing lowering:
The following steps should be taken for preparing the hole during final bit trip
prior to lowering casing:
1. For smooth Casing running, the mast should be centred prior to
spudding.
2. Probe the hole first with 2 stabilizers followed by 3 stabilizers as per
well requirement in Bottom Hole Assembly (BHA) and ream till there
are no tight pulls or held up.
3. Circulate and condition the mud at required discharge to ensure the hole
is free from cuttings.
4. Pull out to last casing shoe.
5. Inspect draw works braking system.
6. Slip and cut casing line, if required.
7. Carry out wiper trip. In case fill is observed, condition drilling fluid
accordingly.
8. Prior to pull out of hole for casing lowering, complete all the
preparations so that casing lowering can be immediately started
after pulling out.
9. Crack open and stack all such assemblies as drill collars, reamers,
stabilizers.
d) Rigging up for lowering casing:

1. Once pull out is complete, cover the rotary.
2. Close blind ram and replace pipe rams with rams of casing size being
lowered.
3. Keep chain tongs, X-over, circulating head at rig floor.
4. Rig up the single joint and side door elevators, slips and power tongs to
lower casing.
Note: Hook up single joint elevator with the help of 19 mm wire rope of
sufficient length so that it can be latched on the casing pipe with the
casing elevator just on top of rotary table. Longer length of sling results
in loss of time.
5. Rig up hydraulic casing tong and attach torque gauge suitable for
appropriate tong lever length (25” or 48”).
6. Ensure rig up back-up power tong with safety line.
7. Install the cull bushing into the rotary opening if required.
8. Keep casing fill up line ready.
9. API Casing thread dope should be used for all casing joints.
10. Ensure availability of lifting belts for lifting pipes from pipe rack to rig
floor.
11. For heavier casings or at rigs with high structures the crane is used
for placing the casing pipes on the inclined ramp/ V-door.
12. It is recommended to re-inspect casing on V-door for any
unwanted material into casing.
13. In case of chrome casing, following steps may be taken:
a) It is mandatory to use Casing Drive System.
b) Recommended casing dope only should be used.
c) Joints should be torqued as per recommendation.
e) Casing lowering Procedure:
1. Latch casing elevator on to the first casing pipe and

slowly lower the casing pipe in the well. Check mud
return at flow line. Rest the casing pipe on the slip and
install additional single joint elevator for safety before
unlatching side door casing elevator.
2. Checking the floating equipment
Shoe: Most important precaution for NRV function
a) Rest the casing pipe on the slip, pick up single above rotary
and check for no mud level in casing to ensure proper
functioning of NRV in shoe.
b) Fill the casing with drilling fluid, Observed return of drilling
fluid. P/up single & check shoe for smooth mud flow. Check
casing for emptiness. RIH Casing & rest it on slip & elevator.
Float Collar: After first two or three as per plan, casing pipes having
float shoe and float collar have been lowered into the well, run one more
single of casing above float collar and lower up to rig floor. Follow the
same test procedure as b) above for float shoe.
3. Lift the block and latch the elevator onto the next pipe.
4. Remove the protector from the pin end of the next pipe, clean pin end
threads on rig floor and apply casing dope, aligned the casing and make
up the joint to shoe joint casing using hydraulic tong.
5. Use both the tongs or break-out tong to make up first few joints up to
the required torque to avoid rotation of bottom casing pipes.
6. In case of buttress thread casings the joint should be tightened up to the
base of the triangle mark on the pin end.
7. Block speed should be low when elevator is nearing rotary table to
facilitate attaching single joint elevator on the next casing joint. While
picking up casing with single joint elevator, ensure lifting sling
should not be entangled with casing slip handle.
8. Casing fill up:
a) Initially for first few joints, fill each joint with mud till
sufficient hook load is attained.
b) In case of NRV type casing shoe, subsequently casing
should be filled after lowering every 5 joints.
c) A good practice is to fill each casing joint while the next
casing joint is being picked up.
9. Install centralizers as per plan with stop collar.
10. Continue lowering casing up to the desired depth. Casing lowering speed
should be moderate to avoid surges and return drilling fluid flow to
be monitored.
11. Active pit drilling fluid volume to be monitored before and after
cementation.
Note: Casing Make-Up:

1. Ensure visually that the stabbed pipe is aligned before making-up.
2. In case of any problem during initial make-up of casing joint, pipe
should not be tightened further which may damage threads on both the
pipes due to cross threading causing heating up of the joint. In such
cases, open the joint, clean and check the threads of both pin and box
ends, apply dope and make up again.
3. While making-up joints with hydraulic tongs, first use low gear
followed by high gear then low gear for final make up.
f) Casing Landing Practices:
Selection of proper casing landing procedure is important to avoid
excessive and unsafe tensile stresses at any time during the life of well.
In view of safety, after cementation, all activities such as crack opening
of bolts and lifting of BOP must be done only after ensuring surface sample of
cement is set (at temperature as close as possible to Bottom Hole Circulating
Temperature) as any unexpected annular activity due to setting of cement will be
a safety threat. Keep watch on annulus during WOC.
One of the following casing landing methods should be adopted:
1. After the cement has set, casing should be landed with exactly the same
tension that was present when cement displacement was completed in
the wells in which mud specific gravity does not exceed 1.5 gm/cc
(12.5 ppg).
2. Casing should be landed in such a manner that the casing at the top of
cement is either in tension or completely balanced so far as tensile and
compressive stresses are concerned.
3. Where excessive specific gravity of mud is used, casing should be
landed with top of freeze point (Top of cement) in tension. In this case
free air weight of the casing above the freeze point is considered for
calculating the slack off weight on the slip.
g) Phase wise checklist/ running procedures for all casings/ liners:
20” Casing Lowering:
 Check list for 20” casing:
S Equipment Size/ Qty Remarks

N capacity
1. Elevators Side Door 20”/150T 2 no.
Single 20” 2 no.
Joint
2. Casing Slips 20” 2 no.
3. Casing Cull Bushing 20” 2 set
4. Casing Power Tong Set 20” 1 set With 2 set of 20”
jaws
5. Hydraulic Power Tong 20” 1 set
Sling for make up 13 mm For casing
tightening
6. Circulating Head 20” 1 no. Ensure it has
same threads as
casing
7. Casing Dope 25 kg 1
(API modified) bucket
8. Casing drift Gauge For 20” 1 No. As per the drift
casing diameter of
casing
9. Clamp-on thread 20” 2 Nos
protector casing
 Running of 20" Casing:
1. R/Up Casing running tools to run casing as per “Casing Lowering

Procedure” at section d) & e) above.
2. Pick up the shoe joint with crane to the rig floor through V-door. Lift
the joint carefully without damaging the shoe.
3. Test shoe & run 20” casing as per plan. Fill all the joints while lifting
the next pipe.
4. Top up with mud every two joints.
5. Make up cementing/ circulating head, connect rig pump and circulate
mud prior to cementing.
6. Reciprocate casing during circulation.
7. Carry out cement job as per plan.
8. In case only guide shoe without NRV is used, then after displacement
keep the circulating head valve closed till surface sample of cement
sets.
Note:
In case of any held up during casing running, try to clear the same by
reciprocation without pushing down the casing. Instead, pull casing out of hole.
Probe the hole with 3 stabilizers in Bottom Hole Assembly (BHA) and ream
till there are no tight pulls or held ups. Pull out of hole completely and re-run
casing.
13 3/8” Casing Lowering:
 Check list for 13-3/8” Casing:

S Equipment Size/ Qty arks
N Rem
1. Links capacity
350 T 1 set
2. Elevator Side 13-3/8”, 2 Nos city of side
Door 200T/250T elevator to be
Cap
a
decided as per
length of casing.
Single 13-3/8” 2 Nos

Joint
3. Spider Elevator 13-3/8”/ 350T 1 set To be used in case
and slip of longer & heavier
weight string.
4. Casing Slip 13-3/8” 2 Nos.
5. Casing Cull 13-3/8” 2 set
Bushing
6. Casing Power 13-3/8” 1 set With 2 set of 13-
Tong Set 3/8” jaws
7. Hydraulic Casing Jaws for 1 set Hydraulic Power

Tong (5”-20”) 13-3/8” Unit with Hoses
and spare sets of
Dies
8. Chain Tong 1 No. To make up Float
collar
9. Circulating Head 13-3/8” 1 No. Ensure it has same
threads as casing
10. Cementing Head 13-3/8” 1 No. Top & bottom
plugs to be
installed prior to
cement job with
11. Casing Dope (API 25 kg 2
modified) buckets
or as per
require
ment
12. Casing drift 13-3/8” casing 2 no. As per the drift
Gauge(s) diameter of
casing(s)
13. Centralizers 13-3/8” x 17- - As per plan.
1/2”
14. Clamp-on thread 13-3/8” casing 2 Nos
protector
 Running of 13-3/8" Casing:

1. R/Up Casing running tools to run casing as per “Rigging up for Casing
Lowering” at section d) above.
2. Prepare rotary table for 13-3/8" casing.
3. Run 13-3/8” casing as per plan following “Casing Lowering
Procedure” at section e) above.
4. Change from side door elevator to slip type elevator/spider before
going into open hole to a) handle heavy casing loads as it holds the
casing at pipe body b) facilitate working on casing in case of any held
up
5. Make up cementing head and circulate and condition mud.
6. Reciprocate casing string if possible.
9.5 /8” Casing Lowering:
 Check list for 9-5/8”casing:
SN Equipment Size/ Qty Remarks

capacity
1. Links 350 T/ 1 set each 500 T link required for
500 T deep wells
Elevator Side Door 9- 2 Capacity of side door
2. 5/8”/250T Nos. elevator to be decided
as per length of casing
Single 9-5/8” 2
Joint Nos.
3. Spider Elevator and 9- 1 set To be used in case of
Spider slip 5/8”/350T longer & heavier
weight string.
4. Casing Slip 9-5/8” 2 nos.
5. Casing Power Tong 9-5/8” 2 set
Set
6. Hydraulic Casing Jaw 1 set Hydraulic Power Unit
Tong (5”-20”) 9-5/8” with Hoses with spare
dies
7. Chain Tong 01 To make up float
No. collar
8. Circulating Head 9-5/8” 1 no. Ensure it has same
threads as casing
9. Cementing Head 9-5/8” 1 no. The top and bottom
plugs to be installed
prior to cement job
with proper check.
(API modified) bucke
t
11. Casing drift Gauge (s) For 2Nos. As per the drift
9-5/8” diameter of the casing
casing
12. Centralizer 9-5/8” x - As per plan.
12-1/4”
13. Clamp-on thread 9-5/8” 2 Nos
protector casing
 Running 9-5/8” Casing:
1. Change rams to 9-5/8” casing rams.

3. Prepare rotary table for 9-5/8" casing lowering.
4. Run 9-5/8” casing as per plan following “Casing Lowering Procedure”
at section e) above.
5. Change from side door elevator to slip type elevator/spider before going
into open hole to
a) Handle heavy casing loads as it holds the casing at pipe body,
b) Facilitate working on casing in case of any held up.
6. While lowering casing, break gel for 30 minutes at last casing shoe.
7. Based on formation characteristics, if the open hole is around 1,000 m
or more, an open hole gel break may be considered for minimum
period (5-10 minutes).Consider additional Gel Breaks if poor returns
are observed while lowering casing.
8. Make sure that the 9-5/8" casing joint does not come across the well
head area.
9. Calculate optimum discharge as per software simulation or circulation
after casing lowering for maintaining the critical annular velocity.
10. Make up cementing head and circulate and condition mud.

11. While running casing, ensure mud tanks have sufficient space for mud
displaced by casing and cement volume.
Production Casing in Final Phase (4 ½’’ Liner / 5 ½” Casing/ 7” Liner in 8

½” Hole):
 Check list for 4 ½’’ Liner / 5-1/2” Casing/ 7” Liner:
SN Equipment Size/ Qt Remarks

capacity y
1. Links 350 T 1
set
Elevator Side 4 ½’’/ 5 ½’’/7” 2 Capacity of side door
2. Door /250T no. elevator to be decided
as per length of the
casing.
Singl 4 ½’’/ 5 ½’’/7” 2
e no.
Joint
3. Casing Slip 4 ½’’/ 5 ½’’/7” 2
no
s.
4. Casing Power 4 ½’’/ 5 ½’’/7” 1
Tong set
1
5. Hydraulic Jaw- 1 Hydraulic Power Unit
Casing Tong 4½’’/5½’’/7” set with Hoses with spare
(5”-20”) dies
6. Circulating Head 4½’’/5½’’/7” 1 Ensure it has same
no. threads as casing
7. Cementing Head 5½’’/7” 1 Top & bottom plugs to
no. be installed prior to
cement job with proper
check.
(API modified) bu
ck
et
9. Casing drift For 1n As per drift diameter
Gauge (Go 4½’’/5½’’/7” o. of the casing
Gauge)
10. Centralizer/ 4½’’/5½’’/7” - As per plan
Turbolizer/
Spirolizer
1. Under normal conditions, the liner will be hung with a 100m overlap into
the previous casing. If a reduced overlap is necessary due to a particular
situation, it will be reviewed by the competent authority.
2. If the rat hole exceeds the overlap length, set a cement plug at a distance
from the liner shoe setting depth shorter than the overlap itself. All
endeavours should be made to keep the shoe of liner at bottom.
3. In mechanical type of liner releasing system, keeping liner at rotary slips,
check the system by rotating the string.
4. In open hole, fill up the string keeping the string in reciprocation, if
possible.
5. Once well is conditioned thoroughly, set liner hanger by dropping ball.
Continue to circulate for ten minutes after ball-seat shearing.
6. Back off setting tool as per design of the liner. In case of mechanical back
off system rotate sufficient turns depending on well profile and depth to
ensure release of running assy.
7. Set packer before starting pull-out.
 Running of 7” Liner
1. R/Up Casing running tools to run liner as per “Rigging up for Casing
2. Change ram of BOP as per casing/ Liner size.
3. Make up landing collar as per tally.
4. Run in liner as per tally and install spirolizers and/or centralizers as
per plan.
5. Keep thick gel of waste oil mixed with grease ready at rig floor.
6. Pick up the Liner Hanger assembly very carefully to avoid right hand
torque.
7. Make up liner wiper plug with slick joint.
8. Make up hanger packer assembly with liner.
9. Ensure that setting tool and all connections are properly made-up.
10. Fill Tie Back Receptacle (TBR) with oil and grease gel before running
in hole.
 Pull slips and lower assembly through rotary and set DP slips on the
setting tool extension at the top of the running tool.
 While running in liner on drill string
 Drift/ Rabbit all the tubulars in liner lowering string with
appropriate rabbit size. While picking up rabbit to diving
board, box end of the tool joint should be covered.
 Apply pipe dope as little as possible with a paintbrush with
safety rope on DP pin end connections only to avoid excess
dope falling down and choking the ports.
 There must not be any jerk or rotation (Mechanically lock
the rotary).
 Take extra care while making up with Top Drive System
(TDS). Ensure no slippage of back up tongs.
 Held up should be cleared by circulation and reciprocation
only. Take care of pressure limit.
 Lowering speed should be 1.0 to 1.5 minutes per stand as
the annulus space between liner and casing/ open hole
has very narrow clearance.
17. Run first stand of drill pipe carefully and slowly when hanger is
passing through BOP and well head area.
18. Circulate to check for leaks and to confirm return.
Note:
This is a very important step to check the sealing of pack off bushing
of liner hanger. Any flow of mud from within the liner thorough the
pack off appearing from top of TBR/ Running Tool indicates lack of
pressure integrity and may cause problems for subsequent setting of
hanger.
19. At any time, do not exceed maximum circulating pressure limit to
avoid premature hanger setting. Maximum circulation and
pressure limit is based on the Liner Hanger shear setting value.
20. Record pick-up and slack-off weight of liner.
21. Resume further running in of liner with drill pipe stands.
22. Fill up after every 10 stands of drill pipe.
23. In deep wells where mud weight, viscosity, temp, etc are too high fill
up every 10 stands with the help of TDS/Circulating Swage and
continue to pump for 5 minutes after getting return.
24. With the liner assembly shoe at the last casing shoe:
a) Break circulation and check free circulation through the liner
assembly. Circulate minimum volume of Liner + Drill Pipe
capacities. Do not exceed pressure limit.
b) Closely monitor for static and dynamic losses and record.
c) Record the up and down weight.
25. Resume further running in to bottom/target depth carefully.
26. In open hole, keep the string under reciprocation while filling.
27. Wash down last stand and tag bottom/reach target depth gently. Tag
bottom with no more than 5-10 T (~10-20 kips).
28. The liner must be set at least about 0.5 m from bottom. Keep pup
joints of various lengths ready to adjust the length.
29. Do not use mud with LCM in any case.
30. Before line up of initial circulation, ensure that all valves
containing dart/ plug should be closed or locked.
31. Circulate at bottom for at least one cycle.
a) Record the up and down weight of string.
b) Pick up to back off point/hanger setting depth and mark the
pipe.
c) Drop ball and set hanger. Continue to circulate for ten minutes
after ball seat shearing. The pressure after ball seat shearing
should be same or more than the earlier pressure and in no
case should be less.
d) Rotate the string at 20-30 rotations to back off setting tool.
Note torque readings.
e) Stop rotation, pick up only about 1/2 to 1 m to confirm back
off.
Note: If picked more, polished nipple will come out of pack off and may
lead to serious complications in cementing.
f) Space out and rig up cement head.
g) Make sure swivel is used on the end of the cement hose to the
cement head and hose weight is correctly supported.
h) Flush cementing hose before connecting it with cement head.
32. Circulate and cement as per cementing plan.
33. During displacement, run extra supercharger to get better efficiency.
34. Remove cementing head and set hanger packer
35. Disengage Liner Hanger Running Tool and pull out 2-5 stands of drill
pipe depending on well profile.
36. Reverse and/or direct wash as per cementing plan.
37. POOH Liner Hanger Running Tool.
 Running of 7”/ 5-1/2” Casing

8. Change rams to 7”/5-1/2” casing.
10. Run 7”/5-1/2” casing as per plan following “Casing Lowering Procedure”
at section e) above.
11. While lowering casing, break gel for 30 minutes at last casing shoe.
12. Based on formation characteristics (In case of higher mud weight), if the
open hole is around 1,000 m or more, an open hole gel break may be
considered for minimum period (5-10 minutes). Consider additional Gel
Breaks if poor returns are observed while lowering casing.
13. Make sure that the 7”/5-1/2” casing joint coming across the well head area
is free from any ovality as this is going to give a pressure seal with the slip
assembly.
14. Calculate optimum discharge as per software simulation or circulation after
casing lowering for maintaining the critical annular velocity.
15. Make up cementing head and circulate mud as per plan. Before line up of
initial circulation, ensure that all valves containing plug should be
closed or locked.
16. While running casing, ensure mud tanks have sufficient space for mud
displaced by casing and cement volume.
 Lowering of 16’’ and 11 ¾’’ Intermediate Liner

If planned/ unplanned 16’’ or 11 ¾’’ liner is required to isolate the
complicated zone. Following materials for 16’’ and 11 ¾’’ are required.
16’’ Liner and Liner Hanger
1. 17 ½’’ X 20’’ Under Reamer (Previous casing 20’’)

2. 20’’ X 16’’ liner hanger system (Complete Set)
3. 14 ½’’ TCR bit for drilling float collar, shoe of 16’’ liner and pilot hole
4. Under reamer – 14 ½’’ X 17 ½’’ (for 13 ⅜’’ casing)
5. Handling tools for 16’’ liner
6. Bit breaker for above sized bits
7. Casing hydraulic tong jaws for 16’’ casing
11 ¾’’ Liner and Liner Hanger
1. 12 ¼’’ X 14’’ or 12 ¼ X 14 ½’’ Under Reamer (previous casing 13 ⅜’’)

2. 13 ⅜’’ X 11 ¾’’ liner hanger system (Complete Set)
3. 10 ½’’ TCR bit for drilling float collar, shoe of 11 ¾’’ liner and pilot hole
4. Under reamer – 10 ½’’ X 12 ¼’’ (For 9 ⅝’’ casing)
5. Handling tools for 11 ¾’’ liner
6. Bit breaker for above sized bits
7. Casing hydraulic tong jaws for 11 ¾’’ casing
7 Cementing
Operation
Cementation is the one of the most vital operation for integrity, safety and
enhancement of the life of the well. Proper cementation is required to ensure
that long term zonal isolation and safety of the well are achieved along with
casing support. To achieve casing cementation as per plan, meticulous
planning and proper execution are of utmost importance. Any shortcoming
may lead to cement repairs involving considerable rig time. Further, cement
repair jobs can rarely result in desired achievement.
This chapter covers the following aspects of cementing operations:
A. Bulk System
B. Preparation Prior to Spudding of the well
C. Relevant operational aspects during lowering of casing/ liner
D. Plan and Execution of Casing/Liner cementing Job
E. Secondary cementation
F. Cement squeezes procedures
G. Well abandonment procedures
H. Salient points of different types of Casing Cementation Jobs
I. Cementing consideration for HPHT wells
J. Safety in Cementing Operations
A. Bulk cement storage and BHP (Bulk Handling Plant)

1. Stacking of Cement and Cement additives at BHP should be done in line
with IS 4082 in a properly ventilated and lit godown.
2. Loading pods, silos should not be over filled.
3. Vent line of adequate size should be clear upto the opening and secured.
The dust collectors should be provided to minimize release of cement dust
in atmosphere. The venting should be done downwind at safe distance.
4. All pressure vessels, compressors, air tanks should be fitted with safety
valves set within 10% of above maximum operating pressure.
5. Hydro testing of all pressure vessels shall be carried out as per prevailing
rules.
6. Airlines for purging and charging of silos/loading pods should be fitted
with NRVs as close to the pressure vessel as possible.
7. Blending of additives should be done in small batches so as to maintain
maximum homogeneity.
8. Silos under pressure should never be hammered.
9. Line, hatch etc. shall be attempted to open with no trapped pressure.
10. The provision for reshuffling in case of any blend, especially
lightweight/heavyweight, should exist. The charge pressure of the silos
should be according to density of the material.
11. Prolonged storage of cement/blend in silos should be avoided. If stored for
long, reshuffling should be
done.
12. MSDS (in English and
vernacular language) of all
additives should be displayed at
the place of storage.
13. Storage of additives to be done
distinctly to enable easy
identification and access.
14. For rain prone areas and A typical on-land cementing unit
particularly during monsoon
season, cement and dry cement chemicals storage should have raised and
covered platform with dry wooden/ plastic/ metal planks flooring.
15. Skid silos and cementing skid units should be properly placed and installed
if it is part of the rig accessory.
16. Dryer of the rig air supply should be in proper working condition.
17.
B. Preparation Prior to Spudding/pre-operation of the well

1. Route survey for safe transportation of cementing units.
2. The provision for reshuffling in case of any blend, especially
lightweight/heavyweight, should exist at rig site.
3. Ensure that cementing line and end connections from ground to derrick
floor is of proper rating and anchored properly.
4. Ensure that all equipment viz. circulating head, change overs, are available
as per the requirement.
5. Ensure that provision of power supply as per requirement of agitator
motors of batch mixers is there.
6. Sufficient and proper space is available for safe placement of cementing
unit and mobile equipment to be deployed for the operation.
7. Ensure that technical water suitable for cementing operation and its
transfer hoses are available.
8. Check chemical/barite mixing system of the rig with tanks.
9. Check facility for storage of cement and cement additives as per
operational requirement is available.
10. Ensure there is provision for supply of water/mud/spacer/chemical treated
water from mud tanks/ chemical mixing tank to cementing unit with
appropriate connections.
11. Ensure provision of cement slurry line from cementing unit to well. If
permanent cementing line is a part of drilling rig, ensure it is in place and
anchored.
C. Operational aspects during lowering of casing/ liner

1. Casing should be landed preferably within 2-3 m off-bottom.
2. Check float function of shoe/ collar before make up with casing. Keep
bottom side up and fill with water, if water is not coming through float, the
float function is OK. Replace same if found leaking. Further, float shoe
should be tested while lowering it with the joint in the well. Wait for a
minute after running in first joint with bell nipple full. Check for entry of
drilling fluid inside casing.
3. Use preferably same type and make of float shoe and float collar in a
casing. In general, float shoe and float collar should be two joints apart.
4. In case of auto fill/ differential float equipment, ensure the availability of
correct size ball before casing lowering as it is required for actuating float
equipment before circulation (Otherwise differential to be converted to
conventional ones before casing lowering).
Floating Equipment
Guide shoe Ball Type Spring Differentia

Float Shoe Loaded l fill float
Float collar
Collar
5. Centralization: Use centralizers as per simulated program to have

minimum 70% stand-off (higher standoff is better) both in vertical and
deviated wells.
6. Near zone of interest, casing should be centralized by turbolizers and also
for caved section.
7. Centralizers/turbolizers not to be fitted on casing coupling.
8. For highly deviated / high drag wells, spirolizers should be used.
9. Positive centralizers can be used in casing overlap.
Bow type Turbolizer Spirolizer Positive

Centralizers centralizer
10. All precaution to be taken while passing through whipstock guide with
centralizers. In such conditions, spirolizers are preferred.
11. Run casing at controlled speed in the open hole to prevent fracturing and
lost circulation.
12. After casing is lowered, start mud pump slowly and reciprocate the string
to break gel and establish circulation. Check for mud returns.
13. In case of differential float (Intermediate/ production casing cementation),
drop ball and continue circulation.
14. Ensure that Mud pumps suction line and strainers are clean. Verify plunger
size of mud pump and the efficiency of the mud pumps to calculate strokes
required for slurry displacement (take suction from one of the pits and take
return in another pit circulating through choke at expected pressure and
discharge).
In addition to the above common points, some specific points must be

considered for:
1
a. Specific points related to lowering of surface casing
1. In specific condition for large size casings
cementation of shoe depth more than 400m,
where cementing head and plugs are not
available, use of stab-in shoe/ collar is
recommended to avoid contamination and
reduced displacement time. Alternatively tail
pipe of suitable length connected to
circulating head may be used.
2. To maintain the well center, a few
centralizers may be fitted at top, apart from
centralization at bottom (against float shoe
and float collar).
3. In offshore exploratory wells, cement rise
should be planned upto sea-bed only. To
ensure annulus above sea-bed is clear of any
cement, circulate through either MLS or
through string.
b. Specific points related to lowering of Production casing
1. Use float shoe and float collar at two joints
apart. For long length (more than 3000m)
and small diameter casings, place float collar
and shoe preferably three joints apart.
2. Float collar depth to be also decided based
on sump required for testing the bottom
most pay zone against the casing. All
endeavors should be made to avoid
drilling of cementing plugs and float
collar for testing/production purpose.
3. In case simulated centralizer program is not
available, always (a) use one centralizer
each for first five casings, (b) minimum
one number per casing against pay zones
and (c) minimum one number per
alternate casing between the gaps of
zones of interest and upto 150m above the
top most zone.
4. Use sufficient numbers of spirolizer/turbolizer against caved/ enlarged
hole section for local turbulence to remove mud properly as required
for quality cementation.
5. In wells with narrow pressure window that restricts higher
displacement rate, use sufficient spirolizer/turbolizer at top and
bottom of each object to induce local turbulence for proper mud
removal.
c. Specific points related to lowering of Liner

General point for lowering of casing is applicable in case
of liner. However, certain additional points must be
followed in case of lowering of liner as follows:
1. Lower liner to the bottom as far as possible. Bottom

of the well may be tagged with slow circulation and
then lift the liner slightly.
2. Length of liner to be decided based on well
requirement subject to load limitation as per
manufacturer’s specification.
3. Check the packer element rating for static or
circulating temperature at that depth, whichever is
higher. Inner dart, ball
& wiper plug
4. Liner shoe and landing collar should be placed at least
two joints apart.
5. Ensure before connecting Liner Cementing Head to drill pipe that:
i. Liner / cementing head to be serviced before and after every job. Spindle
and flapper to be checked for free movement before the job.
ii. Number of shear pins to be used on liner wiper plug and on hanger
are based on anticipated well circulating pressures.
iii. Ball is in Ball Dropping Sub (BDS) and spindle of BDS is in retrieved
and in locked condition.
iv. Dart dropping rod is inside the bore and in locked condition. Thereafter,
load dart in the head.
6. Reciprocate the liner for 3m to 4m during circulation prior to setting.

7. Before setting the liner hanger, ensure that well is thoroughly conditioned
and cleaned.
8. Carry out further operation under supervision of Liner Hanger expert.
9. After back-off of the liner from running string, excessive circulation
should be avoided.
10. For highly deviated wells at the depth of hanger, length of overlap may be
increased in order to ensure hydraulic integrity. Centralizer to be used in
overlap section.
11. In HPHT wells, expandable liner hanger is recommended for
reciprocation/rotation during cementation.
D. Planning and Execution of Casing/Liner Cementation Job
1. Design cement slurry with optimized parameters as per well requirement.
Logging temperature/reference well temperature may be taken for
temperature estimation. Batch mixing time of cement slurry must be
considered for slurry design simulation.
2. For production casings, maximum fluid-loss rate of 100 ml/30 min for oil
wells and 50 ml/30 min for gas wells & Liner cementation job are
recommended.
3. Preflush/spacer design:
Preflush Condition
Water + cake breaking For WBM, SG ≤ 1.20
additive
Spacer For either of the following:
 For WBM, SG≥1.20
 Gas wells
 Unstable shale section
 Well security does not allow water
as preflush
 Horizontal well cementing
 SOBM system
4. In case of Oil base mud system, use combination of spacer and preflush
comprising of surfactant/emulsion breakers and water wetting agent along
with viscous spacers.
5. Spacer should be compatible both with mud as well as cement slurry.
6. Plan for proper density hierarchy and rheological hierarchy of well fluids
at bottom hole circulating temperature and optimize displacement rate
by software simulation.
Rheological hierarchy order (tested at BHCT but limited to maximum
temperature of 88o C)
Rheology of cement slurry > Rheology of weighted spacer > Rheology
of mud.
Wiper
7. Calculate Plugs
the slurry volume using caliper log (preferably four arm caliper
log) for all important casing/ liner cementation jobs to achieve desired
cement rise. In absence of caliper log, use prior field experience to assume
the Annulus Caving factor, which is normally field specific. Calculate dry
cement and additives required as per cement slurry design and volume.
8. Prepare a tentative cement job plan and convey to DIC/RIC prior to
casing/Liner lowering.
9. Selection of float equipment should be in accordance with the well casing
grade, thread and temperature.
10. Identify bottom cement plug with flexible diaphragm by pressing and
hollow aluminum core. In case of excessive vulcanization at the
diaphragm, remove extra rubber. Never rupture bottom plug diaphragm
at surface. Identify top cement plug with solid aluminum core.
11. To confirm from well site chemist for available well site water salinity and
coordinate for sweet water, if salinity is more than 500 ppm.
12. Circulate thoroughly to remove all cuttings/cavings from the wellbore.
Subsequently circulate to condition mud at highest possible discharge to
bring down all parameters of mud to lowest permissible values.
13. Reciprocate the casing up to 3 to 4 meter throughout circulation, cement
pumping and cement slurry displacement if well condition permits.
14. Check total mud volume in all the tanks before cementation to work out as
a reference for mud loss if any, during cementation with due consideration
of volume pumped by cementing unit.
15. Plan with the established mud pump displacement efficiency to work out
total number of corresponding mud pump strokes to complete cement
displacement up to the float shoe.
16. A detailed cementation plan duly discussed by all concerned well-site in-
charges to be circulated prior to the operation. Conduct tool box meeting
prior to each job.
17. Preparation of chemical mix water:
i. Mix water volume to be prepared considering dead volume of the tank,
losses and some safety margin.
ii. Mixing sequence of additives in accordance with slurry design report.
Especially retarders should be added just before preparation of slurry.
iii. Ensure that chemicals in mix water is homogeneous.
iv. Always prefer wet blending to dry blending for homogeneity.
v. Ensure that the pumpable quantity, and supply rates and line-up for pre
hydrated Bentonite gel/ cementing chemical solution, weighted spacer
and water for cementation job are sufficient for uninterrupted
operation.
18. Prepare spacer/ pre-flush volume at the planned/ desired displacement rate,
subject to limitation of the formation fracture pressure (for spacer) and
pore pressure (for pre-flush), preferably providing contact time of 8-10
minutes.
19. In case of Single Plug Container
 Check that bottom cement plug is pushed below cementing line port
inside head before connecting cementing head.
 Roll the stopper rod inside and in locked condition, load the top
cement plug inside cementing head and set the cover.
20. In case of Double Cement Plug Container,
 Ensure that bottom cement plug is loaded first at bottom
position of cementing head with lower stopper rod inside under
locked condition.
 Ensure that top cement plug is loaded next at top with upper
stopper rod inside under locked condition.
21. Ensure that stopper rods are moving freely with minimum effort. Count the
number of turns required for inserting or extracting the stopper rod from
end to end condition. Lock the plug retaining shaft after loading of plug.
22. Connect cementing line to cementing/ circulating head. Before hook up in
the well, flush cement pumping line properly to ensure no debris is
pumped in the well and drain thereafter.
23. For pressure testing line, after hook up, pump water equal to line volume
and thereafter close cementing head valve. After receiving proper signal
from cementing supervisor, test cementing line at 1.5 times the maximum
anticipated plug bumping pressure and bleed off.
24. Pressure test the displacement line up to cementing head at maximum
anticipated plug bumping pressure, if top plug is used and bleed off. Plug
bumping pressure is generally 50 kg/cm2 (~700PSI) over differential
pressure limited to 70% of casing burst pressure rating.
25. Once pressure testing is OK, open cementing head valve after receiving
proper signal from cementing supervisor and pump pre-flush followed by
cement slurry.
26. The pumping line should have minimum two calibrated pressure gauges.
27. Once cement pumping is over,
release pressure in cement pumping
line, retract from cementing head
and wash with water. Completely
remove cement from mixing and
pumping system. All chicksans,
hammer unions, cementing/liner
head and low torque/weco valves,
mixing bowl should be properly
cleaned and serviced after each job
for smooth working subsequently.
28. Ensure minimum time is taken
between final mud circulation and
start of cementation. This will
prevent gelation/ settling of mud
solids (mud sagging). Double plug
container (cementing head) should be used if available to minimize the
time gap.
29. During cement mixing, coordinate with site chemist for measurement of
cement slurry density and collection of cement slurry samples.
30. After getting confirmation from cementing supervisor that cement slurry
pumping is over, close the slurry pumping line. Change the line-up from
cementing unit to mud pump, keeping displacement line valve in close
condition and pressurize up to 500 psi. This will ensure that fluid being
pumped is not by-passed. Reset stroke counter to zero. Keep displacement
volume of water ready in the tank to meet any exigency during cement
slurry displacement by rig pump.
31. Release top plug (If used). Open the required valve for displacement.
Ensure that no other valve in the loop is open.
32. Displace with mud at pre-determined pumping rate, slow down
displacement after 95% of calculated strokes are pumped and thereafter
bump the plug gently.
33. Coordinate with mud logger for monitoring displacement volume, total
strokes, expected pressure rise, loss or gain etc.
34. Check flow channel returns carefully both during cement pumping and
displacement to assess mud loss in the well, if any.
35. If bumping pressure is not holding, stop pumping immediately and keep
the well under differential pressure.
36. If the top plug fails to land on float collar, number of extra displacement
strokes over the calculated strokes should not exceed 50% of calculated
shoe track volume to ensure cement around shoe.
37. If top plug bumping is ok, check floats function by releasing pressure
slowly. Release the pressure through properly secured and anchored line.
38. If float is holding, keep the cementing/circulating head valve open to avoid
pressure build up inside casing due to thermal expansion.
39. If float is not holding (also when only guide shoe is used), keep the well
under pressure of differential head for 6 to 8 hrs to avoid back flow of
cement slurry.
40. In case of long cement column or if gas is expected, keep the well under
pressure through annulus, limited to fracture limit of the formation.
41. During WOC (with or without pressure), monitor the well for any activity
or pressure build-up in well/annulus.
In addition to the above common points, the following points are to be
considered depending on the type of casing to be cemented:
a. Specific points related to planning & execution of surface casing

cementation
1. When float collar / top rubber plug are not used,
 Ensure that minimum 15 m cement plug is planned to be left inside
casing above the shoe.
 Plan for minimum 50m of high viscous gel after cement slurry and
carry out displacement accordingly.
 Displace by mud at pre-determined pumping rate, slow down (during
end of displacement) and thereafter stop displacement at strokes
calculated with 100% efficiency.
If top plug in conjunction with float collar is used, displace upto float
collar with calculated strokes considering mud pump efficiency.
2. Check flow channel returns carefully during cement pumping and

displacement to assess loss behavior of well. Also check whether cement
has surfaced or not to avoid cement being left in the riser and mixing of
cement with mud.
b. Specific points related to Planning and Execution of Liner

Cementation Job
1. Circulate and condition the well within limiting parameters as provided by
the manufacturer.
2. In case of Conventional Liner hanger, plan cement rise of at least 50m
above liner hanger top. For deviated/horizontal hole, may have to use extra
height above liner hanger top. If the caving %age is more than 100%,
consider maximum 100% caving only.
3. For Expandable Liner Hanger, cement top is to be planned only as per well
requirement.
1
4. After slurry pumping is over, drop the dart and thereafter open the required
valves for displacement of cement slurry from top inlet. Ensure that no
other valve is open.
5. Displacement with cementing unit is preferred. If mud pump is used for
displacement, maximum number of pump strokes should be calculated
considering mud pump actual efficiency plus 50% of shoe track volume.
6. Displace with running mud at pre-determined pumping rate and strokes,
slow down temporarily before shearing the wiper plug and shear the same.
Recalculate the number of strokes required for displacement.
7. Continue displacement at predetermined rate and slow down displacement
in last 40-50 strokes and bump the plug slowly.
8. Hand over to Liner hanger expert (to back off for conventional liner or to
drop ball for setting of liner hanger in expandable liner hanger system
followed by back off etc.)
9. Pull out hanger running tool minimum 100m above liner top.
10. After pulling out, reverse circulate cement slurry by pumping 1.5 times
drill pipe volume or till cement is cleared out. Direct circulate 1.5 times
minimum if mud weight is more than 1.6 gm/cc.
11. In high angle wells pull out sufficient stands and direct wash keeping the
string in slow rotation/reciprocation.
12. Pull out of hole (POOH).
13. In a well where loss has taken place during cementation, the decision of
setting packer and direct wash/reverse wash has to be taken at well site
depending on the well condition (including well inclination).
14. R/I with bit to tag cement after WOC.
c. Specific points related to planning & execution of multistage

Cementation
In multi-stage cementing, first stage is conventional with placement of cement
slurry around the lower portion of the casing string. In next stages, placement
of cement slurry at successive upper stage is carried out through ports of stage
collar. Most stage cementing is in
two stages, although additional Stage collar (mechanical)
stages are possible.
1. Plan to maintain a gap of

around 100m between top of
cement of 1st stage and stage
collar position
2. Place stage collar at suitable
depth below zones of interest
being covered of second stage.
3. The first stage slurry thickening 1-Run in Hole 3-Tool Closed
time includes the traveling time
2-Tool Opened
of bomb, opening of ports and
one cycle circulation through
stage collar ports in addition to
slurry pumping and
displacement time and safety factor.
4. Check the stage cementing collar before it is made up on the casing, the
size of the trip plug/ freefall plug/ opening bomb, I.D. of the opening
sleeve and closing sleeve and the size of the seats provided in opening
& closing sleeves.
5. Caution must be exercised in initial handling of the stage collars, as the
equipment is manufactured to close tolerances. Rough handling can
misalign the moving parts, causing job failure.
6. Stage collar should be made up by locking the tongs only at the designated
place on the outer sleeve of the stage collar.
7. The first-stage displacement plug must fit and seal against the float collar.
Keep baffle plate/ baffle collar over float collar/landing collar, as
recommended by manufacturer.
8. If length of first stage plug is longer than to be accommodated in
cementing head, it has to be dropped by opening the cementing head cap.
To minimize intake of air, close annular BOP before opening the cap.
9. One centralizer each to be fitted above and below the stage collar and
against zones of interest.
10. Run casing with the stage collar to the desired depth. The stage collar
should preferably be placed against the shale/clay section.
11. During displacement in first stage cementing, slow down pump
temporarily when 1st stage closing plug is about to cross the stage collar
to avoid any inadvertent opening.
12. After bumping of 1st stage plug, increase pressure slowly to port opening
pressure. If port does not open at recommended manufacturer’s maximum
pressure plus 500 psi. Drop stand-by opening bomb and open the ports
conventionally. In case of anticipated loss condition, it is recommended to
open the ports with opening plug/ opening bomb/ trip plug.
13. In case hydraulic stage collar is used, restrict circulation and displacement
pressure during 1st stage to safe value (refer manufacturer’s spec) below
port opening pressure.
14. After completion of first stage cementation, drop the opening plug or bomb
and allow it to reach the stage collar. Opening plug velocity is
approximately 1m/sec in normal mud. To open the ports, slowly build-up
pressure as per manufacturer’s spec.
15. In case of hydraulic stage collar, pumping pressure during circulation,
cement pumping and displacement should always be restricted to port
opening pressure with safety margin.
16. Circulate the well thoroughly through the stage collar ports to flush out any
contaminated cement (from the first stage) and condition mud for the
second stage.
17. Start 2nd stage cementation after thorough circulation.
18. Second stage cementation immediately after circulation may be carried out
considering:
 Hydrostatic head of both cement columns (1st and 2nd stage),
limited to formation strength.
 Possibility of gas migration during transition phase due to
reduction in head.
Or else, maintain slow circulation for 6-8 hours from completion of 1st
stage cementation before start of the 2nd stage job.
19. In 2nd stage cementing, complete pumping of cement, release shut-off plug,
and displace cement remaining in cement line (up to rig floor) behind the
shut-off plug. Releasing closing/ shut off plug in such a manner would
have some cement slurry above it. This will ensure uncontaminated
cement outside the stage collar in the annulus and minimize the hazards
of contaminated cement outside the stage collar. Further, cement above
shut off plug will help in drilling it out.
20. For closing the cementing ports, specified pressure (refer manufacturer’s
spec) in excess of second stage cementing pressure is to be built up slowly
over the shut off plug. Confirm the closure by bleeding off.
21. ECP (External Casing Packer)

ECP is used to seal off the casing annulus. It can be placed between two
casings or in open hole.
 ECP in combination with stage collar may be used to isolate

fractured basement to avoid entering cement slurry in the
basement.
 Preferably, ECP set in gauged hole. It may be set in an enlarged
hole, but differential pressure rating of the packer gets reduced as
per the manufacturer’s spec.
 Inflating pressure shear pin rating has to be calculated considering
pumping pressure during entire operation.
d. Specific points related to planning & execution of subsea well

Cementation
1. Since all the loads of subsequent casings is taken by the conductor casing,
it is most important casing. The formation is unconsolidated and bottom
hole temperature is low, cement slurry and volume should be designed
accordingly. Especially for
deep water. Low heat of
hydration cement slurry to
be pumped to ensure gas
hydrate stability.
2. Ensure mandrel, used for
connecting subsea top and
bottom plugs have been
serviced immediately after the
last cementation. Swivel above
mandrel should be free.
3. Subsea cementing head is
common for all casings.
Service the head immediately
after each job for proper
functioning of ball releasing
sub, dart holding sub, release
indicator rod and locking
mechanism.
4. Prior to a casing cement
Sub-sea Wiper Plug System
job, keep cementing head ready in advance as follows:
I. Load the ball (for releasing bottom plug) in cementing head and ensure
that ball release sub is in locked position.
II. Before loading the dart (for releasing top plug) in cementing head,
ensure that dart release rod is completely inside the cementing head
bore and is in locked position.
5. Drop the ball from cementing head (for releasing bottom plug) and lock
the ball release sub after checking indicator. Slow the pump rate to
notice release of bottom plug once ball seats on it.
6. After pumping cement slurry, drop the dart to release top plug.
7. Ensure that all substitute/X-over in the drill string above casing hanger are
rabbited (by using size and type of the rabbit recommended by
manufacturer
of subsea plug used) to have ID sufficient for passage of the ball and the
dart.
Some Sub-sea Wiper Plug System come with built-in swivel equalizers
and are released with darts instead of balls. The reason for dart release is
to provide wiping of the drill pipe strings on deep casings or liners and to
avoid having to wait for the gravity settling of balls.
E. Secondary Cementation
1. Circulate and condition well fluid at maximum possible rate for wellbore
cleaning, homogeneity (and lowering of wellbore temperature to
circulating temperature in HPHT wells).
2. Check for wellbore stability and note down the hook load. If found
unstable, circulate the well with suitable well fluid parameter.
176
3. Use 5" drill pipe with diverter tool
 In hole size of 12- ¼” and larger
 In 9-5/8" casing or larger
4. Avoid diverter tool if pressure limitation is expected during reverse
circulation after cement placement which may induce loss in the well.
5. To avoid stuck up of pipe due to cement on the lower side in an inclined
hole, plan direct circulation and the
string must be in continuous
reciprocation and rotation.
6. In case of smaller size hole/casing, use
combination string (preferably with 3
½” or 2 7/8" drill pipe) with tail pipe
of 2 7/8" tubing. Minimum length of
tail pipe should be more than the
intended length of cement plug and
spacer/pre-flush together to be placed.
7. Avoid using tubing string for squeeze jobs in deep wells.
8. Plan longer cement column for highly deviated hole.
9. Calculate the height of cement column with drill pipe/tubing inside cement
slurry and displacement volume accordingly.
10. Length of cement plug preferably be kept at minimum particularly in slim
holes with narrow annulus clearance.
11. For displacement of cement slurry, use cementing unit for accurate
volumetric displacement.
12. Underbalance the plug by 300 to 500 liter volume according to the size of
the casing, if substantial difference is there between mud and cement slurry
SG.
13. Keep lines/valves/ change over connections ready before start of
cementation to facilitate immediate reverse circulation after plug
placement
& pulling out without loss of any time.
1
14. For large/deviated hole, rotate the string (during cement pumping and
displacement) to increase the chances of cement plug success. String
should
2
be kept in rotation while pulling out also. Carry out safety pullout
immediately after reverse wash. Option of direct wash may be considered
in highly deviated wells if rotation is possible.
15. Monitor hook load continuously throughout cementing operations
including pulling out of string for reverse wash. In case of increase in hook
load, pull out fast to safe position and immediately carry out direct wash
at full SPM to avoid any complication.
16. Pulling out speed should not be more than 10-15 m/minute while string is
in cement and thereafter at high speed. In normal case, after pulling out
minimum 100m above plug top, carry out reverse wash
17. It is good practice to pull out in stands; break stand from working joint
while pull out.
18. In all the cases of direct or reverse circulation, slurry thickening time
should consider job time, wash time and with contingency.
19. After carrying out the reverse wash / squeeze operation, ensure the opening
of BOP through physical inspection.
20. In case of problem in closing pipe ram for reverse circulation (after cement
placement and pulling out), resort to direct circulation with reciprocation to
flush out residual cement to avoid any complication.
21. In case of any problem in pulling out from bottom after cement placement,
attempt to rotate the string.
22. Keep cementing unit in readiness after cement pumping and also for any
pressure application required in case circulation could not be established
after pulling out. In case, pressure shoots up during initiation/process of
reversing out, apply pressure through drill string by cementing unit up to
the safe limit of the minimum rating of running string components or
fracture limit of formation in case of open hole.
23. In case cement plug is required to be repeated, ensure that previous cement
cuttings are cleared and flushed out of hole properly (if required, use
viscous sweep). Otherwise large chunk of cement cuttings are likely to
block drill pipe/annulus during reverse/direct wash, resulting in well
complication.
24. In very deep wells with high mud weight to increase the chances of
successful placement of cement plug, mechanical separation inside the
string may be done using sponge ball to avoid the contamination and
cement plug failure.
25. To avoid the chances of stuck up of pipe with cement during cement plug
placement in very deep wells with high mud weight, fiber tubing may be
used @ two times the cement plug length. This will help in case of a stuck
situation to snap the fiber tubing from metal tubing /drill pipe and thereby
saving the well as fiber tubing can be drilled out later.
26. In case of a secondary job in a well with brine solution which is likely to
accelerate the cement setting time, sufficient care should be taken to avoid
flash setting of cement. Sufficient amount of pre-flush and after flush in
proportion (minimum 100m ) to be pumped ahead and behind slurry to
avoid contamination. If brine weight in the well is more than 1.09 SG (9
ppg), it may be replaced with mud.
27. In loss condition, cementitious material viz. RSF pill/cement slurry may be
placed. The specific gravity, thickening time, thixotropic property and
volume of RSF pill/cement slurry is based on the severity of the loss.
28. Always wash the string in loss condition also. If well condition does not
permit wash at deeper depth, pull out to shallower depth and wash the
string/ annulus. In case of total loss/ severe loss, wash volume to be
monitored.
29. Thixotropic cement may be used in case loss cannot be brought under
control using conventional cement.
30. All precautions to be taken during tagging and drilling of cement
 Never attempt to tag cement with open end drill pipe/ tubing.
 Go slowly with bit (preferably without nozzles) rotation and mud
circulation below the depth of reverse/ direct wash. Monitor the torque
& pressure. Also, lift the string intermittently.
Cement Plug in Shallow depth

In shallow depth, plug placement becomes challenging due to larger hole
size causing cement channelizing/contamination problem. Distinctive
precautions for shallow depth plug placement are:
1. Place weighted high viscous pill of around 100 m (150 sec funnel
viscosity or higher) at bottom sump just below planned bottom of
cement plug.
2. Use diverter tool. Lateral exit of fluid from diverter tool will provide
better round the hole cleaning and cement slurry placement.
3. Circulate the well with tandem low vis-high vis sweep. Rotate and
reciprocate the string during circulation and plug placement.
4. Optimize cement slurry thickening time. Slurry must be designed
considering BHCT at plug depth. Use accelerator if necessary.
5. In absence of caliper log, slurry volume should be calculated
considering likely hole size. Also, for safety, pull out at least 150 m
above expected plug top before wash.
6. Design light weight cement slurry for loss situation and high density
slurry for side track plug.
7. Use appropriate spacer /washes to prevent cement contamination. IDT
designed chemical wash is recommended for cement plugs in NDDF
system.
8. Plug placement should be in laminar / plug flow regime.
F. Cement squeeze procedures

1. In case of squeeze jobs, injectivity must be checked in water before taking
up the job.
1
2. If an attempt is to be made to squeeze cement into perforations or into a
casing leak etc., and the cement opposite the point of squeeze is to be
drilled out later, injection rates should be established before cement is
squeezed.
3. Establishment of the injection rate is less important if the well is to be
abandoned and cement will not be drilled out afterwards.
4. If injectivity is not there, try to improve injectivity by acid wash against
perforated areas. Injectivity should be minimum 100 L/min at 1,000 psi in
general.
5. In mud filled or partially plugged perforations where the injectivity is very
poor, one of the best ways to ensure a uniform deposit of cement is to
pump weak hydrochloric or acetic acid solution ahead of the cement as
suggested by WSS expert. The acid shrinks the clay particles and allows
the cement slurry to penetrate farther.
6. High squeeze pressures which may induce formation breakdown must be
avoided, particularly in the vicinity of faults and stacked reservoirs, in
order to prevent zonal communication via vertical fissures. The formation
closure pressure should never be exceeded.
7. When a packer has been set just above the perforations or zone to be
squeezed off, the bottom hole pressure must be kept below 80 % of the
collapse pressure of the weakest casing in use. Changing the setting point
of the packer or applying back pressure may help to increase the allowable
squeeze pressure.
8. The hesitation squeeze technique should be used in lost circulation / high
pressure zones to aid bridging of the cement solids.
9. Apply squeeze pressure in stages to achieve the desired squeezing
pressure. (shown in fig)
10. The simplest way to carry out a squeeze is to place a balanced plug and
squeeze it by applying pressure with the annulus closed. However, a
packer must be used if the pressure during the squeeze will exceed the
maximum allowable pressure at any point above the planned depth of the
cementation.
11. In vertical wells minimum 25 m plug above the perforation should be there
after squeeze, in case of horizontal wells it should be 50 m.
Requirements (cement slurry design requirements)

 A consistent slurry SG is particularly important for cement plugs. The
cement must be batch mixed until the correct SG is achieved.
 The slurries with low fluid loss of less than 50 ml/30 min are used for
regular squeeze cementing jobs, to reduce premature slurry
dehydration during placement.
 Slurries designed for use in remedial cementation operations, will be
formulated such that:
Pumpability Time = Mixing Time + Slurry Displacement Time +
Circulating out Time + 60 mins (Safety margin)
Preparations
 In deviated wells with less than 30° hole angle, a viscous pill of
approximately 100m length can be used as a bottom support for the cement
plug.
 If there are any perforations below that need to be protected from the
squeeze pressure and/or cement that might work its way down the hole, a
drillable bridge plug must be set above the perforation, approximately 7m
below the interval to be squeezed.
Block cementation using a Cement Retainer
The following procedure should be adhered to when preparing for block
cementation (Circulation squeeze using a cement retainer):
i. Set a drillable cement retainer above lower most perforations to be

squeezed.
ii. Before stab-in, circulate and run-in slowly into the retainer and establish
hermeticity of the string.
iii. Now, release the weight and attempt to establish circulation behind the
casing, with pressure less than fracture pressure of the formation.
iv. Use pre-flush and after flush before and after cement slurry.
v. Displace the batch-mixed cement until the first spacer reaches the end of
the stinger.
vi. Stab in stinger into cement retainer immediately.
vii. Squeeze maximum 70% of the cement slurry.
viii. Pull out drill pipe from cement retainer approximately 15m. above the
upper perforations
ix. Reverse wash the string.
x. POOH
xi. Block cementation is not recommended in case mud weights is more than
1.8 gm/cc.
G. Well Abandonment Procedure

Well abandoning procedure is recommended to prevent pressure build up or
cross flow in the well and its surroundings in future. Abandonment shall also
prevent contamination of fresh water aquifers and leakage of any well bore
fluid to the surface.
There are two types of abandonment
 Temporary well abandonment

 Permanent well abandonment
1. Temporary Well Abandonment

i. Place a bridge plug or minimum 100m cement plug at the base of
last casing string. Avoid open hole cement plug.
ii. Put another plug with top of plug not more than 300m below wellhead
/ mud line. This plug may be any of the three types.
 Retrievable Bridge Plug / packer
 Permanent Bridge Plug
 Cement Plug of 100 m
iii. For surface/ subsea wellhead, corrosion cap is to be installed
covering all the annulus and inside casing.
Testing abandonment cement plug for both

permanent and temporary abandonment
 Tag the cement plug, load test with 8 MT of weight and pressure
test with 1,000 psi wherever possible.
 The bore hole including the space between the cement plugs shall
be filled with drilling fluid of sufficient specific gravity and other
properties so as to enable it to withstand any subsequent pressure
which may develop in the bore hole.
2. Permanent Well Abandonment

Permanent abandonment is to be followed in the wells
 Completed as a non-productive well

 Ceases to produce hydrocarbons
 No longer operated
a. Bottom Abandonment Plug
I. Open Hole Abandonment (Take extra height of cement plug to

ensure minimum plug length as below)
 With Oil /Gas/Freshwater Zone
 Place cement plug such that it covers
- minimum 30m below the bottom-most
zone &
- 30 m above the top-most zone.
 If a caliper log is available, correct volume of cement plug

should be calculated and placed to cover the
predetermined length of cement plug.
 Tag the cement plug, load test with 8 MT of weight and
pressure test with 1,000 psi or upto LOT equivalent
pressure at exposed shoe.
 Place thereafter another cement plug such that minimum
30m below the shoe and 30 m above shoe is covered.
 With No Oil / Gas / Freshwater Zone:
 Place cement plug such that minimum 30m below the
shoe and 30 m above shoe is covered.
 For Expected / Known Loss Zone:
 Bridge plug is to be set 15m to 30m above last shoe
followed by 50 m cement plug just above.
II. Cased Hole Abandonment
 Place preferably 100m cement plug such that
minimum 30 m above the top of topmost perforation is
covered after cement is set and squeezed-squeeze volume.
III. Cased Hole Abandonment (earlier producing one):
 Place preferably 100m cement plug such that minimum 30m
below the bottom of bottommost perforation to 30 m above the
top of topmost perforation is covered after cement is set.
 If perforation interval is too big, isolation of all zones are
required or not, to be decided. If required place more than one
plug.
 Top most object in all cases is to be isolated by squeezing
cement slurry. Squeeze can be combined with cement plug
placement while isolating top most object.
 If completion packer is not retrieved, perforation interval
below the packer is to be isolated first by squeezing cement
through packer and thereafter leaving a cement plug of
minimum 30m above packer.
b. Intermediate Abandonment Plug
I. For Well With Liner
In case well is completed with liner cementation in the final
phase, place 100m cement plug such that minimum 30m below
the liner hanger top to 30 m above the liner hanger top is covered
after cement is set.
II. For Well with Retrieved Casing Leaving A Stub:

If casing is retrieved leaving a stub inside the previous casing,
place 100m cement plug such that minimum 30m inside stub and
minimum 30 m above the stub is covered after cement is set.
III. For Offshore Well (additional safety):

Check well for annulus activity. In case no activity is observed in
offshore exploratory well, place 100m cement plug in production
casing at 1,000m – 1,500m depth. Alternatively bridge plug is to
be set if top zone is already isolated by cement plug/squeeze.
c. Top abandonment plug:
I. For Onshore Wells:

 Check 13⅜ x9⅝’’ annulus and 9⅝’’ x 7’’/ 5½’’ annulus for any
activity.
 Fill both annuli with suitable mud. Perforate 7’’/ 5½’’ and 9⅝’’
casings 25m above 13⅜’’ shoe (9⅝’’ shoe in case of 2 casing
policy) position with 8 shots per foot.
 Open 9⅝’’ x 7’’/ 5½’’ and 13⅜ x9⅝’’ annuli valve one by one &
try to establish circulation individually with required mud (within
LOT value).
 Place a balanced cement plug of calculated volume and try to raise
minimum 30 m cement slurry in annulus one by one by operating
annulus valves and closing BOP such that 30m plug remains
inside casing above perforation. Pump/Squeeze slurry up to
1,000psi/ within LOT value.
 If circulation does not establish, in addition to squeeze against
perforation, outer most annulus to be top filled with cement slurry
through tubing after removal of Well Head.
 In case of 4 casing policy (18⅝’’/ 20’’ surface casing), perforation
to be done 20 – 30 m above 18⅝’’/ 20’’ shoe depth assuming that
there is no hydrocarbon show above 20’’ casing shoe.
 After removing all well heads a plate (Minimum thickness of 10
mm) to be welded on the outermost casing with vent line and
provision for pressure gauge.
 If casings are retrieved, place a progressive surface plug of 60 m
height covering all the annulus and inner most casing stub.
II. For Offshore Wells with Surface BOP:

 Check 20’’ x 13⅜’’ annulus and 13⅜’’ x 9⅝’’ annulus for any
activity. Fill both annuli with suitable mud.
 Perforate 9⅝’’ and 13⅜’’ casings 25m above 20’’ shoe (13⅜’’ or
9⅝’’ shoe in case of 3 casing/ 2 casing policy respectively)
position with 8 shots per foot. Open 13⅜”x9⅝” and
20’’X13⅜’’ annuli valve one by one & try to establish
circulation individually with required mud (within LOT value).
 Place a balanced cement plug of calculated volume and try to raise
minimum 30 m cement slurry in both annuli one by one by closing
BOP and operating annulus valves such that 30m plug remains
inside casing above perforation.
 Squeeze slurry up to 1,000psi/ LOT value.
III. For Offshore Wells with Sub-surface BOP:

 Place a cement plug of 100 m length such that top of cement plug
is at about 100m below well head.
d. Surface abandonment plug for offshore:
I. With surface BOP:

If MLS (Mudline suspension) is used and it covers all the casings,
retrieve all casings from MLS. However if there is any pressure in any
of the annulus (20’’X13⅜’’ & 13⅜’’ X 9⅝’’), it needs to be subdued.
After well is subdued and casing is retrieved from MLS, Place
Corrosion/ (T/A) Cap which covers all the annulus and inner casing
stub.
If MLS is not used, check for any annulus activity. Subdue the well if
any activity is observed. Cut 9⅝’’ casing from 15m, 13⅜’’ casing
from 10m and 20’’ casing from 5m below sea bed. Cut and retrieve all
the casings and place a progressive surface plug of 60 m height
covering all the annulus and inner most casing stub. After cement plug
placement, wash down the cement up to 2m to 3m below sea bed. Cut
and retrieve back 30’’ casing at 2m below sea bed.
II. With Sub-surface BOP:

When well head is not retrieved and annuli are sealed by energization,
no surface abandon plug is required.
j) Salient points of different types of Casing Cementation Jobs
Description Surface Casing Intermediate Liner Production

18⅝” and 13⅜”/ Casing (Intermediate/ Casing
above 9⅝” Production)
Casing
Shoe Type Float Type Float Float Type Float Type Float Type
Type (with side
ports)
Float collar For 20” size: Float Float Type Float Type Landing
Stab-in F/C Type collar of
for casing same liner
shoe > 500m hanger make
(alternatively
& F/shoe
may be used)
Shoe track 15m cement Two 2 joints apart 2 joints apart
(distance to be left casing (3 joints for smaller size csg
between F/C inside above joints in deep well)
and shoe) shoe preferably
Wiper Plug Preferably Both top Both top & Liner dart & Both top &
top plug to and bottom wiper plug of bottom
be used bottom plugs same liner plugs. (Two
plugs hanger make bottom plugs
preferably & one top
may be used
for critical
jobs)
Annulus  Annulus Caving Factor  Slurry  Slurry volume to be
Caving volume: as calculated as per caliper +
to be taken as per earlier
Factor (to be per caliper 10%- 20%
job experience in the
considered
for slurry
same field with 10%  Preferably four arm caliper
 Or else 100% caving excess should be recorded
volume
calculation) may be considered for  If caliper
surface rise (In case is not
surface casing). taken,
caving to
be
considered
as per
earlier job
experience
in same
field or
else
around
20% over
ideal
annulus
18⅝” and 13⅜”/ Casing (Intermediate/ Casing
above Production)
9⅝”
Casing
Centralizer 4-5 nos to be used  1  Use centralizers as per
centralizer program ensuring minimum
per joint 70% standoff.
for first 5
joints
&then
 1
centralizer
after every
fourth
joint up-to
cement
top.
Spirolizer Nil To be used To be used to induce local
to induce turbulence against
local  caved section
turbulence
against
 top and bottom of each zone
of interest
caved
portion
Mud N/A Rheology After casing lowering, Pv, Yp
properties (Pv, Yp) to and filtration loss should be
(after casing be maintained at minimum
lowering) maintained possible.
to optimum Preferred Yp < 25 lbs/100ft2
values
Gel break/
Circulation/
Only Circulation and  Gel break  Gel break for 30 mins at the
conditioning for bottoms for 30 previous csg shoe.
Mud up.
conditioning minutes at  Additional gel break (5-10
the min) if OH > 1000m.
previous
casing  Additional gel break (5-10
shoe. min) if poor returns are
 Final observed during casing
circulation lowering.
at bottom  Final circulation at bottom
1
Reciprocation N/A Preferred To be done To be done
of casing for till end of
conventional displacement
till hanger set
and for
expandable
Liner Hanger
till end of
displacement
Fresh Mud N/A In case of  Around 30-35 M3 of
Oil based freshly prepared mud
mud, entire having the same drilling
annulus mud properties to be used.
volume may
be replaced  In case of Oil based mud,
with fresh entire annulus volume may
water based be replaced with fresh
mud water based mud with
fluid loss/ rheology
control before cementation
Pre-flush/ Water  Pre-flush/ weighted spacer in water base
Spacer type
mud below 1.20 SG.
 Weighted Spacer if mud weight > 1.20 SG.
(Refer detail at D (24))
 A set of spacers and pre-flush to be used in
Oil base mud system which should also
change the wettability of the formation and
18⅝” 13⅜”/ Casing (Intermediate/ Casing
and 9⅝” Production)
above Casing
Pre-flush/ Water: For 7” csg/ liner: around 14.0 M3 (min 10.0 M3)*
Spacer 6.0 m3 for 20”/ For 5½” csg : around 20.0 M3 (min 14.0 M3)*
Volume 18⅝” * subject to formation fracture pressure and pore
3.0 m3 for 13⅜”/ pressure limitations.
9⅝”
Major At the rate At maximum At desired rate to achieve minimum
Displacement equivalent to that possible rate required annular velocity (1.3 to 1.8
rate used during subject to m/s), depending on the size of
drilling formation casing/ liner and hole size subject to
fracture and formation fracture strength. In case
pump pressure of weighted spacer optimize
limitation. discharge rate based on rheological
hierarchy graph.
Desired minimum rate (for gauged
hole):
> 3.0 m3/min for 9⅝” csg
> 2.3 m3/min for 5½” csg
> 1.7 m3/min for 7” L/ csg
> 1.0 m3/min for 5” csg
WOC Decide WOC needed by the time Decide WOC needed by the time
required to attain 500 psi required to attain 2000 psi
compressive strength of cement compressive strength of cement
slurry (as per UCA test for the slurry (as per UCA test for the
cement slurry used for the actual cement slurry used for the actual
BHP/ BHST) BHP/ BHST)
H. Cementing Considerations for HPHT wells
 Cementation of HPHT wells encounters a wide range of unique
challenges. The most common HPHT definition is when bottom hole
temperature exceeds 300°F (149°C) and/ or bottom hole pressure
exceeds 10,000 psi.
The rheologies of the well fluids varies considerably in high
temperature wellbore environment. Therefore, rheologies of well
fluids require careful evaluation at BHCT to comply with the
requirement for good cementation:
Rheology of cement slurry > Rheology of weighted spacer >
Rheology of mud.
 Induced thermal stresses on cement sheath in HPHT wellbore should
be evaluated.
 The cement design should consider specific additives for better
mechanical properties.
 Use of expandable liner hanger is always better option as it facilitates
reciprocation and rotation of string till cement displacement. Also
cement at liner hanger top can be avoided. In HPHT well, cement rise
above liner top should be avoided. Longer liner overlap section may be
planned for conventional liner hanger for achieving hermeticity at
hanger top.
Following steps needs to be carefully planned/ executed:-
1. The Planning Process

2. Slurry Design
3. Spacer Design
1. The Planning Process

1.1 Casing Eccentricity
a) Proper Directional survey and four arms caliper are recommended to
determine a proper centralizer placement in critical wells.
b) Generally, for casing centralization, 70% standoff is considered as the
minimum requirement to have good cement bond as per the latest
guidelines.
1.2 Temperature estimation
In HPHT wells, simulation should be carried out to accurately predict the
BHCT from BHST for correct assessment of thickening time. Temperature
attainment with time from simulation should be used for evaluating
compressive strength. The more data and modelling, the better the most
likely temperatures can be bracketed and the appropriate lab designs
chosen.
1.3 Mud Removal

Mud removal planning is crucial in achieving proper cement placement
and strong cement bond in HPHT wells. The plans include the
a) Thoroughly circulate the well for cutting removal before lowing of the
casing. Surge/swab model should be run on simulator to calculate
suitable casing lowering speed and mud properties. Condition the
drilling fluid to lower the mud viscosity to permissible limit before
pull out of the drill string. This will reduce effect of surge/swab
while casing/liner lowering and reciprocation.
b) Break gel intermittently during casing lowering. After casing lowering,
reach stepwise up to planned circulation rate and plot graph between
pressure v/s discharge rate, mud properties.
c) Circulate the well at planned circulation rate for 2 to 3 times of well
volume to lower BHCT.
d) Time gap between end of circulation and start of cement job should be
minimum.
e) The important factors to achieve a good mud removal are: (a)
Improving pipe stand-off, (b) increasing Pv/Yp ratio, (c) decreasing
mud gel strength, and (d) increasing flow rate.
f) Use of pre-flush/ chemical wash/ spacer ahead of slurry to act as a
buffer between possibly incompatible mud and cement. To avoid slurry
contamination, at least 200m (650 ft) of spacer ahead and 50m (170 ft)
behind cement slurry to be maintained for separation from mud during
displacement. Difference between spacer and mud densities and
cement and spacer densities should be around 10%. To get
effective flow, minimum of 1.33 m/sec annular velocity should be
considered. However in case of HPHT wells, it is not possible to
achieve 1.33 m/sec annular velocity always, hence rheological
hierarchy of well fluids should be optimized at feasible discharge
rate by using software simulation.
1.4 Cementing Computer Program
Cementing operation could be optimized by simulating it first in cementing
computer program. It will give an overview of the proper flow pump
sequence, pumping schedule (include stage timing, flow rate, volume for
each fluid, worse depth scenario regarding collapse and burst), and
centralizer placement. It also gives ECD predictions and the efficient
displacement rate. The program can give illustrations of pore and fracture
pressure window, which help in deciding the best slurry density, drilling
fluid conditioning, spacer, lead or tail slurry etc.
In critical well conditions, set cement sheath characteristics should be

analyzed using advanced software. The software can quantify the risk of
wellbore set cement sheath failure by applying stress analysis and
sensitization criteria. The software analysis of radial and tangential stresses
can determine cement sheath performance in compression, tension or both,
enabling the design of the set cement behind the casing.
1.5 Contingency Planning:

 Make sure that contingency slurries are developed as the well
progresses. Setting any casing at deeper depth can have a profound
effect on the slurry design due to increased temperature and pressure
condition and may take a week of lab testing if pilot studies are not
already underway.
 As contingency plan, Lab testing to obtain a suitable Kick-off plug/
plug designs for shoe squeezes should be made available.
2. Slurry Design
Cement slurry system, pre-flush and spacer should be designed and tested in
the laboratory to fit the objective of the cementing job. When mixing
slurry, laboratory testing needs to be run to ensure right slurry properties at
surface and down-hole conditions. Mixing sequence/ technique need to be
followed since some of the additives are sensitive to shear. In general
retarder should be blended just before the job. Laboratory tests simulated at
appropriate period of ambient pressure and temperature to provide proper
mixing energy. The slurry should be tested ± 50°F (10°C) from targeted
BHCT (Bottom Hole Circulation Temperature).
Key areas to be considered in designing an HPHT cement slurry are:
• Bulk cement sampling

• Temperature
• Cement selection
• Additive selection:
 Retarder
 Fluid Loss Aid
 Silica
 Weighting Agent
 Gas Migration Control
• Slurry Sensitivity
2.1 Bulk Cement Sampling:

HT wells will require silica, most commonly dry blended silica flour.
For lab testing, samples should be collected from three sources viz.,
(i) individual samples of cement and silica,

(ii) sample taken from the bulk blending plant and
(iii) samples brought back from the rig
The samples should be properly packed (Containers must be moisture
proof and airtight, full and uncontaminated by anything) with the lids
marked with well name, date etc.
2.2 Temperature
2.2.1 Bottom hole circulating temperature
Bottom hole Circulating Temperature (BHCT) is the temperature that
influences the thickening time or pumpability of the cement slurry. In all
HPHT wells use of thermal simulator for accurate temperature prediction
is recommended.
However, for cementing deep wells, temperatures should be verified by
some form of actual down hole measurement, preferably during the
circulation phase.
2.2.2 Bottom hole Static Temperature

Knowing the bottom hole static temperature (BHST) is important for
designing and assessing long term stability or rate of compressive strength
development of a cement slurry. Determining BHST is especially
important in deep well cementing—where the temperature differential
between the top and bottom of the cement can be high and cement slurries
that are designed for safe placement at times may be over retarded at top-
of-cement (TOC) temperatures, resulting in poor compressive strength
development. Generally, if the BHST at the top of the cement column
exceeds the BHCT, over retardation is not expected.
Maximum recorded bottom hole log temperature (BHLT) after suitable

correction (as shown in table) should be considered for bottom hole static
temperature (BHST).
BHST Correction Factor
Time period Correction formula

3 to 4 hrs BHLT X 1.08 = BHST
49 hrs onwards BHLT X 1.00 = BHST
2.3 Cement selection

High temperature cementing jobs are generally performed with API Class
G or Class H cement. Wherever possible in HPHT cementing, a
recognized high quality well cement with a track record at such conditions
should be used.
Cements with non-linear response to retarder concentration should be

avoided. Cement properties and response to cement additives varies from
batch to batch/manufacturer to manufacturer. The cement lot destined for
HPHT job must be identified and set aside for intended use.
The API Specification does not address suitability for HT conditions. For
slurry density > 2.1 SG (17.5 ppg) at BHST above 300 DegF (149 DegC),
the reactivity of some cements can make the slurry very difficult to retard
at high temperature and difficult to disperse thereby affecting slurry
rheology and amount of weighting agent required to create a pumpable
slurry.
2.4 Additive Selection

2.4.1 Retarder (Thickening Time)
Proper amounts of retarder must be blended with the cement. In deep
wells, differential static temperature between top and bottom of cement
column can exceed 100°F (55 DegC). Retarder has varying sensitivity
levels to temperature. Hence, small temperature difference can cause
significant changes in thickening time. Higher dose may delay the
setting process which in turn may lead the entry of gas into the cement
in high pressure wells. For extreme temperature conditions, thickening
time for a cement lot should be measured with ±5% of the retarder
concentration. Variance in thickening time due to concentration
sensitivity should be within acceptable for safe cement job execution.
2.4.2 Fluid Loss Control

Maintaining constant fluid loss in HPHT well is necessary to preserve the
chemical and physical characteristic of the cement slurry, especially due to
high hydrostatic pressure in deep wells. On the other hand, it needs to
prevent the development of filter cake that could cause bridging in the
annulus. Fluid loss is crucial, especially in deep wells having narrow
clearance between wellbore and liner/casing.
For high temperature application, the latex based fluid loss additives are
widely used, the advantage being that latex does not viscosify adversely.
The design criteria for fluid loss control for HPHT cementing operation are
linked to dynamic filtration rather than static filtration. Conditioning with
stirred fluid loss cell is preferred.
Recommended API Fluid Loss (For HTHP wells) < 50 ml/ 30 min
2.4.3 Silica
Above 230°F (110 degC) BHST, commonly used Portland cement
undergo retrogression phenomenon (i.e. it loses strength and gain
permeability, which can be minimized/ prevented by adding at least 35 %
silica.
In HPHT wells, changes in down hole temperature and pressure in later

stage can crack or even shatter the cement sheath; radial
pressure/temperature fluctuations can create a micro annulus. To avoid
such failures high temperature flexible cement having lower Young’s
modulus should be used. Suitable expanding agent along with flexible
additive provides desirable characteristics to set cement. Use of blend of
Class G cement with 40% silica flour, prevents mechanical strength
retrogression and also provides retardation property.
Two forms of silica are normally available:

• Silica flour (fine)
• Silica sand (coarse)
The concentration of silica added to cement should be 35-40%.
Silica flour must be pre-blended with the cement. Where large slurry
volumes are to be pumped, pre-blended silica is only practical option.
Pre-blending of silica with cement adds a significant risk as the bulk is

often not fully homogeneous and sampling errors can occur. With
subsequent transfers, the blend becomes more homogeneous. However, it
may undergo some changes (aeration) due to moisture in the compressed
air transfer system. Therefore, samples taken from a blend at the yard may
not match those taken at the rig. Variation in the flour content of a blend
can impact the retarder response.
Silica sand should not be used if temperatures exceeding 572°F [300°C]

are anticipated. Because of changes in the crystalline structure, thermal
expansion of quartz is relatively high at these temperatures, and thermal
cycling could eventually disrupt the cement. Thermally stable cement
system like High Alumina cement may be used beyond 300°C.
2.4.4 Weighing Agents

It is crucial to maintain hydrostatic pressure in the well to balance or
exceed the formation pressure. Cement slurry with density over 16.5 ppg
(1.98 SG) require weighing agents such as hematite, tri-manganese tetra
oxide.
2.4.5 Gas Migration Control:

It is very important to control the flow of influx after cementing for deeper
high pressure oil and gas wells. Most of the gas channeling in cement
column occurs during a transition period from liquid to solid, adding latex
additives help to delay cement pore pressure drop and shortened transition
time between liquid and solid stage.
To prevent gas migration, slurry modification can be done by decreasing

fluid loss, extend zero gel time, reduce transition time adding gas influx
preventing material and increase slurry compressibility. Job design
changes could be done by decreasing effective column height, increasing
overbalance pressure, interfering with gelation process and drilling a
larger diameter hole. Static Gel Strength Analyzer (SGSA) is utilized to
evaluate the transition time in cement slurry.
2.5 Slurry Sensitivity

1
In most cases additives for HPHT slurries are being used at the upper end
of their design limits. As a consequence the slurry properties are much
more likely to be influenced by changes in:
• temperature
• mixing/shear
• mix water
• Slurry Stability
• density
• Sensitivity testing (additional TT test to the expected conditions).
The impact of each of these on the slurry design should be assessed.
2.5.1 Sensitivity to Temperature:

Once BHCT has been determined, the thickening time of slurry should be
obtained for 10°C higher than BHCT. The compressive strength should
also be determined for a test temperature 10°C lower, or at BHST at liner
top whichever is less. If no set is seen in 36 hours retarder selection should
be re-addressed.
2.5.2 Mixing / Shear

Cement slurry properties can be affected by both the time they are held on
surface after mixing and the mixing energy they receive.
When a slurry is designed for an HPHT application, batch mixing time

should be considered while evaluating thickening time. Some cements
have been shown to have 6 hour pump times at high temperature but to
exhibit significant viscosity rise when held at low temperature and
pressure. Any rise in consistency above 30 Bc during this surface
conditioning should be redesigned.
2.5.3 Mix water:

Long time waiting on cement job arrangement after chemical mix water
preparation may reduce its effectiveness and thus may change cement
slurry properties. To prevent ageing of mix water, it should be prepared
just prior to cement job.
Always use weighing balance / calibrated bucket for accurate cement

additive measuring at well site.
2.5.4 Cement slurry Stability

• Conditioning in HPHT consistometer or cured in HPHT curing
chamber
• If well deviation is below 15 deg - Free Fluid test is run vertical
• If well deviation is above 15 deg - Free Fluid test is run at 45 deg
• Free Fluid = Zero
• (Static) Sedimentation test: less than 5 % deviation from theoretical
cement slurry density
• Dynamic Settling Test: The SG of cement is measured from the top,
middle and bottom of the BP settling tube after the cement has set.
• Consistency spike after motor shut off: below 70 Bc, Also simulates
dropping the top plug or the shutdown period prior to sting-out of the
liner and circulate/reverse circulate.
2.5.5 Density
The slurry should be pumped after checking with a pressurized mud
balance (calibrated at the appropriate range).
2.5.6 Sensitivity testing (additional TT test to the expected conditions):

• At maximum BHCT
• Minimum BHST for the compressive strength at top of the liner
• Minus 5% retarder concentration or 0.02 gps whichever is
greater (Same for retarder aids)
• Plus 5% retarder concentration or 0.02 gps whichever is greater
(Same for retarder aids)
• Plus 0.25 Ib/gal slurry density
• Minus 0.25 lb/gal slurry density
Design cement slurry for thickening time equal to: Surface mixing
time/batch mix time + placement time + time to pull running tool clear of
the liner top (In case of liner) + 60 minute safety.
Test slurry for minus 5% retarder concentration. If TT is sufficient to pull

running tool clear of the liner top (In case of liner) + 60 minute safety,
design is OK, else reconsider retarder dose.
3. Spacer Design
In HPHT wells, both water and emulsion spacers (with OBM) have been used.
The main areas of concern with spacer design are:
• spacer stability
• rheology
• compatibility
3.1 Spacer Stability

The ability of the spacer to support the weighting agent on surface and
under down-hole conditions should be confirmed. This is particularly
critical where pore and fracture gradient margins result in spacer density
being very close to mud weight. Prior to pumping, the density should be
confirmed with a pressurized mud balance.
The down-hole stability should be assessed using hot roller for temperature/
HPHT consistometer slurry cup for pressure and temperature condition after
leaving for a minimum of 1 hour.
3.2 Spacer Rheology

In many cases the ability to achieve turbulent flow of the spacer, or a
density hierarchy between the spacer and the drilling fluid is
compromised, due to the small difference between pore and fracture
pressures, rheology of the spacer and pipe movement will be the only
available methods for achieving good mud displacement.
To optimize spacer rheology it should be determined at simulated down-
hole temperatures (along with the mud) to ensure effective mud
displacement. Spacer rheology should preferably be 20% higher than mud
rheology and 20% less than cement slurry rheology. Surface rheology
measurement should also be taken to provide a quality control step on the
rig.
3.3 Spacer Compatibility

It is critical that the compatibility of the spacer is confirmed with both the
mud and the cement. Using a range of mixtures (as a minimum 95/5,
75/25, 50/50, 25/75, 5/95), the rheology should be determined at BHCT.
In the absence of HPHT rheometer, It is advised to condition the spacer in
HPHT consistometer at BHCT & cool down to 88°C for measuring its
rheology.
10 minute gels should also be included. If the 100 rpm of admixtures is

25% greater than the highest 100 rpm reading of the uncontaminated
fluids, the spacer design should be reviewed. If plastic viscosity/yield
point or 10 minute gels suggest the slurry may become un-pumpable, or
separate into one or more phases, the spacer design should be changed. In
addition, the thickening time & compressive strength of the cement
with spacer contamination in the ratio of 90:10 must be determined.
Oil-based drilling fluids pose additional problems during cementing

operations compared to Water based muds because they frequently exhibit
poor interfacial compatibility with water-based fluids. There is a potential
to form interfacial mixtures that can be extremely viscous and non
pumpable. An oil film remaining on the pipe surface from the drilling fluid
can hinder a good cement-to-pipe bond.
For Oil based muds the Spacer Surfactant screening test should be
performed using a wettability tester as per API 10B 2, 2013.
J. Safety in Cementing Operations
1. For safety, cordon off and restrict access to high pressure
cementing line during pressure testing and cementation job.
2. While pumping by cementing unit, ensure that power from the
chassis engine is not be transmitted to the chassis wheels.
Additionally, chock (stopper e.g. wooden wedges) should be
placed against the wheels.
3. Bleed high pressure only through choke or smaller size lo-torc
valve in controlled manner.
4. Never hammer pressurized lines.
5. After lo-torc release valve on cementing unit, return line to
displacement tank should have fail safe mechanism which enables
one of the valves always in open position.
6. All High Pressure flexible hoses should be in good condition.
Inspect and test the hose before every job and replace the same
periodically to avoid blockage by rubber chunks / rupture of the
hose.
7. It is preferable to use chicksan line for cement pumping and
displacement. If at all high pressure rubber hose is to be used, it
should only be of recommended type for the purpose (API 7K and
ISO 14693).
8. During well killing operation, always place a NRV in pumping
line just after the cementing unit.
9. Any equipment used at rigsite (e.g. cementing unit, cement
bunkers, silos etc.) should be equipped with spark arrestor.
General
1. Guidelines GIVEN IN THE OISD STANDARD MANUAL (175) should
be followed.
2. Conduct extended LOT in deep / HP wells and in well with narrow
pressure margins.
8 Installation of
Well Head
A wellhead is the equipment installed at the surface of an oil or gas

well that provides the structural and pressure-containing interface for the
drilling and production equipment.
The primary purpose of a wellhead is to provide the suspension point
and pressure seals for the casing strings that run in the well.
After WOC, casing head also referred as a casing bowl is fitted on the surface
casing. It is the first well head component to be installed and is the lowest part
of the well head assembly. The bottom of the casing head is configured to
attach to the casing below (typically, the surface casing). The upper inside of
the casing head provides a bowl in which the next casing string can be set and
sealed. The top of the casing head then connects to the next wellhead
component.
After the well is completed, one of the side outlets may be converted to a
surface casing vent. This can then be used to monitor any flows or pressure
build-up of gas, water or hydrocarbon liquids within the surface casing. These
can indicate a failure in the integrity of the inner casing cement,
production casing, or annular seals that may present an environmental hazard.
If a well includes one or more intermediate casing strings between the surface
and production casing, the next component required after the casing head is the
casing spool. The bottom of the casing spool mounts on top of a casing head or
previous spool, and the top connects to the next spool or tubing head assembly.
The spool is designed so the bottom bowl or counterbore will allow a
secondary seal to be set on the previous casing string, while the top bowl will
hold a casing hanger to suspend and allow a primary seal around the next
string of casing. Multiple casing spools may be used, one on top of the
other, to hang intermediate casing strings and the final production casing
string.
Casing spools with a flanged connection is provided with a test port to enable a
pressure test between the primary and secondary seal. This test will determine
if the seals are holding pressure and that the annulus remains isolated.
This chapter covers the following aspects of well head operations:-

h) Installation of casing head (Section-C)
i) Installation of casing spool (Section-B and A)
j) Pressure Testing of Well Head
a) Installation of casing head (Section-C):

There is fixed clearance between rotary beams and ground level in a
drilling rig which is required to accommodate all well head sections,
BOPs, adaptor flanges, drilling spools and riser nipple. Hence,
installation of the surface casing head (Section-C) at appropriate height
within cellar pit is of utmost importance as any improper cut may lead to
complication in accommodating other wellhead and BOP components.
The following procedure is to be adopted for land rigs:
1. Remove false conductor.
2. Cut surface casing at a measured height from the bottom of the cellar
pit. The height is calculated as follows:
Measure heights of all the well head components except the tubing
spool and make a mark on the surface casing measuring from the top
of the cellar pit. First make a rough cut approximately 10 cm above
the mark, and then the final cut can be made for dressing and
chamfering.
A-Section Z
4-CP Wellhead Hook-up
For example, considering a 4-CP well head, length of the casing to be

cut from top of the cellar pit can be obtained H from the following
formula: B-Section Y
H=X+Y+Z
Where;
H- Height of the casing to be cut from top of the cellar pit
I- Height of Casing Bowl section ‘C’
Y- Height of Well head section ‘B’ X
Z- Height of Well head section ‘A’

C-Section
Point of final cut
3. casing
on surface The marks are put all around the casing at a number of points and
thenSurface
a circular mark put all around.
Casing To be cut
Bottom of cellar pit
4. Cut casing and chamfer properly on the inside,
 The weld-on housing of the casing head (Section-A) is placed on the
cut casing and is kept perfectly horizontal using spirit level and welded
Weld On Flange
from both inside and outside after preheating using the recommended
high pressure welding electrodes
Note: Use low-hydrogen arc-welding rods #E7018

Inner Welding Lap or #8018-C3 when
welding API H40, J55 or K55 casing to the casing bowl. Use low-
hydrogen arc-welding rods #8018-C3 when welding API L80 casing
to the casing bowl Test Port
5. The welded casing head housing is allowed to cool normally
(Do not use water to cool casing).
Top of
final cut casing
Sectional View of Weld on Type Casing Head
showing Inner & Outer Welding Lap.
Outer Welding Lap

Table: Types of casing heads (Section-C) generally available
Size top flange Working Used with casing

of casing head Pressure PSI
(Nominal bore)
2,000
8" 7-5/8" or 8-5/8"
3,000
2,000
10" 3,000 9-5/8" or 10-3/4"
5,000
2,000
12" 11-3/4" or 11-3/8"
3,000
13-5/8" 5,000 11-3/4" or 13-3/8"
2,000
16" 16"
3,000
2,000
21-1/4” 3,000 20” or 18-5/8”
Slip on welded bottom casing head housing is shown below:
This type of housing is equipped with a socket weld preparation which slips
over the casing and has provision for welding the top of the casing to the ID of
the housing and also for welding the bottom of the housing to the OD of the
casing. One housing can be used over all the weights and grades of a particular
size casing. Housing/bowl flange should be aligned with respect to the cellar
pit.
1
Outlets on the Casing Head Housing:
A casing head must have at least one threaded, flanged, or studded side outlet
with a valve. In certain operations, regulators may require two outlets with a
valve.
Outlets are provided on the casing head housings for access to the annulus.
b) Installation of casing spool (Section- B and A):

Once intermediate/final casing is run and cemented, after WOC following
activities are to be done:
i. Unbolt and lift BOP
ii. Land casing and set slip
iii. Lay down 21-1/4” BOP (Only in case of 4-CP wellhead)
iv. Installation of primary and secondary packer
v. Install casing spool (section-B/A)
In view of safety, after cementation, all activities such as unbolting and

lifting of BOP must be done only after ensuring cement is set as any unexpected
annular activity due to setting of cement will be a safety threat.
i. Unbolt and lift BOP:

1. Have 2 heavy duty hammers available on the rig
2. Use correct size of hammer wrench for opening nuts of
flange connections in crisscross pattern and store nuts in a
safe place
3. Ensure BOP is lifted without jerk with slings and shackles of
rated load capacity that are in good condition
4. Ensure that BOP is secured on tripod
ii. Land casing and set slip:

1. Make sure that casing is centered. Place the slip around
casing pipe using all 4 eye bolts carefully so that it
remains at the same level to avoid jamming of slip and
eccentric setting
2. While using housing type slip, Allen bolts should be loosened
just enough to make sure that dies are moving just freely
3. While setting the slip, ensure that un-cemented casing pipe
remains in tension after setting slip (Refer Section-(f) ‘Casing
Landing Practices’ in Chapter: ‘Casing Operations’) and the
slip is set properly with top of the slip at same point all
around the casing
4. Rough cut on casing should be made about 15” above the top
of flange and remove the cut pipe
Courtesy-BHEL
Slip Seal Casing Hanger Casing Slips
(Type BCMBFNS) (Type BCMBNS)
iii. Lay down 21-1/4” BOP (Only in case of 4-CP wellhead):

1. 21-1/4” BOP is installed only in 4-CP wells and is to be laid
down as the next phase requires 13-5/8” BOP stack
2. Take extra care to lay down 21-1/4” BOP with crane with
special attention on slings as breaking of slings may result in
damage to BOP
iv. Installation of primary and secondary packer:
Primary and Secondary Seals Casing strings (other than the surface casing) that
terminate in the wellhead are typically sealed twice. First, a primary seal is set
when a casing is suspended by a casing hanger in the top bowl of a casing head
or casing spool. This seal will isolate the annulus between this casing string
and the previous casing string. The casing itself extends into the counterbore
of the next wellhead component where a secondary seal will be set.
Installation of Primary Seals:

1. Make final cut on the casing such that:
Height for final cut = Total height of both the pressure plates with
secondary lip seal in between in the assembled positions above the top
of flange.
2. Remove burrs and chamfer the top of cut pipe.
3. Install the lower pressure plate with the flat face at the bottom over the
casing and into the body counter bore.
4. Thoroughly clean and lubricate the casing with oil and install lip seal
with proper care. Care must be taken to avoid damage to the lips of the
rubber packing.
5. Drive the packing down until it is flush with the lower pressure plate.
6. Install the upper pressure plate with flat surface facing up.
Installation of Secondary Seals:
Install the lower pressure plate with the flat face at the bottom over the casing.
1. Install the secondary seal with its lip face up over the casing.
2. Thoroughly clean and lubricate the casing with oil and install lip seal
with proper care. Care must be taken to avoid damage to the lips of the
rubber packing.
3. Drive the packing down until it is flush with the lower pressure plate.
4. Install the upper pressure plate with flat surface facing up.
v. Install casing spool

1. Carefully lower the casing spool over the secondary lip seal
to avoid damage to lip seal
2. Install all studs with nut and tighten in crisscross pattern to
recommended torque. Do not use oversize hammer wrench as
it may round off nuts at edges.
c) Pressure Testing of Well Head:
 Testing – Weld on Bowl:
Test port is provided to test the integrity of welding.
1. Remove the ½” LP plug from the casing bowl.

2. After cooling of welding joint, the welding seal is to be tested
preferably with N2 through the test port to the minimum of:
o maximum anticipated surface pressure from the next phase
or rated working pressure of the flange or
o 80% of the casing collapse pressure
 Testing- Casing spool/ Tubing Spool:

1. Casing spool or tubing spool is tested by connecting test pump to
the test port on the lower flange of spool.
2. Carry out pressure test at rated working pressure of lower flange of
spool or 80% casing collapse pressure whichever is less.
 Testing of Primary and Secondary Seals:
When both a primary and secondary seal are set, the seals themselves and the
connection between the two wellhead components can be pressure tested for integrity
via a test port.
The testing should consist of
1. Primary pressure holding period
2. Followed by bleeding off pressure
3. Secondary pressure holding period.
The pressure holding period should be 5 min.
The maximum allowable test pressure should not exceed the lowest pressure
determined from the following:
(A) Rated working pressure of lower flange of connection.
(B) Rated working pressure on primary seal.
(C) Collapse pressure of casing pipe after taking into consideration safety
factor.
Casing spool Tubing Spool
Test Port:
The two flanged connections of well head equipment are joined together
with studs and nuts with a steel ring gasket in between. The test port is
provided in the lower flange of a casing or tubing spool to pressure test
the sealing area of the ring gasket, the primary packing group and the
secondary packing group. 1/4" NPT ball check valve is installed behind
1/2" NPT plug to allow the safe removal of 1/2" pipe plug when
checking for a leak between cross over seals.
Note: The above test procedure is for BHEL wellheads. The
manufacturers’ manual may be referred for other make of well heads.
Test Procedure:
1. Remove 1/2" plug and check valve provided at the outlet of the test
port and make connection of the test pump at the test port
2. Open valves in the annulus of the casing head housing or casing
head spool as the case may be.
3. Start pumping water with the help of hand operated hydraulic test
pump.
4. Carry out low pressure (300 psi) and high pressure test at rated working
pressure of lower flange of spool or / 80% casing collapse pressure
whichever is less.
5. Hold the pressure for 5 minute after pressure stabilization subject to
maximum drop of 5% of the test pressure, and then the test of primary
and secondary seals and the steel ring gasket is considered OK.
6. If there is drop in pressure, check for the leakage point:
 If the leakage is in between the flanges, ring gasket is not
holding and the flanges should be retightened and tested again.
If leakage persists, change ring gasket. Test again.
 If the leakage is observed from the side valve in the annulus of
casing, the primary seal is not holding, the flanged connection
should be separated out and the seal and the sealing surface to
be checked. Replace the seal if damaged. Test again.
 If the leakage is observed from the top, visible on seeing with
the help of a torch, the secondary seat is not holding, the
flanged connection should be separated out and secondary seal
and the sealing surface to be checked. Replace the seal if
damaged. Test again.
The secondary seal is intended to hold pressure from wellbore side and
prevents wellbore pressure reaching the ring gasket between the two spools.
Therefore the secondary seal should be tested from above by using cup-
tester. Best practice is to pressure test primary seals to the
pressure rating of the Lower Flange and Secondary Seals to
either the Maximum Anticipated Wellhead Pressure for the
casing that has been hung off or to the pressure planned for
pressure test of casing.
4CP Well Head Hook Up During 17.5” Hole
Bolt Ring
Flange Size Type Length Qty. Spanner
Size No.
21-1/4" x
Bolted 1-5/8" 12 1/4" 24 65 R-73
2M
4-1/16" x
Studded 7/8" 4-5/8" 8 36 R-37
2M
4-1/16" x
Studded 1-1/8" 6-1/4" 8 46 BX-155
10M
4-1/16" x
Bolted 1-1/8" 8-1/2" 8 46 BX-155
10M
2-1/16" x
Studded 3/4" 4" 8 32 BX-152
10M
Bolt Lengt Qty Spanne Ring

Flange Size Type
Size h . r No.
21-1/4" x 2M Studded 1-5/8" 9-1/4" 24 65 R-73
10-
20-3/4" x 3M Studded 2" 20 80 R-74
5/8"
13-5/8" x 5M Studded 1-5/8" 9-1/2" 16 65 BX-160
11-
13-5/8" x 10M Studded 1-7/8" 20 75 BX-159
3/4"
13-5/8" x 10M Bolted 1-7/8" 18" 20 75 BX-159
4-1/16" x 10M Studded 1-1/8" 6-1/4" 8 46 BX-155
4-1/16" x 10M Bolted 1-1/8" 8-1/2" 8 46 BX-155
2-1/16" x 10M Studded 3/4" 4" 8 32 BX-152
Bolt Lengt Qty Spanne Ring
Flange Size Type
Size h . r No.
21-1/4" x Studde
1-5/8" 9-1/4" 24 65 R-73
2M d
20-3/4" x Studde
2" 10-5/8" 20 80 R-74
3M d
13-5/8" x Studde
1-5/8" 9-1/2" 16 65 BX-160
5M d
13-5/8" x
Bolted 1-5/8" 12-1/2" 16 65 BX-160
5M
13-5/8" x Studde
1-7/8" 11-3/4" 20 75 BX-159
10M d
13-5/8" x
Bolted 1-7/8" 18" 20 75 BX-159
10M
Studde
11" x 10M 1-3/4" 10-1/2" 16 70 BX-158
d
4-1/16" x Studde
1-1/8" 6-1/4" 8 46 BX-155
10M d
4-1/16" x
Bolted 1-1/8" 8-1/2" 8 46 BX-155
10M
2-1/16" x Studde
3/4" 4" 8 32 BX-152
10M d
1
9
Directional
Drilling
Directional drilling is the science and art of deflecting a well bore in specified
direction in order to reach a predetermined objective below the surface of the
earth. Directional drilling is employed in circumstances where the area above
the targeted hydrocarbon deposit is inaccessible such as reservoirs that exist
under shallow lakes, protected areas, railroads, or any other area on which the
rig cannot be set up. With directional drilling, the offshore rig can gain access
to deposits that are not directly beneath the rig and many wells can be drilled
from a single location, making it more cost effective to drill offshore and also
onshore. It is also useful for thin reservoirs which are not efficiently produced
with a vertical completion, horizontal entry into the reservoir allows it to be
drained more efficiently. Directional drilling is especially useful for offshore
locations where operating cost of offshore drilling rigs can make it
uneconomical to drill a single well.
This chapter deals with various tools and techniques utilized in directional
drilling as follows:
a) Conventional direction drilling survey tools

b) Steerable Downhole Mud Motor (SDMM)
c) Measurement While Drilling (MWD)
d) Rotary Steerable System (RSS)
e) Time Drilling for Side-track
f) Cased hole Side-tracking with Whipstock
a) Conventional direction drilling survey tools
The conventional PDM is used to drive bit without rotating the string and
deflection with bend sub placed above it to create a side force at bit. The tool
face direction is received through survey tool at surface by aligning the sleeve
placed in UBHO sub with the bend direction.
Bent sub: is used with conventional PDM is made of short length of drill
collar usually 2 ft. In which the axis of lower pin connection is machined
slightly of the vertical. This offset may vary from ½0 to 30 for deviating the
well from vertical. The bent sub force the bit & PDM to drill in specific
direction.
Universal Bottom Hole Orienting sub (UBHO): This sub houses the Mule
shoe stringer and is used to establish the “tool face” of the deflection tool. It is
placed below the non-magnetic
drill collar which houses the
survey tool. The Mule shoe
sleeve is placed within the
UBHO sub and acts as a
landing of mule shoe stringer
of directional survey tool. It
facilitates the alignment of
bend sub with the directional
survey tool.
In SDMM UBHO is placed

below the non-magnetic drill collar which houses the directional tool but bend
is in the body of motor so its
alignment is done as below:
Scribing of survey tool with

SDMM tool face direction
Scribing is done by putting a
scribe-line to measure alignment of
SDMM bend scribe line with the
key of the mule-shoe.
There is a slight difference in the
procedure for scribing is
conventional and contemporary
assemblies.
223
Scribing in conventional assembly:
1. Identify motor reference point (Tool face) in bend section.
2. Scribe a line vertically from motor reference point to UBHO.
3. The key of the mule-shoe sleeve is aligned to this reference point on UBHO at
surface.
4. Lock in place the mule shoe sleeve using screw.
Now the orientation of mule shoe is same as that of the motor bend.
Scribing in contemporary assembly
1. Identify motor reference point (Tool face) in bend section.
2.
2. Scribe a line vertically from motor reference point to UBHO sub.
3. Measure tool face offset angle (angle between the scribed line and line
etched on UBHO sub) looking clockwise downhole, record it for entry into
system.
b) Steerable Downhole Mud Motor (SDMM)
SDMM is a tool which converts hydraulic energy of drilling fluid into

mechanical energy and rotates the bit to drill and deviate the well bore
without drill string rotation. It can drill in both rotary and oriented
mode.
SDMM Basic Design
1
SDMM power section consist of stator
and rotor.
Power section is described in terms of
ratio of the lobes in rotor (a) to the
lobes in stator (b) and “n” no. of
stages. Where, b = a+1.
i.e. ‘a:b’ lobes and ‘n’ stages
For example- 4:5 lobes and 3 stage.
 More lobes = More torque, Lesser RPM

 Lesser lobes = Higher RPM, Lower torque
• More stages = More torque, More pressure
drop across motor
• Lesser stages = Lower torque, Lower pressure
drop across motor
• Torque is proportional to pressure drop and
RPM to discharge.
In order to get the best performance and optimum life of mud motors, the
standard procedures guidelines as mentioned below should be followed during
operation.
Assembly Procedure & Surface Check Prior To Running in Hole
A thread protector should be installed in the bit box of the motor
whenever handling the motor on surface.
1. The lift sub supplied with the mud motor should be used for handling
and making up of the motor. Also make sure the connection between
the lift sub and the motor is tight.
2. Check the bearing condition and note down the gap of thrust bearing for
wear. Acceptable bearing wear tolerance are as given table 1 below.
3. The adjustable assembly or bent housing is set to the desired bend.

4. Remove the thread protector from the bit box of motor, inspect threads
and tighten the bit by applying recommended torque. Set the motor in
the slips and install a safety clamp.
5. Remove the lift sub, put the strainer and connect the Kelly to the mud
motor. Remove the safety clamp and lift the motor out of the slips.
6. Lower SDMM just below rotary table and just above riser such that
bit and bit- box is visible.
7. Start mud pump slowly to avoid excessive vibrations. Check if bit is
rotating. Check if mud is flowing from nozzles or from both, nozzles
and bearing gap. (For SDMM with oil sealed bearings it must flow from
only nozzles).
8. All joints up to Non Magnetic Drill Collars (NMDC) are to be tightened
upto the recommended torque.
Break joints with tong Lift adjusting ring Match angle
&tighten lock housing
Hang the SDMM freely, measure distance D1 between lower end of

bearing housing and drive sub. Set SDMM down on the rig floor
measure the same distance as D2. Calculate (D1-D2)
Table-1: Tool Size (OD) and Maximum Tolerance
Tool Size OD Max Tolerance

(inch) (D1-D2)
mm inch
2-3/8 1.68 0.066
2-3/4 2.49 0.098
33-3/4 3.99 0.157
4-3/4 3.99 0.157
6-1/4 5.99 0.236
6-3/4 5.99 0.236
8 8.00 0.315
9-1/2 8.00 0.315
11-1/4 8.00 0.315
Tripping with SDMM
1. The drill string should be tripped with special care while passing through
BOP, well head, casing shoe, liner hanger top, held up portions and near
bottom.
2. Tight spots should be cleared by starting the pumps and reaming slowly at
manufacturer’s recommended RPM for the motor and bent setting.
3. When tripping to deeper depths, or where hole temperatures are high,
periodic gel break circulation is recommended. This prevents bit plugging,
aids in cooling the mud motor and high temperature damage.
4. During circulation through a mud motor inside casing, string should be
reciprocated.
Drilling
After the assembly has been tripped to the bottom of the hole, mud motors
should be operated in the following manner:
1. With the bit 1-2 meters off bottom, start the pumps slowly and increase to
recommended flow rate.
2. Record flow rate and the pump pressure after mud conditioning.
3. Orient the drill string as desired, lock rotary and lower the bit to bottom
and slowly apply further weight on the bit. Pump pressure will rise as the
weight on bit is increased. Record the change in system pressure between
the off bottom and on bottom values. This will be the differential
pressure. Try to drill with steady differential pressure.
4. Adding weight on bit will cause both the differential pressure and torque to
increase. Similarly, reducing weight on bit will reduce both the differential
pressure and the torque. Therefore, the rig pressure gauge enables the
operator to monitor the performance of mud motor.
5. If the differential pressure exceeds the motor design, the motor will stall.
An increase in standpipe pressure will occur and bit rotation will cease. If a
stall condition occurs immediately lift the string to
a Release trapped torque in controlled manner.
b Stop pumps, if necessary.
6. Optimum differential pressure can be determined by monitoring motor
performance, penetration rate, and drilling requirements. Also, maintaining
a constant differential pressure assists in maintaining orientation of the drill
string.
Reactive Torque in SDMM
Mud motors drive the bit with a right-hand (clockwise) rotation. As weight is
added to the bit, reactive torque acting on the drilling motor housing is
developed. Therefore, this reactive torque must be taken into account while
orienting the SDMM from the surface in the desired direction. Entire string
may start rotating anticlockwise due to reactive torque, therefore keep the
rotary locked to prevent reverse rotation during sliding mode.
Drilling Fluids: Limitations with SDMM
Drilling fluids pH should be in the range of 8.5-10. Chlorides in drilling fluids
can reduce rotor and stator life due to corrosion, especially at elevated
temperatures. The motor should be flushed with water and serviced as soon as
possible if it has been exposed to chlorides.
Drilling mud with a density of more than 16.7 PPG (SG =2) will cause
abnormal erosion of motor internals due to suspended particles in these muds.
The percentage of drill solids should be kept to a minimum. Large amounts of

abrasive solids in the drilling fluid will dramatically increase the wear on a
stator. It is recommended that the sand content be kept below 2% for an
acceptable operational life.
Well-mixed fine to medium Lost Circulation Material (LCM) can be used

without plugging or causing motor damage. In the loss prone area, a PBL
circulating sub should be installed above the motor assembly to bypass the
motor.
Hydraulics
The use of a SDMM in the drill string changes the hydraulic calculations.
Various factors have to be taken into account. Each size of SDMM is designed
for a certain flow range and corresponding pressure drop range (as per
1
manufacturer’s catalogue), the same should be taken into consideration while
designing hydraulics of the well.
Detection of down hole problems in SDMM
1. Mud Motor not generating sufficient torque for drilling – Motor is

not generating torque to drill ahead, showing low differential pressure
at surface.
2. Pressure fluctuation while rotating –Fluctuation in stand pipe
pressure may indicate problem in mud motor.
3. Abnormally high surface pressure –When the stator
elastomer(rubber) is worn out it may break into pieces, small parts of
rubber can jam the flow path in the motor or choke bit nozzles
resulting in shoot up of stand pipe pressure.
4. Reduction in Rate of Penetration – If poor ROP is observed without
any significant changes in formation and drilling parameters, this may
indicate problem in down hole motor or bit failure.
Based on the above mentioned indicators, suspected problem should be
identified and POOH of SDMM BHA for surface check of mud motor for
remedial action.
c) Measurement While Drilling (MWD)

MWD is a tool used to measure real-time downhole information such as
directional data, formation characteristics and drilling parameters near the bit
and transmit it to the surface without interrupting normal drilling operation.
In MWD tool, sensors are installed which transmits down hole signals to the
surface via various telemetry systems like mud pulse, electro-magnetic and
hard wired pipe methods. These signals are detected at the surface,
decoded and processed by surface equipment. The required information is
displayed at driller’s console in a usable format.
Most common method of transmitting Information is mud pulse telemetry
(positive pulse and negative pulse).
Positive Mud Pulse Telemetry
In positive mud pulse telemetry a restrictor valve is actuated at bottom of tool

which increases stand pipe pressure due to temporary restriction in flow. To
transmit data, valve is operated several times creating a series of pulses.
Surface transducers detect pulses and are decoded by surface computer.
Surface computer initially detects a set of reference pulses followed by
data pulse. Message is decoded by detecting the presence or absence of a
pulse within a particular time frame.
Negative Mud Pulse Telemetry
In negative mud pulse telemetry a restrictor valve is operated by decrease in

stand pipe pressure due to temporary
bleeding off mud from drill pipe to annulus.
To transmit data valve is operated several
times creating a series of pulses. Surface
transducer detects pulses and is decoded by
surface computer. Surface computer
initially detects a set of reference pulses
followed by data pulse.
Message is decoded by detecting

presence or absence of a pulse within
a particular time frame.
Pulse generated in due course is affected by vibration and fluctuation in pump
pressure. These problems have to be identified and rectified to ensure data
quality.
Electromagnetic transmission (EMT) Method
Data is transmitted by Electro-magnetic

transmission signals through formation
and independent of drilling fluid.
Signals are sent through low frequency
[2-10Hz] electromagnetic waves using
a gap sub that propagates through
earth’s crust. Signals generated are
modulated to send required data in the
form of binary code. At surface these
signals are detected by an antenna near
rig. EMT is the only commercial
means for MWD data transmission in
compressible fluid environments
common in UBD applications.
Wired drill pipe

Wired drill pipe have insulated
conductor cable running through
drill string. These drill pipes are
designed to have Inductive
coupling at tool joint. The data
transfer is thus independent of
drilling fluid. High data band
width of around 56 kbps can be
obtained as against 6bps available
with mud pulse telemetry.
d) Rotary Steerable System
Rotary Steerable System (RSS): is the latest technology used in directional

drilling. This tool is designed to drill directionally with continuous rotation of
the string thus eliminating the need of not rotating the string during slide mode.
The tools are programmed to take command transmitted using surface
equipment typically with drill string mud pressure fluctuations, which the down
hole tool decodes and steers the bit into the desired direction.
The methods used to direct the well path fall into two broad categories: Push-
the-bit and Point-the-bit
Push-the-bit tools use pads on the surface of the tool which presses against the
well bore thereby causing the bit to deviate on the opposite side causing a
direction change.
Point-the-bit tools cause the direction of the bit to change relative to the rest
of the tool by bending the main shaft running through it. The later require
some kind of non-rotating housing or reference housing in order to create this
deflection within the shaft.
Hybrid Tools are a combination of push and point the bit technologies.
e) Time drilling for side-track
 Cement plug of minimum 100m or as per plan should be placed.

 To dress the cement plug, a “slick” assembly should be used.
 Tag cement top and drill down 10-15 m of soft cement till hard cement
(taking ~10T load) is encountered.
 Side-track with time drilling as per table below
Table-2: Time Drill in a staged approach.
Stage Sliding rate % of formations in cuttings at shale shaker
1 30-40 min/m Visually 20-30% Formation observed in

for first 2-3m cuttings
2 20-30 min/m- Visually 50% or more formation observed in
for Next 1-2m cuttings
3 10-20 min/m or Visually 80% or more formation observed in
at normal rate cuttings, reactive torque apparent and bit taking
on weight
f) Cased hole Side-tracking with Whipstock:
Whipstocks are the specialized tools, often quite used to side-track the well
from cased hole.
Well Preparation prior to whipstock side-tracking job:
 Prior to whipstock job conduct a gauge run and casing

scraper run. It is recommended to run the scraper below
the setting depth by about 30 meters, and then pulled
back to ensure any debris present is pushed below the
setting depth. Prior to pull out pump ~20 bbls hi-vis pill.
 The casing scraper clean out run BHA should simulate
the stiffness of the Whipstock assembly.
 Record CCL-CBL log, prior to Whipstock run to
decide as the Whipstock setting depth. Interval should be
such that the window is milled through in the body of
casing joint, and not across a casing collar and also
ensure good cement bond against the casing string,
where the milling is proposed for the exit.
Cased hole Side-tracking procedure with Whipstock:
 M/up Whipstock assembly as per the procedure of

service provider.
 Make up MWD and shallow test as per service
providers.
 Make up hydraulic lines of
Whipstock.
 Run very carefully and slowly
through BOP & Well Head.
 Further RIH 2-3 minutes per stand
and Set slips with care,
 Do not rotate the string. Use both
tongs for make up or else lock the rotary table
during make up.
 Do not jerk the string, do not bounce
the string.
 The running in should be smooth in
all aspects and should be done at controlled
speed with full use of main and auxiliary
brake.
 If case of any resistance stop and run
as per instruction of service Engineer.
 Do not pump under any condition. If
well condition dictates pumping it should only
be done under the supervision/presence of
Whipstock engineer.
 Last few stands should be run in
presence of service engineer. Continue to
lower the string until anchor has reached
setting depth.
 Pass by setting depth ± 5’ and mark
setting depth on pipe, work pipe couple of
times to get rid of torque.
 Orientate Whipstock with MWD
survey.
 Use clean drilling fluid, solids and
barite can block hydraulic line. Minimum
viscosity should be 50-60.
 Increase flow rate to calculated GPM, check if
whipstock is set, if not increase GPM to higher rate and
check for whipstock setting, when whipstock set slack off
weight down.
 If packer and slips are solid, increase weight until shear, continue pumping until
sheared off whipstock.
 After successful shearing off, apply down weight for few minutes, pick up string
± 5’ and circulate calculated GPM.
 Start milling with very low weight on mill parameters given by W/Stock
Engineer.
 Mill window and cut rat hole of few meters so that mills are totally out of
window, circulate high with viscous fluid.
 Ream window as per W/stock engineer advice.
 Circulate out the pill.
 POOH with mills.
 Check gauge of Mills at surface.
 An additional /clean out run should be done if mills on pull out are found more
than ¼” under gauged.
 Else further drilling can be done as per Drilling Program.
Typical Material Requirement list for (9 5/8”) Whipstock job:

For Dummy Run:
- X/over: 4 ½” IF Box x 4” IF Pin (1 each)
- Bit Sub: 4 ½” Reg Box x 4” IF Box (1 each)
- 15 singles 6 ½” Drill Collar (4” IFP X B)
- 24 singles 5” HWDP (4-1/2” IFP X B)
- 20 bbls Hi- vis pill.
For Whipstock Setting and Window Milling Run:
- X/over: 4 ½” IF Box x 4” IF Pin, (1 each, Same as dummy run)
- X/over: 4 ½” IF Pin x 4” IF Box, (1 each)
- single 5” HWDP (4-1/2” IF P X B)
- 24 singles 5” HWDP (Same as dummy run)
- 15 singles 6 ½” Drill Collar (Same as dummy run)
- Drill Pipe Pup Joints of various lengths for Space out (Optional
depending upon tally)
- Ditch Magnets (2 nos.)
- 100 bbls Hi- vis pill
10 Fishing
Introduction:
A “Fish” in a drilling well is a length of drill string or tool or any
undesirable object or junk left in the well bore that must be removed
before further drilling operation. The tool required to recover fish is
called a fishing tool. Failure to recover the fish may necessitate side
tracking or even abandonment of the well. Most common causes of fish in
a well are:
a) Parting of drill string due to tensile failure, mud cut etc.
b) Twisting off of drill string due to torsional failure.
c) Bit rollers left in the well
d) Logging tool sticking
e) Inadvertently dropped metal objects such as dies, bolts, hammers,
wrench etc.
f) Drill string opening due to back-torque
The chapter covers the following topics:

a) General Fishing Practices
b) Fishing procedures
c) Margin of Over Pull
d) Determination of Length of Free Pipe
e) External Catch Fishing Tools
f) Internal Catch Fishing Tools
g) Junk Catch tools
h) Milling Tools
i) Accessory tools
a) General Fishing Practices:

Ensure that
 Drilling crew has good understanding of the fishing tools (their
1
strengths and applied stresses) during each fishing operation.
 All fishing equipment are properly maintained and dressed.
2
 Dimensions and drawing of all down hole equipment are recorded
prior to running into hole. It is a good practice to measure OD of box
end of entire BHA to ascertain reduction in OD due to wear.
 All depths and pipe tallies are correct.
 All fishing tools should have provision to accommodate any internal
fishing or back-off tool which maybe run to recover fishing tool itself
subsequently.
b) Fishing Procedures:
 Prior to engaging a fish, ensure that the following are known:
 String up, down and rotating weight with and without
circulation (as applicable for each tool run).
 Free rotating torque of the fishing string.
 Jarring calculations, safe working loads, strengths of fishing
tools, etc.
 Record SPM and pressures.
 Circulate and condition mud prior to fishing. Avoid excessive
circulation to prevent cutting accumulation on top of fish and washing
out the hole around or above the fish.
 Ensure that during the fishing operation, tool joints of drill pipe are
not against Rams of BOP (Adjust length with pup joint).
 Circulate slowly when locating fish top. An increase in pressure, while
lowering, and/or rotating, will confirm tool is on top of fish (pack-off
rubbers normally good for up to 1,000 psi).
 At this point shut pump, if required.
 Do not pull more than 80% of the minimum yield strength of the pipe
or minimum strength of fishing tool.
 When fish is free, circulate bottoms up.
 Flow check the well.
 In many cases, the pipe may come out full as wet pull out as fish may
be choked. In such cases, following precautions must be taken:
i. The well may be filled continuously through trip tank.
ii. Trip tank volume may be closely observed for activity with
the help of trip sheet with closed end volume of string.
iii. Use mud bucket to avoid mud splashing and continue wet pull
out.
 Pick up and set string in slips carefully avoiding any shock loading to
drill string.
 Do not rotate string while pulling out of the hole.
 While pulling out after a twist off/ wash, check string.
 In case of parted string, check at surface the pulled out string to
determine as accurately as possible, size, shape and condition of the
fish top in hole.
 When bit cones or similar junk items have been lost on bottom
 It is considered better to fish with Reverse Circulating Junk
Basket (RCJB) in soft/ medium hard formations.
 In hard formations, junk mill with junk sub is better choice.
c) Margin of Over Pull (MOP)

MOP is the desired amount of excess tension above working load (Pw)
to account for hole drag, excess pull capacity in case of pipe stuck
situation
MOP = Pt x 0.9 – Pw
Where Pt=Tensile capacity of pipe
Pw=Working load on pipe
d) Determination of Length of Free Pipe (in a stuck string)
The relation between the differential stretch and the length of a frozen string
due to differential pull is:
L= 2.1 x 103 x A x E
P2-P1
Where:
L= Length of free pipe (m)
A= Cross sectional area of drill pipe (cm2)

e= differential stretch (m)
P2-P1= Differential pull (kg)
Considering a correction factor of 1.05 for tool joint the equivalent length (
Leq) of free drill pipe is given by:
Leq= 1.05 × L
Note: This method is fairly accurate in straight wells (For directional wells
Free Point Indicator Tool to be used).
Method of application of this technique:
Prior to measuring the differential stretch the string should be thoroughly

worked so as to minimize the effect of residual stress in the string.
1. A pull (P1) of 10-15T greater than the air weight of the drill string is
applied to the stuck string and a mark is made on the kelly or pipe as
the case may be.
2. This pull is released and equal pull (P1) is applied once again.
Another mark is made on the kelly. The two marks do not coincide
due to the friction in the hole. The mid-point between the two marks
is taken as the upper reference mark A.
3. A pull P2 (P1+ 10-15T) is applied and a lower reference mark B is
made following the steps mentioned above.
4. The distance between the two marks A and B is measured as “e”.
Note: The pull must be within the safe limits of the margin of over-pull of the
string
e) External Catch Fishing Tools:

External catch fishing tools engage fish on its OD. These tools help in
recovering fish by using an Overshot with grapple or Die Collar threading
directly to its OD.
Overshots:
The different types of over shots are as follows:
1. Full Strength (FS):
Capable to withstand all pulling, torsional and jarring strain. This is
the most widely used overshot in oil industry.
2. Extra Full Strength (XFS):
Engineered for extreme use but with limited catch size compared to
FS. Jarring is recommended.
3. Semi Full Strength (SFS):

Engineered for special hole condition commensurate with max.
strength and max range of catch size. Jarring is not recommended.
4. Slim Hole (SH):

Meant for heavy pulling strain only. Jarring is not recommended.
5. Extra Slim Hole (XSH):

For pick up jobs only. Jarring is not recommended.
6. Short Catch:……………
Overshot with spiral Grapple Overshot with Basket
Grapple
Spiral Grapple
Type A Packer
Rotary Die Collars:
Rotary Die Collars are simplest fishing tools available for engaging a
fish externally. This is not a positive engagement tool and hence jarring
is not recommended.
Wickers: The hardened cutting teeth (wickers) are machined on a shallow
taper to provide an excellent grip. Wickers are plain water tight non-fluted
design if circulation is required below stuck point. Fluted type design also
available to flush cutting while engaging fish.
Length of wicker: The length of wicker is up to 24”. Length larger

than 24” require two piece constructions.
Wall thickness: It should never be less than ¼” to avoid

developing cracks.
Taper per foot (TPF): Standard TPF is ¾”. It should never

exceed 1” TPF as it reduces no of wickers which can engage
fish during fishing operation.
Water course: All die collars are furnished with a circulation hole
drilled through the centre.
Selection of Die Collar:
Larger wicker I.D: Larger wicker ID should be at least ½” larger

than fish O.D.
Smaller wicker I.D: The smaller wicker I.D should be at least ½”
smaller than fish O.D. The smaller wicker ID should never be less than 1-1/2”
due to boring and wickering operation during manufacturing process.
Operation:
In operation, it is necessary only to run the Die Collar in the hole to the top of
fish, apply less than 1 T weight and rotate sufficiently to embed taper threads of
the Die Collar into the fish till rotation ceases or torque increases and pull the
fish.
j) Internal Catch Fishing Tools:
These tools engage the fish in its inner diameter. Similar to External Catch
Tools, this is achieved by a grapple or by threading directly to the fish’s inside
surface. These tools are Casing /Drill pipe Spear and Male Tap.
Spears: Common types of spear are:-

a) Itco type
b) Full circle
ITCO Type Releasing Spear:

 It provides a dependable, inexpensive and simple means of
engaging a fish internally.
 These Spears ensure positive engagement, easy release from the
fish when desired and easy re-engagement after the Spear has been
released. It is ruggedly built to withstand severe jarring and pulling
strains.
 It engages the fish over a large area without damage or distortion
of the fish.
 The ITCO Type release spear consists of a mandrel, grapple,
Release Ring & Nut.
Full Circle Type Releasing Spear:

Full Circle Type Releasing Spears are recommended when fishing for smaller
casing sizes or for thin walled casing or for corroded casing that might easily
be distorted.
The Full Circle Slips, which are completely backed up by tapers on the Body,
contact virtually the entire inner surface of a very long section of the fish.
Consequently, when a fish is engaged and upward pull is exerted, the
expansion strain is spread over such a large area that there is no fish
distortion. In the larger sizes, the tool employs a Friction Block Assembly and
in the smaller sizes it employs a Friction Spring Assembly. These assemblies
serve the purpose of holding the Slips stationary while the Body is rotated to
place the tool into its engaging or releasing position.
ITCO-type Spear
Full Circle Spear
Unitizer
Retainer
Screw
Friction
Retainer
1
Taper Taps
Rotary Taper Taps are the simplest fishing tools for engaging a fish internally
when there is insufficient clearance to permit the use of an externally engaging
fishing tool or when there is a damaged joint. The taper tool enters into the
bore of the fish and secure a firm holds on its internal diameter. This tool is
good for straight pull.
k) Junk Catch
Junk catch are fishing tools used to remove “junk”, from the wellbore and are
categorizes as:
1. Junk sub
2. Junk Basket or Globe basket
Never 3. RCJB
apply tong 4. Magnet.
Magnets and junk baskets are ideal when retrieving a fish that is broken into
pieces or has an irregular shape.
Junk sub
Junk Subs are normally run just above the drill bit and have a cup for catching
objects too heavy to be completely circulated out of the hole. This is
particularly advantageous in junk milling operations. It is always a good
practice to run a Junk Sub above scraper to make scraping jobs more
effective.
Note: Never apply tong on the cup body as it may get crushed.
Junk Basket (Globe Basket)
The Junk Basket is equipped

with one or two catcher
assemblies that should revolve
freely. These catchers are to
retain the junk in the basket. .
The junk head is very similar to a

rotary shoe and is available in
most of the same types as rotary
shoes.
It is used to retrieve all sorts of

junk that may accumulate at the
bottom of the well like bit cones, bearings, broken slips, pins, hand
tools, cuttings, and other debris.
The object is to get the basket over the junk and cut a core. To do this,
run the basket in the hole a few feet above the fish and put the pump
on. Reverse Circulation Junk Basket (RCJB)
Insert Pic
Reverse Circulation Junk Basket is used to recover all types of small junk
objects from well bore.
The unique principle of this tool of reverse circulation ensures complete

recovery of all junk.
A drain through the tool also eliminates the possibility of pulling a wet string
even though the inner barrel is plugged by the core.
After reaching to top of junk, the steel ball is dropped into the valve seat, fluid
flows through the inner passage of the barrel and out the vents in its lower end.
The fluid is directed outward and downward and flows in a continuous stream
to the centre of the tool and up through return ports in the upper end of the
barrel. All junk is thus carried into the barrel above the Junk catcher.
Fishing Magnets
Fishing Magnets are used to recover small magnetic objects from well bore.
Such un-drillable objects like bit cones, bearings, slips, tong pins& dies, and
milling cuttings, hammer can often be retrieved only by magnet.
Fishing Magnets trip is particularly advisable prior to diamond coring.
In a single trip, the Fishing Magnet will completely clean the hole of junk and
protect the bit.
Milling Tools
These fishing tools are used to mill objects down hole for a specific reason that
cannot be fished out with other conventional fishing tools.
CIRCULATION REQUIREMENT FOR MILLING:
•Recommended minimum annular velocity = 80’-120’/minute

•Highest circulation rate should be used to attain above annular
velocity
• Junk Sub should be used directly above the mill
• Most efficient surface removal system like Ditch Magnet for cuttings
removal should be utilized; to ensure the cuttings do not get re-
circulated in the hole
• In-efficient removal of cuttings leads to a build-up of cuttings on
bottom, therefore milling rate drops off.
RATES AND SPEEDS
• Excessive rate will allow the mill to flare the top of the fish rather
than mill the fish.
• The mill should never be started directly on the fish. The rotary
should be engaged with the mill one or two feet above the fish and
then lowered on the fish. Penetration may then be improved by
increasing the feed and weight.
• To even out the wear on the mill, it is best to develop a new wear
pattern by picking the mill up from time to time and lowering it on the
fish while rotating. If the mill is operating on the fish for a long period,
a deep wear pattern will develop, and there is a quite possibility that
the mill will work-harden.
• During milling operations, an increase in torque could mean that a
sliver of junk is lodged alongside the mill. The mill should be
spudded several times, allowing the sliver to drop to the bottom.
• While long milling jobs, periodic inspection of the mill will give a
pretty good indication of how the particular design of mill is
functioning downhole.
GENERAL OPERATING RECOMMENDATIONS
Type RPM Weight Remarks
(1000
lbs)
Junk Mill 60-140 0-30 Spud mill from time to time
Pilot Mill 60-140 0-30 Vary weight to find best

ROP.
Taper Mill 60-140 0-30 Start with light weight and
low rpm
Flat Mill 60-140 0-30 Start mill above fish
Rotary Mill 60-140 0-30 Pick up from time to time.

Check over pull and
torque. Do not spud
unless absolutely
necessary
EXPECTED MILLING RATES
Material Junk Mill Pilot Mill Flat Mill Washover
(ft/hr) (ft/hr) (ft/hr) Shoe
(ft/hr)
Drillpipe 2.0 - 6.0 2.0 - 4.0 - 6.0
Drill Collars 1.0 - 2.0 1.0 - 2.0 - 4.0 - 10.0
Packers 4.0 - 2.0 - 3.0 -
Bit cones etc. 2.0 - 4.0 - - -

General junk 3.0 - 5.0 - 2.0 - 4.0 -
Washover 2.0 - 4.0 4.0 - 10.0 - -

pipe/string
Casing 2.0 – 4.0 4.0 - 10.0 - -
TUNGSTEN CARBIDE REDRESSING
Entire success of the milling operation is reliant on the Type of tungsten
carbide & Technique of application
• Tungsten carbide hard-surfacing material is used in welding rod form.
• Tungsten carbide fragments are interspersed in a matrix of special
metal which acts as a sort of shock absorber yet is still strong
enough to hold together under severe loading.
• The matrix is designed so that it wears away in service, exposing new
carbide fragments as the tool is used.
Techniques used in applying tungsten carbide:
1. All rust, scale or paint should be cleaned from the work surface and
the work surface brightened to parent metal.
2. The work surface should be preheated to 850° F.
3. When applying tungsten carbide rod to the working surface, use a
brazing flux, being careful not to overheat the filler metal.
4. The surface to be covered should be pre-tinned with filler rod
before application of the tungsten carbide. A filler rod
should be used to fill up the voids or low spots
between the carbide particles as the rod is applied.
The extra filler rod holds the carbide in place,
preventing a porous structure. Utilize 1 lb. of filler
rod to 3 lb. of tungsten carbide rod. In thin wall
sections such as rotary shoes, the side opposite that
being worked should not be heated to a point that it
becomes oxidized.
5. It is important that the same particle size tungsten carbide
be used as was used in the original application.
TAPER MILL
• Used to establish gage diameter and primarily to mill
collapsed casing
• Design of the taper mill allows the small-diameter lower-mill end
to enter the collapsed section and then the slightly spiraled
reamer edges mill away the undersized section to the full
diameter.
• May be used in conjunction with other mills to prepare a fish for
internal engagement.
• Used for Deburring the window after a whipstock operation is
completed.
FLAT BOTTOM MILLS

• Dressed with crushed sintered tungsten carbide on the face
• standard junk, reamers,
packers, retainers, and bit
cones, drill pipe, wash
pipe, casing and liners.
CONCAVE MILLS
• Similar to the flat bottom mill, only it is concaved on the face, to keep
the milling action centered
on the mill.
• bit cones, drill pipe, wash
pipe, casing, and liners.
• Especially good for milling
bit cones, when the cone is
facing up
Rotary Shoe
SHOE USE
TYPE
A Used to cut soft formation at bottom
only
B Used inside casing to washover the

fish without damaging the casing
C Designed to use inside of casing and

cuts on the bottom only
D Designed to cut the formation only.

Cuts on the OD and bottom only
E Designed to use inside casing to cut

metal on the fish. It cuts on the ID
and bottom only
F Designed to use inside casing to cut
soft formation. Cuts at the bottom
only.
G Designed for open hole to cut metal,

formation and cement. Cuts on the
ID, OD and bottom.
H Designed to use inside casing to cut

and bottom aggressively.
M Designed for open hole to cut metal,
formation and cement when clearance
inside the hole is limited. Cuts on the
OD and bottom.
N Designed to use inside casing to dress
and size the fish. It cuts on the ID and
bottom only.
P Designed to cut formation metal and

cement. Cuts on the ID, OD and
bottom.
R Designed to use in open hole to cut

metal, cement and formation. It cuts
on the OD and bottom only.
S Designed to use inside casing to cut

and bottom only.
T Designed to use in open hole to cut

metal, cement and formation. It cuts
on the OD, ID and bottom only.
l) Accessory Tools
Accessory tools like Bumper sub, Fishing Jar, intensifier improve the success
of fishing operation.
 Bumper subs provide that extra movement in the drill string when
finding the top of the fish and it helps in disengaging the overshot.
 Fishing jars create the impact and impulse force to free the stuck fish.
 Intensifiers are run in combination with the fishing jar to increase the
jarring impact.
1
Hydraulic Up Fishing Jar:
The hydraulic jar is an easy to use
accessory tool that assist in various
operations such as fishing and wash over.
This is installed in the string above
fishing tool assembly. It delivers an
upward blow to fishing string below the
jar. Setting or adjustment is not required
prior to lowering in the hole. Hydraulic
oil jar is composed of cylinder and
piston assembly. Piston assembly slides
within the cylinder assembly for jar to
give impact. It is a closed hydraulic
system.
Time delay mechanism:
It is designed in such a way that the
intensity of jarring can be varied from a
very light impact to a blow of very high
impact by the metering action of piston
assembly. As pulled is applied for the jar
to trip, a small amount of oil is leaked
through piston rings in such a manner that
the stroke is delayed until necessary
stretch in the running string is achieved.
Metering stroke: The movement of the

piston assembly from bottom most
position to the internal splines position is
called metering stroke.
Free stroke: Free movement of mandrel

from internal splines position to the top
most position of the piston assembly is
called free stroke.
Hence Total stroke = Metering stroke +
Free stroke
FISHING BUMPER SUB
One of the most common tools used for any kind of fishing job is the bumper
sub. The tool’s design
allows full torque and
unrestricted fluid
circulation at all times.
The Fishing Bumper
Sub can bump up or
down to engage or
disengage overshots or
spears, or be used as a
feed-off tool in
milling or cutting
operations. Other
typical operations
include releasing stuck drill pipe, drill collars, tubing, test tools, and safety
joints. The fishing bumper sub can be used in conjunction with an overshot or
spear.
14
11 Completion
Well Control
Fluid
Management
Well control means to manage the formation pressure. Primarily the formation
pressure is managed by well bore pressure provided by mud hydrostatic
column in the wellbore but still there is a chance to get formation fluid into the
well bore as soon as formation pressure is greater than hydrostatic pressure. In
the event of any imbalance, a kick is experienced, which if uncontrolled may
lead to a blowout.
The focus of well control therefore lies on prevention and early intervention
using proper planning & counter measures. It also focuses on proper
knowledge and testing of the equipment used in well control. One common
feature in all well control procedures for handling of kick is to maintain
constant bottom hole pressure throughout the procedure while the influx is
removed and balance of pressures restored. Hence, an understanding of well
control is of utmost importance for the drilling crew.
By using standard procedures, the well control problems can be minimized and
tackled effectively which also helps in maintaining work consistency across the
organization. The contents here in are as below:
a) Identification of a kick and precautions.
b) Shut-in procedures
c) Stripping procedures
d) Handling of shallow gas
e) Blow out prevention equipment
f) Choke & kill manifolds, BOP Control System, MGS & Diverter Unit
g) Function and pressure testing of equipment
h) Well control drills
i) Well killing methods-Driller’s, Wait & Weight and Volumetric
j) Bleeding
k) Common problems during well killing.
l) References
m) Formats: Drills, function and pressure tests
Well control means to have BHP in the well more than formation pressure all
the time. It is classified in to three categories as given below:
Primary Well Control: While drilling maintain hydrostatic pressure more than
expected formation pressure.
Secondary Well Control: After losing primary well control and in kick
situation, close the BOP at surface and apply back pressure (SIDPP and SICP)
to keep BHP above or equal to formation pressure. This also involves killing of
well to regain primary control.
Tertiary Well Control: In case secondary control is lost due to BOP failure
then Tertiary Well Control enables regaining secondary control over well by
replacing the damaged BOP stack with the working BOP stack.
Note: Well control manual published by IDT should be available at rig for
ready reference at all times.
a) Identification of a kick and precautions.
Influx is the flow of formation fluids into the wellbore. Kick is continuous
entry of formation fluid into the wellbore when BHP exerted by fluid column
becomes less than the formation pressure. Influx may result in a kick only
if BHP is reduced below formation pressure.
Well shows kick sign when INFLUX enters the well bore and
increased/ self-flow is noticed by driller during drilling/tripping.
Kick normally is associated with some early warning signs that give
indications to the driller about approaching abnormal/High pressures in the
well. If the driller is able to notice these signs in time, situation can be
managed in a more controlled manner.
While Drilling
Warning signs Responsibility Recommende
d action
Drilling break: Driller Stopdrillingimmediat
Sudden increase in ROP is ely and
observed(30-100% increase) have flowcheck
Back ground gas % increasing Chemist/ Mud
Loggertoreport
to driller
Increase in torque & drag with Driller
sudden increase in ROP
Shale density reduced as seen Geologisttorep
by geologist ort todriller
Mud temperature increasing Mud chemist
continuously to report
Salinity of mud increasing
Large volume of angular
shaped cuttings noticed at
shaker
Swabbing while Tripping:
Most well activities occur in wells duringpullingout of hole when the hole fill up
volume is less than the steel volume of pulled out pipes. Systematic recording of
the pipe steel volume vs volume taken by the well is the only way to detect a kick
in POOH. Hence, Trip Sheet must be filled up during every trip out to avoid well
Warning signs Responsibility Recommende Precautions
d action
Based on trip sheet Assistant Flow Check Do not resume
readings, while Shift-in-charge  If +ve, tripping out even
POOH if well is shut-in the if no self-flow is
taking less than well found during
calculated volume  If –ve, run flow check.
of mud to top up back to Influx is already
the annulus, it bottom in the well and
shows formation and needs to be
fluid is entering in circulate removed from
the well bore due to bottoms up well prior to
swabbing (Piston while commencing
effect).This reduces monitoring POOH.
Bottom Hole the returns. Hole fill should
Pressure (BHP) of be done using
well and may lead only trip tank
to more influx if with trip sheet
BHP falls below to check
formation pressure. swabbing.
Above precautions are also required in case of a very narrow mud weight
window.
All above mentioned warning signs are to be taken seriously and
should be responded to in time.
Trip Tank:
Trip tank is one of the most important equipment which is used during tripping
operation for early detection of kick/swab. It is the most accurate way to
measure the fill up volumes.
It is a small capacity tank (30-60 bbls) with a low pressure piping to a
point in the annulus below the flow line. Fill up mud can be fed from the tank
into the well by centrifugal pump called trip tank pump. When lined up on trip
tank, the return flow comes back to trip tank in a closed loop system.
The dimensions are calibrated so that driller can easily track the fill up
or displacement volumes even in small volume of 0.1 m3or 0.5 bbl.
Procedure for using trip tank:

1. Fill trip tank with the mud used in for final circulation before
pulling out.
2. Line up trip tank so as the return flow from the bell nipple is
coming back to the trip tank in a closed loop.
3. Run the trip tank pump and check for its functioning and leakage.
4. Record the initial reading on the calibrated indicator at rig floor.
5. Prepare Trip Sheet(with calculated metal volume if P/O is dry)
6. Start pulling out and fill up reading from trip tank in trip sheet after
pulling out every three or five stands. Compare the calculated volume
vs actual fill up volume.
7. Run the pump continuously throughout the pulling out. This keeps the
hole full and helps in monitoring of the mud volume
taken by the well during pulling out.
8. If there is any deviation between calculated volume v/s actual fill
up volume, go in for flow check. Even if flow check is negative i.e no
self flow, run back to bottom and circulate bottoms up.
Trip tank is also to be used during running-in and returns to be
monitored for indication of losses due to surging. Losses if not
detected may reduce the level of mud in the well and cause a kick.
Flow Check:
The first action after getting any warning sign is to go for FLOW CHECK as
per following procedure.
 Flow Check before Pulling out:
 Flow Check Procedure for Water Based Muds (WBM):

1. Stop rotary.
2. Pick up Kelly to clear tool joint above rotary table.
3. Stop pump.
4. Check for self-flow for minimum 5 minutes.
a. If flow check is positive, shut in the well.
b. If flow check is negative and everything is normal, resume drilling.
 Flow Check Procedure for Oil Based Muds (SOBM):
Due to high solubility of gas in OBM, the flow check procedures and
actions are different as compared to WBM.
 Flow Check Procedure (SOBM):

1. Stop rotary.
2. Pick up Kelly to clear tool joint above rotary table.
3. Stop pump.
4. Check for self-flow for minimum 15 minutes
5. If flow check is positive, shut in the well.
6. If flow check is negative but presence of dissolved gas is suspected
due to drilling break or change of formation, circulate out the
bottoms up through full choke opening. In case of sudden change in
choke pressure, the well may be closed immediately for recording
Shut-in pressures if any.
7. If bottoms-up does not indicate influx, resume drilling.
Recording of Slow Circulating Rate (SCR)/Kill Rate Pressure (KRP):

SCR/KRP should be recorded afresh using Drill Pipe Pressure Gauge on
Choke Panel (The gauge which will be used during killing preferably
Choke Panel Gauge) by keeping the string at bottom and circulating at two
reduced flow rates, generally 30 & 40 SPM for both pumps separately for the
following cases:
1. At the beginning of each shift
2. Change in bit, nozzle and BHA
3. After drilling of more than 150/200 m in the same shift
4. After change of mud weight
5. After change in size of pump liners
6. After repair of mud pumps
Ensure that string is not in idle condition during recording of SCR.
b) Shut–in Line Up for Well Closure:

Reasons for shut in the well : Having identified that the well is
flowing, it is important to react positively and quickly. Shutting the
well will stop and prevent further influx.
When one or more positive kick signs are observed, flow check is made. In
case of self-flow, there are two possible Shut-In Procedures in practice:
 Hard Shut-In: This is most recommended procedure to shut-in the well
to minimize influx unless instructions exist for soft shut-in due to
reasons such as Low MAASP value & shallow depth with low LOT
value
 Soft Shut-In
Before shut-in, choke manifold should be lined up for the shut-in
procedure to be adopted during different operations/situations.
Position of Valves during Drilling / Tripping (Hard Shut-In):

Hydraulic valves (HCR) in choke & kill line Closed
Manual valves in choke & kill line Open
All valves between choke line valve & up to choke Open
Hydraulic / Manual choke Closed
Valves downstream of choke and up to Mud Gas Separator Open
(MGS)
Line to MGS & shale Shaker
Choke
Remote
HCR valve
Bleed line
Manual
Gate
valve
Adjustable
Position of ValCvheoskde uring Drilling/Tripping (Softt Shu -In):
leCSlhoaskeedr shakers
Hydraulic valves (HCR) in choke & kill lineLine to MGS &Sha
Manual valves in choke & kill line Open
All valves between choke line valve & up to choke Open
Hydraulic / Manual choke 1/3rd open
Valves downstream of choke and up to MGS Open
Remote choke
HCR Bleed line
Choke line
Manual
Gate valve
Adjustable
1
Hard Shut-In Procedure: (Land & Jack-Up Rigs):
 While Drilling:
1. Ensure tool joint is 1 m above the rotary table
2. Reconfirm that the pump is switched off
3. Close annular BOP or upper pipe rams
4. Open hydraulic valve (HCR) on choke line
5. Record SIDPP, SICP and pit gain
 While Tripping:
1. Set string on slips and install FOSV (Kelly cock) in open position.
Close it.
2. Close annular BOP or upper pipe rams
4. Make up Kelly/ TDS and open FOSV.
5. Record SIDPP, SICP and pit gain
 Recording SIDPP with float

If there is a float in the string, SIDPP will read zero. Therefore, start
pumping slowly into the string until a change in SICP is noticed.
The drill pipe pressure at this point is equivalent to SIDPP.
 While Lowering Casing:

1. Set casing on slips.
2. Close annular BOP or casing rams
3. Install casing to drill pipe X-over
4. Install FOSV (Kelly cock) in open position and close it.
6. Make up Kelly /TDS and open FOSV.
7. Record SIDPP, SICP and pit gain.
 While String is out of Hole:
When string is out of hole, soft shut in procedures are recommended
2. Close blind / shear-blind rams
3. Close choke
4. Record SICP and pit gain
Recording of Shut-In Pressures:
After shut in the well it is the driller’s duty to ensure that well is secure (BOP
closed) and there are no leaks in any manifolds. Flow line to be lined up to trip
tank for monitoring of BOP leaks. After shut-in, both SIDPP and SICP should
be recorded after every 5 or 10 minutes in form of a table till they become
stabilized. After stabilization of pressure, if SIDPP and SICP are further
increasing at the same rate, it indicates that gas migration is taking place.
Driller should maintain SIDPP constant at stabilized SIDPP value by
intermittently bleeding through choke. Do not bleed while keeping the casing
pressure constant.
 Interpretation of Shut-In Pressures:

Given below is an example of a well that was shut in after a kick and tabulated
values of SIDPP and SICP recorded at an interval of every 5 min:
Time SIDPP(psi) SICP(psi)

0600 100 150
0605 200 270
0610 275 370
0615 340 450
0620 400 520
0625 405 525
0630 415 535
0635 430 550
0640 450 570
It is clear from the table above that rate of increase in pressure of
SIDPP& SICP has reduced after 0620 hrs and both SIDPP & SICP are
rising by same amount. This indicates that the pressures have stabilized
at 0620 hrs. and subsequent increase is due to migration of gas in the
annulus. Therefore the value recorded at 0620 hrs i.e. 400 psi is the true
SIDPP.
NOTE:
The time taken to get stabilized pressure depends on the permeability
of the formation. The proper recognition of Stabilized value of SIDPP
is very important as it is used for calculation of right kill mud weight
and formation pressure.
c) Stripping Procedures:
Stripping-in is the process of lowering drill string into the wellbore with BOP
in closed on kick. Use of Annular Preventer for stripping in is an easy choice to
make because tool joint can be stripped through the closed Annular. Sometimes
it may be necessary to use two Ram preventers or an Annular/Ram
combination if well pressure is too high to strip with one Annular.
Stripping is to be carried out only under strict supervision of Crisis
Management Team.
 Stripping-in with Annular Preventer:

Pipe completely out of hole and annular preventer closed on open hole
1. Check that Blind ram preventer below the Annular Preventer is closed
2. Bleed off pressure between Ram preventer and Annular BOP.
3. Open the Annular preventer
4. Lower the bit with NRV and drill collars above the closed ram
preventer.
5. Close the Annular preventer and pressure up to well pressure between
the two closed preventers (preferably by cementing unit). Once
pressure across the blind ram is equalized, open the ram preventer.
6. Reduce the closing pressure of Annular BOP until a small amount of
leakage is observed between the pipe and seal when the pipe is
stripped in. A rule of thumbs holds that 0.5 to 2.5 barrels of leakage
per thousand feet of stripped pipe, depending on its size. Closing
pressure on the preventer is to be adjusted time to time during the
job so that target leakage rate can be maintained.
7. As the pipe is stripped into the well, bleed mud from the well at regular
intervals to maintain a fairly constant bottom hole pressure, which
should be equal to the closed end displacement of the stripped in pipe.
Also fill the inside of the stripped pipe at regular intervals, which
should be equal to the inside capacity of the stripped in pipe.
8. When lowering the pipe in the hole, do not exceed 50-60 feet per
minute speed. A slower rate should prevail when passing tool joints
through the preventer with utmost care and adjustment of annular
closing pressures.
9. Proceed with stripping until bottom is reached keeping record of the
mud displaced. Every stand of pipe must displace mud. If no
displacement shows, circulation has been lost.
Note: In case the drill string is partially in hole, then start from step No-5.
 Stripping Using Ram Preventer:

1. Strip with lower stripper ram closed until the tool joint is about
midway between the two stripping rams.
2. Stop string movement and close the upper stripper ram.
3. Open the valve on equalizing loop with the bleed off line closed.
4. Allow pressure between the two rams to equalize.
5. Open the lower stripper ram.
6. Close the equalizing loop valve.
7. Strip against the upper stripper ram until the tool joint is below the
lower stripper ram.
8. Stop string movement and close the lower stripper ram.
9. Open the bleed line valve.
10. Allow pressure between the two rams to dissipate.
11. Open the upper stripper ram.
12. Close the bleed line.
13. Repeat the procedure.
While doing this, maintain the casing pressure constant by bleeding
mud from the choke. For most stripping jobs, if gas migration is not taking
place holding casing pressure constant should be adequate. If the casing
pressure starts rising between stands it means gas migration, then follow the
volumetric method in IDT Well Control Manual.
d) Handling of shallow Gas:

Shallow gas is defined as quick, unexpected and uncontrolled flow of gas from
top hole with unconsolidated formations wherein BOP closure may result
fracture around casing shoe
 Recommended Procedure to Drill Top Hole
1. Drill a pilot hole of smaller size.
2. Include diverter in the line up
3. Keep sufficient source of water and stock of mud to handle shallow
gas.
4. Circulate the cuttings out after every 2-3 pipe connections to
avoid loading of the annulus.
5. Drill at controlled rate
6. Circulate while pulling out through tight spots.
 Shallow Gas Occurrence during Drilling

1. At first sign of flow, immediately stop rotary, raise the kelly until tool
joint is above rotary.
2. Open both vent line valves
3. Close diverter packer (considering flow line to shaker is above packing
element).
4. Close the diverter overboard line valves depending upon wind
direction.
5. Circulate out with available drilling fluid at maximum possible pump
rate.
6. Evacuate non-essential personnel from the rig.
 Shallow Gas Occurrence while Tripping:

1. Set pipe on slips.
2. Install FOSV and close it.
3. Open diverter line valves depending upon wind direction.
4. Close diverter packer.
5. Connect Kelly or circulating head.
6. Open FOSV.
7. Circulate out with available drilling fluid at maximum possible pump
rate.
8. Evacuate non-essential personnel from the rig.
e) Blowout Prevention Equipment:

For H2S prone areas, all well control equipment should be H2S trimmed.
 Blowout Preventer Size:

The size of BOP means the vertical Nominal inside diameter of BOP
stack. The selection of BOP size should be such that it should allow
passage of all the tools required for drilling operations.
 Connections, Size & Pressure Rating of Wellhead Flanges:
1. BOP& well head pressure rating should be more than the maximum
anticipated surface pressure.
2. API standard rating flanges are to be used and BOP stack should have
minimum connections as far as possible.
3. Only studded/flange/hub types of connections are to be used in BOP
stack.
4. BOP side outlets should be of the same rating as of BOP stack.
 Classification of Surface BOP Stack:
The following BOP stack configuration should be used as per working

pressure classifications. These configurations are in line with API STD
53and OISD RP-174
 The quantity of pressure containment sealing components in the
vertical wellbore of a BOP stack is used to identify the classification
or “class” for the BOP system installed. The designation Class 6
represents a combination of a total of six ram and/or annular
preventers installed (e.g. two annular and four ram preventers or one
annular and five ram preventers)
The ram and annular preventer positions and outlets on the BOP stack shall
provide reliable means to handle potential well control events. The system
shall provide a means to:
a) close and seal on the drill pipe, tubing, casing, or liner and allow
circulation;
b) close and seal on open hole and allow volumetric well control operations;
c) strip the drill string.
 Annular preventers having a lower RWP than ram preventers are

acceptable.
 The configurations are as per the recommendations of API STD.53. A
documented risk assessment shall be performed by the operator for all
classes of BOP arrangements to identify ram placements and configurations
to be installed. This assessment shall include tapered strings, casings,
completion equipment, test tools, etc.
CLASS DESCRIPTION
Class 1 Annular / Pipe ram
Class 2 A minimum of one set of blind rams or blind shear rams
(BSRs) shall be installed when ram-type preventers are to
be installed. This requirement shall also apply to 3M or
lesser-rated working pressure systems and a minimum
Class 2 BOP stack arrangement.
Class 3 A minimum of a Class 3 stack arrangement with one set of
blind or blind shear rams and pipe rams shall be installed
for a 5M pressure rated system. The third device may be a
ram or annular type preventer, whichever is desired.
Class 4 The minimum stack arrangement for Class 4 BOPs shall
include one annular, one blind ram or BSR, and one pipe
ram. The fourth device may be a ram or annular type
preventer, whichever is desired.
A minimum Class 4 BOP stack arrangement shall be
installed for 10M pressure rated systems, with a minimum
of one blind ram or a BSR capable of shearing and sealing
the drill pipe in use.
Class 5 A Class 5 BOP arrangement or greater shall be installed
for 15M and greater pressure rated systems. The
minimum requirements for a Class 5 BOP stack
arrangement shall include one annular, one BSR, and two
pipe rams. The fifth device may be a ram or annular type
preventer, whichever is desired. A risk assessment shall be
performed to identify ram placements and configurations,
and taking into account annular and large tubular(s) for
Class 6 The minimum stack arrangement for Class 6 BOPs shall
include one annular, one blind shear ram, and two pipe
rams in the arrangement. The remaining devices may be a
ram (pipe, blind, blind shear, casing shear, test, or
variable), or annular-type preventer, or a combination
thereof, as determined by a risk assessment.
f) Choke & kill manifolds, BOP Control System, MGS & Diverter Unit:
Choke Manifold:
The choke line and manifold provides means of applying back pressure
required on the formation while killing the well and circulating out influx
from the wellbore.
 Recommendation for Choke Manifold and Choke Line:

a) Upstream valves, connections and lines including the choke should
have a working pressure equal to or greater than the rated working
pressure of the ram BOPs in use and all the connections should be
either flanged, welded or hub.
b) Minimum two valves are recommended in choke line immediately
after the BOP stack with rated working pressure equal or greater than
the rated working pressure of Ram BOP in use. One of these two
valves should be remotely controlled.
c) A minimum of one remote operated choke should be installed on all
choke manifolds and choke manifold above 10000 psi rating should
have two remote operated chokes.
d) Any remotely operated valve or choke should be equipped with an
emergency back-up power source or manual override.
e) Pressure gauges suitable for operating pressure and drilling fluid
service should be installed so that drill pipe and annulus pressures
may be accurately monitored and readily observed at the station
where well control operations are to be conducted.
f) Manufacturer’s guidelines should be followed for flexible line on
minimum working bend radius to ensure proper length determination
and safe working configuration.
g) The choke line nominal diameter should not be less than 3 inches and
all other components should not be less than 2 inches.
h) The vent/bleed line that bypasses the chokes should be at least equal
to the diameter of choke line.
i) All choke manifold valves should be full bore and during operations
and should be either fully opened or fully closed.
 Kill Manifold and Kill Lines:

Kill lines are an integral part of the surface equipment required for well
control during drilling. The kill line system provides a means of pumping
into the wellbore when the normal method of circulating down through the
Kelly or drill pipe cannot be employed.
a) All lines, valves, check valves and flow fittings should have a working
pressure at least equal to the rated working pressure of the ram BOPs
in use.
b) All the connections should be flanged, welded or hubbed.
c) All Components should not be less than 2” nominal diameter.
d) T wo full bore manual valves (one should be remotely operated) between
the stack outlets and kill line.
e) The rig pump line to kill manifold should have a check valve and the
auxiliary pumping line to the kill manifold should have a gate valve.
f) The kill line should not be used as fill up line
g) Check valves installed on the kill line should be low and high pressure
tested from the well bore side.
BOP CONTROL SYSTEM
BOP control system provides pressurized hydraulic fluid to operate BOP stack
functions promptly and in absence of power as well.
Accumulator Check:
Before connecting the system to the stack, the unit should be visually inspected
and the fluid reservoir checked to ensure that no foreign fluids, other debris are
present and pre-charge pressure verification also should be done. Accumulator
& pump closure tests should be conducted before pressure testing BOP.
 Accumulator Bottle Pre-Charge Pressure Verification:

a. Open the bottom valve on each bottle & drain the operating fluid into
the reservoir.
b. Measure the Nitrogen pressure on each bottle (1000 + 100 psi) and
charge if necessary.
c. Charge the control unit to its max operating pressure (Example 3,000 psi
for 3,000 psi unit) by running electric and pneumatic pumps. Record
time taken for charging the unit (should be within 15 Min with both
charging pumps combined).
 Accumulator Closure Test:
a. Position a joint of drill-pipe in the stack.
b. Shut off the power supply to the control system pumps.
c. Confirm that the accumulator pressure is within 100 psi of the rated
working pressure.
d. Confirm that the manifold (1500 psi) and annular regulators (500-1500
psi) are set.
e. Sequentially close one pipe ram and one annular. Open the HCR valve.
f. Record the BOP closure time and the time to open the HCR.
g. Record the final accumulator pressure (Should not fall below min.
operating pressure equal to 1200 psi)
h. Restore the BOP controls to their original position.
i. Restore power to the pumps and recharge the accumulator.
j. Record the time required to recharge the system to full operating
pressure. (Max. 15 minutes)
 Pump Closure Test:

a. Position a joint of drill-pipe of minimum size to be used in the stack.
b. Isolate the accumulator bottles bank from closing manifold and pumps.
c. Isolate the Electric supply and use only air pumps to charge.
d. Simultaneously close the annular & open the HCR valve.
e. Record the time to close the annular and open HCR.(Max. 2 minutes.)
f. Restore the control to their original position.
g. Repeat the test using the other power source for the pumps.
h. Open the accumulator to the closing unit and pump.
 BOP Remote Panel:

Two remote panels should be kept at site (one near the driller and
another near DIC/Tool pusher cabin) and the control hose bundle and
pneumatic supply should be connected. The control bundle should be
well protected through a conduit/grating so as to prevent any damage
during the course of well. Ensure pressure gauges are in working
condition.
 Mud Gas Separator (MGS):

1. A suitable atmospheric mud gas separator, arranged with the inlet line
from choke manifold and the vent line (discharging released gas)
1
connected to a flare line, must be provided. The dia. of the shell should
not be less than 36”.
2. Vent line should not be less than 6” nominal pipe diameter and
should be of sufficient length to end at safe distance from rig.
3. The Vertical MGS should be properly anchored to prevent toppling
down while venting the gas during well killing.
4. During drilling, the MGS should be regularly checked for proper
functioning of all valves and flange connections. MGS should be
regularly cleaned by washing with water.
5. Keep drain valve in bottom of MGS in open condition during drilling.
Diverter Equipment:
Whenever GTO indicates possibility of shallow gas, include Diverter in the top
hole drilling plan.
Note: For setting up and selection of diverter WCS-IDT well control
manual available at rig may be referred.
Drill String BOP Valves (FOSV/KellyCock/Inside BOP):
a) The Kelly or Top Drive should be equipped with an upper and a lower
Kelly cock and should be pressure tested. The working pressure of
Kelly cock should be equal to or greater than the rating of the BOP
stack in use. The upper Kelly cock of the top drive should be
hydraulically operated.
b) A spare Kelly cock ie Full Open safety Valve (FOSV) that is
compatible with drill pipe in use should be available on the rig floor at
all times in the open position. It should be equipped with removable
handles for easier stabbing.
Note: Operating handle of FOSV should be easily accessible near
driller’s console at all times.
c) An Inside BOP Valve (IBOP), with the appropriate connections for the
drill string in use, should be available on the rig floor at all times in
open condition.
d) All required Crossovers for connecting the FOSV/IBOP to the drill
collars or tubing in use should be available on the rig floor.
h) Function and pressure testing of equipment and various drills
Pressure & Function Testing of Well Control Equipment:
The BOP Stack and allied equipment should be tested as per the OISD-RP-
174 and/or API STD 53 using chart recorder.
TESTING EQUIPMENTS
 Test pumps:
A low discharge high pressure pump should be used for pressure testing.
In case the test pump is not available then cementing unit should be used.
Never use rig pump for pressure test.
 Test Plugs:
 While testing BOP stack and other equipment, test plug with O-
rings/seals should always be used to isolate BOP from casing.
Note: Ensure that the test plug being used is compatible with
Well head and the bottom plug of the test plug is removed.
 The annulus valves of the well head should be kept open before
lowering the test plug.
 Test plug is to be lowered and landed in to the well head with a test
drill pipe joint.
 To test the blind or shear-blind ram, bottom plug of the test plug
should be installed and test pipe should be removed, leaving the
test plug resting on the wellhead.
 Cup Tester:
Most Important:
Cup of the cup tester should be selected on the basis of :
a) Burst strength of upper most part of casing
b) Compatible with the casing size & grade.
c) The tensile strength of the test drill pipe used with cup tester
should be sufficient to avoid failure during testing. Wherever
possible, “S” grade pipe should be used with cup tester.
Test Fluids:
Clear water should be used for testing of BOP stack and other well control
equipment.
Test Pressures:
All BOP components that are exposed to well pressure should be tested first to
a low pressure of 250-350 psi and then to a high pressure as per API STD
53/OISD-174.
 Low Pressure Test:

First low pressure test should be conducted at 250-350 psi on all the rams,
annular preventers, manifolds, lower Kelly cock etc. any leak observed at
low pressure, the corrective remedial measure should be taken
accordingly. DO NOT GO AHEAD WITH HIGH PRESSURE TEST
IF LOW PRESSURE TEST FAILS.
 High Pressure Test
Initial Pressure Test:
It is conducted prior to spud or upon installation with Test Pump or
Cementing unit. Pressure chart recorder should be used for pressure
testing.
i. Rams, choke manifold and choke/kill lines should be tested to the rated
working pressure (RWP)of the ram BOPs or to the RWP of the
wellhead on which the stack is installed, whichever is lower.
ii. Annular BOPs may be tested to70% of the RWP or to the test pressure
applied to the ram BOPs, whichever is lower.
iii. Lower Kelly cock, upper Kelly cock and drill pipe safety valve should be
tested to the RWP from the well bore side.
Subsequent Pressure Test:

(To be carried out within 21 Days Interval)
1. Subsequent high pressure test of ram BOPs and choke manifold should
be limited to maximum anticipated surface pressure +10 % margin but
not to exceed the RWP of the ram BOPs.
2. The maximum anticipated surface pressure should be determined by
the data given in GTO. Maximum anticipated surface pressure is
formation pressure reduced by gas column hydrostatic for well depth
in terms of TVD at gas density of 2.5 ppg (0.3 SG).
3. Annular BOPs should be tested to a minimum of
 70% of their working pressure
or
 The ram test pressure as in Point 1 above.
 Test Duration:
Hold the pressure for 5 minute after pressure stabilization subject to
maximum drop of 5% of the test pressure.
TESTFREQUENCY
 Function Test:
All operational components of BOP equipment systems should be
function tested at least once a week. Casing shear and blind shear rams
should be function tested at least once every 21 days.
 Pressure Test:
Pressure test on the well control equipment should be
conducted:
a. Prior to spud or upon installation
b. After the repair/disconnection of any pressure containments in the
BOP stack, choke line or choke manifold, but limited to the affected
component.
c. Not to exceed 21days.
 Function Test Procedure:

 Ensure that pressure reading on unit gauges after charging are:
o Accumulator pressure: 3,000 psi,
o Manifold pressure: 1,500 psi
o Annular Pressure:500-1500 psi (Operating pressure to be
maintained as per the manufacture recommendation & as
per operation)
 Check if pressure is holding. If not, repair the leakages first.
 Close all pipe ram & Annular with pipe in the hole and open HCR
valve. Check for leakages in hydraulic line & then in 3 position 4 way
valve.
 Check closing response time after each BOP stack function
 For surface BOP stack, closing time should not exceed
o 30 seconds for each ram preventers
o 30 seconds for annular preventers smaller than 18¾"
o 45 seconds for annular preventers 18 ¾” and larger.
 Operating response time for choke and kill line HCR valves (either
open or close) should not exceed the minimum observed ram BOP
close response time.
 All the operating levers of gate valves and blow out preventers
should be returned to their original position before resuming
operations and should either be in open or closed position only.
 All the results should be recorded in the prescribed format.
 Testing of Kelly Cocks/IBOP:

Arrangement should be made to pressure test Kelly cock/ IBOP from
the well bore side. Kelly cock should be tested at rated working
pressure using test pump or cementing unit every time the BOP stack
is tested.
h) Well Control Drills:
The competence of the drilling personnel to respond to well control situations
and follow correct procedures can be improved by carrying out emergency
drills regularly.
1. BOP drills should be conducted once a week with each crew.
2. Drill should be initiated at unscheduled times if operations and hole
condition permits.
3. Responsibilities should be assigned to the persons during emergency as
part of the Rig/ Installation Emergency Response Plan (ERP) to take
care of all emergency operations.
4. While drilling in H2S/Sour gas prone area, detectors must be installed
and breathing apparatus in sufficient quantity and Cascade System
must be made available. Crew must be trained to handle situation
in this environment.
5. To conduct a drill, kick should be simulated by manipulating primary
kick indicator such as the pit level indicator or the flow line indicator
by raising its float/paddle gradually and checking for the alarm and
reaction of the crew.
6. The reaction time from float raising to the designated crew member's
readiness to start the closing procedure should be recorded and
response time should not be more than 60 seconds.
7. Total time taken to complete the drill should be recorded and it should
not be more than 2 minutes.
Following drills should be performed and documented

i. Pit drill
ii. Trip drill
 Pit Drill (On Bottom):

o Raise alarm by shouting or raise float to set off auto alarm.
o Stop rotary & pick-up Kelly.
o Position tool joint for closing BOP.
o Stop mud pump.
o Secure brake and ensure designated crew is at assigned position.
o Check for self-flow.
o Record the response time. (should be 1 minute or less)
 Trip Drill (Drill Pipe in BOP):

o Raise alarm by shouting or raise float to set off auto alarm.
o Position tool joint above rotary and set the pipe on slips.
o Install full opening safety valve in open position.
o Close FOSV after installation.
o Close BOP.
o Ensure Position of designated crew members at assigned place.
o Record response time. (should be 2 minute or less)
Trip drill should be carried out preferably when bit is inside the casing.
A full opening safety valve for each size and type of connection in the string
should be open and available on derrick floor.
Safety valves should be clearly marked for size and connection.
 Trip Drill (Drill Collar in Blowout Preventer):

o Raise alarm by shouting or raise float to set off auto alarm
o Position upper drill collar box at rotary table and set it on slips.
o Connect a drill pipe joint or stand of drill pipe on drill collar tool joint
with change over sub and position drill pipe in BOP.
o Install FOSV in open position.
o Close FOSV.
o Ensure Position of designated crew members at assigned place.
o Close BOP.
o Record response time. (should be 2 minutes or less)
Under actual kick conditions (other than drills) if only one stand of drill collar
remained in the hole it would be probably faster to simply pull the last stand
and close the blind ram. If numbers of drill collar stands are more, then install
FOSV with change over sub on drill collar, close it and close annular preventer.
Note: Preparation for this should be done in advance prior to starting pull out
of drill collar by making up one single/ stand of drill pipe with drill collar
change over sub.
 Trip Drill (String is Out of Hole):

 Raise alarm by shouting or raise float to set off auto alarm.
 Close blind/ blind-shear ram.
 Ensure Position of designated crew members at assigned place.
 Record response time.(should be 2 minutes or less)
 Strip Drill
1. The stripping drill should be performed by at least one crew on each
well.
2. This drill can be conveniently performed after casing is set and before
drilling out cement.
3. Keep the drill string in the hole, install NRV on drill pipe & close a
blowout preventer
4. Pressurized the BOP at desired pressure.
5. Reduce the operating pressure of BOP to an acceptable value.
6. Assign position of each crew member.
7. Follow an acceptable procedure and the crew should strip sufficient
pipe into the hole to establish the workability of the equipment and to
allow each crew member to learn to perform their assignments. In
addition to establishing equipment reliability, this will permit the
training of at least one crew on each well.
Note: Over a period of time, all crews should become proficient in stripping
operations.
i) Well Killing Methods-Driller’s, Wait & Weight and Volumetric:
The main principle involved in all well killing methods is to keep bottom hole
pressure constant. The various kill methods are as follows:
a) Driller’s Method
b) Wait and Weight Method
c) Volumetric Method
In the first two methods the influx is circulated out and the heavy mud is
pumped in the well keeping the bottom hole pressure constant. The third
method i.e. volumetric method is a non-circulating method in which the
influx is brought out & heavy mud is placed in the well bore without
circulation.
 Before starting killing prepare complete plan for killing.

Complete kill sheet based on Shut-In data and well configuration.
 Instruct Mud Chemist to start preparing Kill Mud Weight as per
calculated KMW.
Pump start up for Land rig ( or Jack up rig )
Bring the pump to kill speed in steps of 5 SPM holding casing pressure
constant(keep positive safety factor depending upon safety margin) by
manipulating the choke opening. Always be cautious not to allow pressure to
shoot up too much or fall below the initial SICP.
1
If killing could not be started immediately then driller should maintain SIDPP
on the gauge constant by regularly bleeding mud through choke after a rise of
around 50-100 psi on SIDPP gauge.
If SIDPP is not available due to NRV in the string, then to read SIDPP value:
 Pump very slowly (2-5 SPM) and watch SICP gauge.

 When the SICP gauge deflects then the pressure showing on the D/P
pressure gauge is the SIDPP value.
Driller’s Method: In this method the well is killed in two circulations.
 First Circulation
a) Bring the pump up to kill speed in steps of 5 SPM, gradually opening
the choke holding casing pressure constant.
b) When the pump is up to kill speed, maintain drill pipe pressure constant.
c) c) Circulate out the influx from the well maintaining drill pipe
pressure constant.
d) d) When the influx is out, stop the pump reducing the pump speed in
steps of 5 SPM, gradually closing the choke, maintaining casing
pressure constant. Record pressure, SIDPP and SICP should be equal
to original SIDPP.
Note: In case recorded SIDPP & SICP are equal but more than original SIDPP
value, it indicates trapped pressure in wellbore. Whereas if SICP is more than
original SIDPP, it indicates that some influx is still in the wellbore.
 Second Circulation
a) Line up suction with kill mud.
b) Bring the pump up to kill speed in steps of 5 SPM, gradually opening

the choke, holding casing pressure constant.
c) When the pump is at kill speed, pump kill mud from surface to bit
(String strokes + Surface line volume), maintaining casing pressure
constant.
d) Pump kill mud from bit to surface (Total annulus strokes), maintaining
drill pipe pressure constant.
e) When the kill mud reaches surface, stop the pump reducing the pump in
steps of 5 SPM, gradually closing the choke maintaining casing
pressure constant. Record pressures, SIDPP and SICP both should be
equal to zero.
Open & observe the well. Add trip margin (0.2-0.3 ppg or 0.025-0.035 gm/cc)
before resuming normal operation.
Wait & Weight Method: In W&W method killing is done directly with Kill
Mud Weight in one circulation. This method is preferred when:
Open hole volume is more than drill string volume and pressure safety margin
is small. (Pressure safety margin is initial MAASP – SICP).
While waiting for KMW preparation driller should maintain proper BHP
maintaining SIDPP constant within +100 psi range by frequently bleeding
through choke.
Killing Procedure (Wait and Weight Method):
a) Line up suction with kill mud.
b) Bring the pump up to kill speed in steps of 5 SPM, gradually opening
the choke, holding casing pressure constant.
c) When the pump is at kill speed, pump kill mud from surface to bit,
maintaining drill pipe pressure as per step down schedule( during this
step drill pipe pressure will fall from ICP to FCP ).
d) Pump kill mud from bit to surface, maintaining drill pipe pressure
constant equal to FCP.
e) When the kill mud reaches surface, stop the pump reducing the pump
speed in steps of 5 SPM, gradually closing the choke maintaining
casing pressure constant. Record pressures, SIDPP and SICP both
should be equal to zero.
Open & observe the well. Add trip margin (0.2-0.3 ppg or 0.025-0.035 gm/cc)
before resuming normal operation.
Volumetric Method
It is applicable for Gas influx only in the situations like:
1. All nozzles of Bit plugged.
2. Gas influx is below the bit while tripping.
3. Drill pie is parted or mud cut above the influx position.
4. Well is closed on Blind ram without string.
Volumetric killing is accomplished in two steps, namely ‘Bleeding’ &

‘Lubrication and bleed ’.
j) Bleeding:
In bleeding operation the influx is allowed to migrate and BHP is maintained
by bleeding mud hydrostatic equivalent to pressure rise .This brings the influx
to the surface in steps.
DIC/Tool pusher has to prepare a plan for bleeding in advance by calculating
the volume to bleed for the working margin pressure.
Calculation in API units for Volume to bleed
Volume to bleed in bbls.=
Working margin pr (psi) x Annular capacity (bbl/ft) (OH x Tubular)
0.052 x Mud Wt (ppg)
Suppose the recorded SICP is 500 psi and the calculated volume to bleed is 5
bbls.
a) Allow the casing pressure to increase by pre-decided safety margin
about 100psi (500+100=600 psi)
b) Allow the Casing pressure to increase further by working margin (say
30 psi) (600+30=630 psi).
c) Bleed mud through choke taking returns into a small measuring tank
allowing the casing pressure to drop by working pressure only and
then close the choke.
d) Allow the pressure to rise back and bleed mud in steps the same way
for total 5 bbls required for decrease of Working margin pressure (30
psi in this case) equivalent of HP.
e) This procedure should be repeated until gas reaches surface.
Thereafter, Lubrication technique is to be used for reducing the casing
pressure.
Lubrication and bleed
The lubrication technique is used to Kill the well/ reduce the casing pressure
when gas is at the surface so that other operation such as tripping / stripping
can be performed.
Again calculation for volume pump-in to increase the HP by working pressure

margin is to be done prior to commencing lubrication.
Volume to pump-in (bbls) =

Working margin pr (psi) x Ann Cap ( bbl /ft) (Cased Hole x Tubular)
0.052x Kill Mud Wt (ppg)
Kill Mud Weight = OMW + SICP/(0.052 x Ht. of Gas Col. after bleeding)
Height of GAS COLUMN = Total Pit Gain/Annular capacity
Suppose for this case the Volume to pump-in for Working pressure Margin
increase is 4 bbls.
1. Slowly pump KMW through kill line while watching casing pressure
and pump till the pressure rises by working pressure margin (100 psi in
this case). Allow the mud to fall or lubricate through the gas. This is a
slow process, but can be speeded up by using a low yield point mud.
2. After sufficient delay for lubrication of mud bleed gas through choke
until the surface pressure is reduced by working pressure margin (100
psi in this case). In no case mud is to be bled off.
3. Repeat the process until all of the gas has been bled off and KMW is
seen at choke. Also at this point the casing pressure should read around
ZERO.
Note: During the pumping and gas bleeding process, it will usually be
necessary to decrease the volume of mud pumped before gas is bled off
particularly near the end of the operation. This is because the annular volume
occupied by the gas decreases with each pump & bleed sequence. Watch the
pumping pressure closely and when it reaches 50-100 psi above the shut in
casing pressure, stop pumping. Measure the volume of mud pumped,
calculate the hydrostatic pressure of that volume in the annulus and bleed
sufficient gas to drop the casing
pressure by the amount of hydrostatic pressure plus any increment of trapped
pressure because of pumping operation.
Volumetric process is applied in cases where no other option is available for

normal killing.
General instructions for crew while killing
1. While killing, there should be a proper co-ordination between driller at
Drillers console and DIC/Tool Pusher at choke.
2. Mud chemist should monitor Mud density in and out, pit level and ensure
correct mud weight is pumped into the well.
3. MAASP value for the section being drilled should be clearly displayed in
the Drillers Cabin and should be updated with every change in mud
weight.
4. All abnormal observations should be immediately brought to the notice of
DIC/Tool pusher/Driller.
5. All the rig man /Top man should assist the Mud chemist for recording the
mud parameters and mud preparation.
6. Assistant to driller should stand by with driller and co-ordinate for all the
preparedness for killing operations.
7. Rig mechanics should ensure availability of all the equipment specially
hoppers, mud pumps, Vacuum Degasser and shale shaker.
8. Rig should hold frequent meetings for making the crew aware about their
respective roles during well killing situation.
9. The Rig manager/Area manager should ensure that the all Drillers and
DIC/Tool Pusher at rig must be holding valid well control certificate.
k) Common Well Killing Problems:
SN Indications Problem Action required

1 Rapid increase on D/P and Casing Plugged Stop Pump
pressure gauges. May lead to Choke Close HCR
fracture/loss if not attended Line up other
immediately. choke.
2 Continuous choke closure to Choke Stop Pump
maintain pressure schedule. May Wash Out Close HCR
lead to excessive BHP drop and Line up other
additional influx into the well. choke.
3 Sudden decrease in Drill Pipe Pump Shut-in the well
pressure and casing pressure as failure ( and plan for
well. Also the Pump SPM showing Electrical) killing with other
zero reading. May lead to pump.
excessive BHP drop and additional
influx into the well.
4 Sudden increase in D/P pressure Bit nozzle Stop pump in steps
only. No change in SICP partially of 5 SPM
plugged maintaining casing
pressure constant.
5 Sudden one time drop in D/P Nozzle Stop pump in steps
pressure but no change in casing wash out of 5 SPM
pressure. maintaining casing
pressure constant.
6 Increase in drill pipe pressure is Annulus Shut-In the well
erratic and not responding to pack off and analyze.
choke operation.
7 MVT/PVT showing partial loss Induced Reduce Pump
loss speed
8 Rotary hose suddenly vibrating Suction Shut-In the well
problem and analyze.
9 Gradual drop in D/P pressure with Pump side Stop pump in steps
no change in casing pressure. /string side of 5 SPM
leakage maintaining casing
problems pressure constant.
l) References:
1. API STD 53: Standards for Blowout Prevention Equipment Systems
for Drilling Wells
2. API-RP 59: Recommended Practices for Well Control Operations
3. API-RP 64: Recommended Practices for Diverter Systems
Equipment and Operations
4. API-SPEC 16C: Specifications for Choke and Kill Systems
5. API-SPEC 16D: Specifications for Control Systems for Drilling Well
Control Equipment
6. API-SPEC 16R: Specification for Marine Drilling Riser Couplings
7. OISD-RP-174: Recommended Practices for Well Control
8. Well Control Manual, IDT
Rig: Project: Date:

Well: Time:
Driller: Trip sheet no.: Depth:
Reason for trip:
No. Of stands up to casing shoe:
m) Formats:
No of Steel Vol. Cum. Cum. Variation Cum. Remarks

stands displ. Pumped Steel Mud Variation
p/o Vol. In from trip displ. Vol. vol.
tank Filled
Cu.m. Cu.m. Cu.m.

Cu.m.
Pull Tick Displacement 8’’ D/C 6 ½” D/C 5” 5”HWDP
out DP
Even Length (m)
Single Cu.m./m
Double Cu.m/std.
Stand
Volume cu.m.
Signature of Shift In Charge Signature of Shift Chemist

Pit Drill (While Drilling)
Rig: Project/Asset:
Well No.: Date:
This is conducted/practiced during the drilling operation. The call for kick is
given by DIC/Tool pusher/Shift in charge by shouting or by lifting the flow meter flap
on the mud return channel. The person at break takes the action i.e. stop rotary, lift the
Kelly such that the tool joint comes to above rotary. Stop pump and check flow.
Following check to be made:
1. Call by DIC/Shift in charge__ Shouting / Flap raising
2. Rotary stop
3. String lifted
4. Mud pump stopped
5. Man at flow channel_
6. Man at R. panel/ Koomey unit

(for shut in well if required)
7. Response time_
(From first call given for readiness
to actual closing of BOP)
Sign:
Name:
Designation:
(DIC/Shift in charge)
Note:
1. Minimum frequency one drill per week per shift during drilling.
2. Please check the hole condition before conducting the drill.
3. Please record in the DPR
4. Response time should be 1 minute or less.
BOP Function Test Format
Asset / Basin: Field: Well No.:

Rig: Date:
1. Specifications
(i) Diverter
Mfg. ………………. Model ……………….. Size ………………..
Rating ……………… Volume: Close………… Open ………………
(ii) Annular preventer
Mfg. ………………. Model ……………….. Size ………………..
Rating ……………… Volume: Close………… Open ………………
(iii) Ram preventers

a. Mfg. ………………. Model ……………….. Type ………………..
Size: ………………. Rating ………… Volume: Close……Open ……
b. Mfg. ………………. Model ……………….. Type ………………..
c. Mfg. ………………. Model ……………….. Type ………………..
(iv) Choke manifold

Mfg. ………………. Model ……………….. Size ………………..
Rating ………………
(v) Kill manifold

Mfg. ………………. Model ……………….. Size ………………..
(vi) BOP Control Unit

Mfg. ………………. Model ……………….. Capacity…………..
Rating ……………… Pre-charge pressure ………………
Operating fluid ……… Operating pressure building time ………sec.
Charging system ……………………..
Alternate charging system ………………………….
2. Control unit operated:

(i) Rig floor mounted ( )
(ii) Accumulator system ( )
1
Pressure Test Format
Asset / Basin: Field: Well No.:

Rig: Date:
1. Specifications
(i) Diverter
Mfg. ………………. Model ………………..
Size ……………….. Rating ………………
(ii) Annular preventer
Mfg. ………………. Model ………………..
Size ……………….. Rating ………………
(iii) Ram preventers
a. Mfg. ………………. Model ……………….. Type ……………
Size: ………………. Rating …………
b. Mfg. ………………. Model ……………….. Type
……… Size: ………………. Rating …………
c. Mfg. ………………. Model ……………….. Type ………… Size:
………………. Rating …………
(iv) Well Head
Manufacturer………………………………………………………………
Section size ……………Rating ………………… psi
(iv) Choke manifold
Mfg. ………………. Size ………………..
(iv) Kill manifold
Mfg. ………………. Size ………………..
2. Date of BOP stack installation ……………………………………

3. Test conducted by ……………………………………………….
4. Test fluid………………………………………..........................
5. Test Plug …………………………………………………………
Pressure Test Format
6. Results of Test
SN Type of Preventer / Test pressure Period of test Remarks
equipment (minutes)
Low High Low High
1 Annular preventer
2. Upper pipe ram
3. Lower pipe ram
4. Blind/ Shear rams
5. Well head
6. Kill line hydraulic valve.
7. Kill line Manual valve
8. Kill line choke valve
9. Choke line hydraulic valve
10. Choke line manual valve
11. Choke manifold
12. Kill manifold
13. Inside BOP
14. FOSV
15. Lower Kelly cock
16. Upper Kelly cock
17. Swivel
Note:
i) Valves on casing head below plug tester should be kept open during the
test to verify leakage through plug tester.
ii) High pressure test should be limited to rated working pressure of the
weakest member exposed to the test pressure.
iii) Record total testing time: minutes
iv) Any leakage flange connection / joint found?
Yes ………………………… No …………………………………
If yes, what measures taken and time required to rectify
……………………..
v) Special attention needed to
……………………………………………………
Signature of S/I: Signature of T/P:

Name: Name:
Designation: Designation:
12 Wire Ropes
Wire rope is an important part of all rig operations viz: hoisting in Drilling,
tripping, material handling, tightening in tong lines etc. Wire rope consists of a
group of strands laid helically around a core. The strands of a wire rope consist
of a number of individual wires laid about a central wire.
All wire ropes have specific application and performance. With many
specialized operations required for efficient well drilling, it is important to
select ropes that are best suited for each application. Care, handling and
maintenance of wire rope are of utmost importance.
The chapter includes the following topics:
a) Specification of Wire Rope
b) Care while handling the wire rope reel
c) Reeving casing line on blocks before raising mast
d) Replacement of casing line during operation
e) Casing line slip and cut procedure
f) Care of wire rope during service
g) Drilling line and sheave diameters
h) Calculation of Work Done by Casing Line
i) Attachment of U-clamps on wire rope
Specification of Wire Ropes (as per API 9B)

Wire Rope can be specified by indicating the parameters such as
i) No. of wires & strands
ii) Lay- Direction and length of of twist of wires in a strand and of the
strand forming a wire rope.
iii) Core- The heart of wire rope around which strands are laid up. e.g.
Fibre, independent wire rope
iv) ) Length- in feet or metres
v) Size- Diameter in mm or inches.
vi) Construction - no of strands, no of wires in a strands and type of strand
i.e. Seale – The two outer layers of wires in the strands have similar no of
wire ,
Warrigton – Alternative sizes of wire in the outer or inner
layer of the strand &
Filler – An inner layer of wires in the strands to fill the valleys between
larger wires.
vii) Finish – Coating to protect against corrosion
viii) Quality – The tensile strength of the wire in the rope controlling the
breaking strain e.g. Plow , Improved Plow
Example : 5000 ft, 1-1/8”, 6 X 19 Seale, RLRL, IPS, Preformed, IWRC
 5000 ft- rope length

 1-1/8”- rope diameter
 6 x 19 Seale - rope construction
 RLRL- strand and wire twisting in rope
 IPS- grade of steel
 Preformed- Preformed or not
 IWRC- type of core
Table: Drilling Line Sizes for different rigs in ONGC
Wire Rope Size 29mm 32mm 35mm 38mm

(1 1/8’’ ) (1 ¼’’) (1-3/8’’) (1 ½’’) or more
Type of RIG Cardwell E-1400 E-2000 E-3000
F-4900 F-6100 Floater
BI-1500 BI-2000
E-760 Offshore Jack-up
F-3050 ARMCUE-1320
Table: Wire rope size for tong lines

Tong Hanging Line 14 mm
Tong Pull Line 19 mm
Tong Safety Line 22 mm
a) Care while handling the wire rope reel:

1. Do not drop the wire reel on any hard or sharp while unloading from a
truck.
2. Use crow bar against drum rim only for moving the reel and not
against the rope.
3. Protect wire rope reel from mud/water as it may lead to rusting/
corrosion.
4. Store wire rope in properly lubricated condition to minimize the
effects of corrosion on wire rope.
5. Never use wire rope in an arc welding circuit as it damages line.
6. Always protect the rope from the flame and sparks while cutting/
welding.
7. Do not lift wire rope reel with wire rope sling which may crush the
wire.
b) Reeving casing line on blocks before raising mast:
1. While reeving casing line, travelling block should be placed on
horizontal pipe walk and the mast on bigger horse.
2. Casing line is reeved with the help of crane from deadline anchor
sheave through both blocks to fast end of draw works. Precaution may
be taken so that the kinking of wire rope does not take place.
3. After reeving is complete, ensure fast end and dead end of casing line
are secured properly.
c) Replacement of casing line during operation:

1. The travelling block should be hung/ supported in a vertical position
as close to rotary table as possible.
2. Cut the old line near old wire rope drum and replace the old drum
with the new one.
3. Connect the old line to the new line with a snake grip suited to the
particular casing line size.
Snake grip
Note: Never weld the new casing line to the old one.
4. Care should be taken to see that the grip is properly made up.
5. Loosen the dead line anchor and slowly reeve the old drilling line
completely on the draw works drum and pull enough (6-9 wraps) of
the new rope on the drum.
6. Secure the new line so that it will not run back through the blocks.
7. De-reeve the line and remove the snake grip.
8. Remove the old line completely from the drum by reverse rotation and
discard the same.
9. Connect the new line into fast end wedge on the draw works. Reeve
new line on the drum to take load ensuring proper wrapping in the
drum grooves and remove the securing line.
10. Check the condition of brass inserts in clamp and replace if worn.
11. Tighten deadline anchor bolts to recommended torque in proper
sequence (cross tightening). Over-torquing may damage the wire.
12. After anchoring casing line at the dead end, raise the travelling block
and take off the hang off line.
13. To ensure proper wrapping and tensioning of the wire line, lower the
travelling block through the V-door and reeve again casing line on
drum under load.
Note: Do not install a new casing line just before setting a heavy load of
casing. New or unused rope is more susceptible to crushing than a rope
that has been in service.
d) Casing line slip and cut :
Service life of casing lines is increased substantially by following a planned
slip and cut program based on work performed. This shifts the bending points
of the wire rope through the system so wear is spread out uniformly along the
entire length of the rope extending its service life.
It is recommended to slip and cut casing line at casing shoe during RIH as it
gives more time to understand well behavior. Slip and cut at casing shoe
during POOH and with bit out of hole should be avoided for safety of well.
The following two slip and cut programs are followed on rigs:
A. Slip and cut casing line each time
B. 3/4 slips followed by and cutting entire slipped length of last 3/4 slips
Procedure:
1. Disengage Twin Stop / crown-o-matic before slip and cut.
2. Before slip and cut, rest the drill string in slips as low as possible and
with FOSV installed in open position.
3. Hang/ support travelling block in a vertical position as close to rotary
table as possible.
A. Securing the travelling Block on onshore rig
a. Hang / Support the block on hang off line using the D-
Shackle of appropriate strength with hang-off line properly
suspended on Mast
b. If there is no string in the hole, Rest the travelling block on
rotary prior proceeding for Cut of casing line
B. Securing the travelling block on offshore rig
a. Use the wedge with proper u-clamps and chain of proper
strength to suspend the travelling block (fast line U-clamped
with the line from the wedge) to the base of rig floor through
the means of wedge. On releasing the brake the chain will
take the load of travelling block, fast end of casing line will
be free for de-reeving.
4. Ensure that the casing spool is free to rotate and pay out the wire.
5. Loosen the dead line anchor bolts and slip the desired length/no. of
wraps of casing line using braking lever.
1
6. Ensure proper spooling on draw works drum by maintaining
2
sufficient tension on the rope.
7. Tighten deadline anchor bolts to recommended torque in proper
sequence (cross tightening). Over-torquing may damage the wire.
8. Put paint mark on dead end wire to check for any line slippage during
operations. Do not use U-clamps for this purpose.
9. For slip and cut program, secure the fast line so that it does not
accidentally run back through the block.
10. De-reeve the calculated length of wire till cut point is reached by
reverse rotation of draw works.
11. Cut the used up line, open the fast end wedge/ clamp and remove
from drum.
12. Attach the end of new line into fast end wedge/clamp of the draw
works and secure.
13. Reeve the wire on drum. Minimum wraps should be 5-6 on grooved
drum, for the closest (lowest) position of travelling block to rotary
14. Raise the travelling block and disconnect hang-off line.
15. To ensure proper wrapping and tensioning of the wire line, lower the
travelling block through the V-door and reeve again casing line on
drum under load.
16. Pick up on blocks. Lower the block fast and apply brakes to ensure
both the clamps are secured satisfactorily and tripping can be resumed
safely.
17. Whenever possible, a new wire line should be run under controlled
loads and speeds for a short period after installation as it will help to
adjust the rope to working condition.
18. When following program-B, it is most important to get the first drum
layer full and tight without overcrowding at the ends during
subsequent slips so that it will support the succeeding layers. Step No-
8 to 12 is not applicable for this.
e) Care of wire rope during service:

1. Never strike the wire rope with hammer or crow bar directly; it may
cause kinks or bruises.
2. Use a wooden block between hammer and rope while hitting wire line
for spooling it properly in the grooves on drum.
3. Do not allow the line to rub against any member of the derrick or
other substructure.
4. Ensure that brass bushings inside wire rope clamp are not worn out
otherwise it may damage the rope.
5. Turn-back rollers on draw works should be in good condition for
smooth change of directions of casing line at the ends of draw work
drum.
6. Whipping of line causes fatigue in line; therefore, a wire line stabilizer
(Rolly Guide) must be installed on fast line with all rollers in good
condition.
7. Vibration may cause fatigue failure of drilling line shortening its life.
It is most serious at the sheave at crown block leading to deadline.
Stabilizers should be used to avoid whipping of the dead line end.
8. All sheaves should be in proper alignment. The fast sheave should line
up with the center of the hoisting drum.
9. Sheave grooves in the crown and travelling blocks should be checked
periodically with the gauge.
Place sheave gauges in grooves as shown in figure below.
 Detail "A" reflects gauge fit in sheave and is OK.
 Detail "B" reflects gauge "fit" in a worn (tight groove) sheave.
 Detail "C" reflects gauge "fit" in a sheave where the groove is
too large.
Sheave grooves must neither be too small nor too large to avoid
damage to the line. Small grooves cause pinching and overheating
while large grooves allow flattening of the line.
10. Visual inspection and check of wire line viz broken wires, crushing;
kinks etc. should be carried daily.
11. A proper slip and cut- off practice should be followed and daily record
of work done by casing line should be maintained
12. Make sure dead anchor drum moves up and down freely at hinge pin
and is greased regularly.
13. All sheaves should be properly lubricated to ensure minimum turning
efforts.
14. Wire ropes are well lubricated when manufactured; however, the
lubrication will not last throughout the entire service life of the rope.
In corrosive environment area, if the rope is getting dried, it should be
lubricated with the used burnt oil available at the rig.
15. Avoid developing kink due to improper handling that may be caused
by pulling a loop in a slack line. Early rope failure will undoubtedly
occur at this point.
Kink
16. Avoid bird caging caused by sudden release of tension and resultant
rebound of rope from over loaded condition.
Bird caging
f) Drilling line and sheave diameters:
1. Bending reduces the amount of load casing line can carry.
2. Bending of casing line over sheaves causes re-adjustment of wires
and strands as well as bending of wires themselves and results in
fatigue failure and breaking of wires due to continuous bending.
3. To minimize the fatigue of the drilling line due to bending, sheave
diameters should be within the following limit:
Rope dia,
Sheave diameter, inches
inch
Recommended for Minimum for
(6 X19) rope (6 X 19) rope
8/7 93 62
1 54 93
1-1/7 43 95
1-1/5 42 97
1-9/7 26 51
1-1/6 28 54
4. When wire rope is used over sheaves that are too small its service life
is reduced.
g) Calculation of Work Done by Casing Line:

1. Excessive wear occurs in a few localized sections where rope makes
contact with travelling block sheaves and crown block sheaves at
pick-up points during tripping and on the drum where each wrap of
rope crosses over the rope on the layer below. If broken wires are
seen in these points of critical wear or any other point, then length of
wire rope up to damaged point should be discarded.
2. Slip and cut the rope in time otherwise sections of drilling line will be
worn to such an extent that there is danger of failure, injury to
personnel and damage to equipment.
3. Drilling line should be cut as per program to optimize rope service
life without compromising on safety of rig operation.
4. For an accurate record of the amount of work done by a drilling line, it
is necessary to calculate the weight being lifted and the distance it is
raised and lowered. On a drilling rig the loads and distances are so
heavy that we use "Ton-Miles." or “Tonne-Kms” for work done
calculations.
5. Most of the rigs are equipped with Ton-mile (Tonne-Kms) indicator.
Work Done by a Drilling Line during Round-Trip Operations:
Work done by wire rope can be calculated as follows:
1. Work done to pull out bit from L depth and running it back to same
depth with new bit,
TL= 0.98[pL(L+l)+4L(P+d/2)]10-6
Where
TL= Amount of work (in 103 daN.Km)
L= Depth of hole (m)
l= Length of a drill pipe stand (m)
d= (BHA weight–Weight of same length of drill pipe string) in
mud, Kg
p= Buoyant weight of drill pipe with tool joint in Kg/m
P=Total weight of Traveling block/elevator assembly (Kg)
Work Done by a Drilling Line during Drilling Operations:

Work done in round trip operations from L1 depth = TL1
Work done in round trip operations from L2 depth = TL2
Where L2 is deeper than L1.
Work done to drill from L1 to L2 depth = TL1-2= 3[TL2-TL1]103 daN.Km
Work Done by a Drilling Line during Coring Operations:

Work done to core from L1 to L2 depth = TL1-2= 2[TL2-TL1]103 daN.Km
Work Done by a Drilling Line during Casing Operations:

Work done casing line to run casing to L depth is as follows:
TL= ½*0.98[pL(L+l)+4LP]10-6
Where
TL= Amount of work done (103 daN.Km)
L= Depth of hole (m)
l= Length of a single joint of casing (m)
p= Buoyant weight of casing along with coupling in Kg/m
P=Total weight of Traveling block/elevator assembly (Kg)
Table: Cut Off Length and Wraps
Cut off length as a function of derrick and must height and drum diameter
Mast Height (ft)
Draw Works Drum Diameter (inch)

20 22 24 26 28 30 32 34 36
Cut off length in meters
&
No of wraps per cut off
151 Length 34.6 34.7 34.5 33.9 33
or
Wraps 15 ½ 14 ½ 13 ½ 12 ½ 11 ½
more
(1)
142 Length 25.9 25.9 25.7 27.5 26.8
to
Wraps 13 ½ 12 ½ 11 ½ 11 ½ 10 ½
150
133 Length 24.7 25.5 23.9 23.9 25.7 25.1 24.3
to
Wraps 15 ½ 14 ½ 12 ½ 11 ½ 11 ½ 10 ½ 9½
140
120 Length 23.1 21.9 23.9 23.9 23.5 22.7 24.3
to
Wraps 14 ½ 12 ½ 12 ½ 11 ½ 10 ½ 9½ 9½
132
91 Length 18.4 18.4 18.2 19.7 19.0
to
Wraps 11 ½ 10 ½ 9½ 9½ 8½
119
Note: The cut-off length given is a whole number of drum laps plus one half
laps in order to change rope cross over point, which is a point of high wear.
Table: Cumulative Work Done before First Cut off
Formation
Total work of drilling line before the first cut off
Derrick or Mast Height,
1" 1 1/8" 1 1/4" 1 3/8" 1 ½’
Ton Mile
Ton Mile
Ton Mile
Ton Mile
Ton Mile
daN.Km103
daN.Km103
daN.Km103
daN.Km103
daN.Km
103
Formation Hardness
Very hard 716 500

80
to Hard 716 50
0
87 Medium 716 500
Soft 859 600
Very hard 716 500 859 600
94
to Hard 716 500 1,003 700
Medium 716 500 1,146 800
100 Soft 859 600 1,289 900
Very hard 859 600 1,432 1,000
126 to Hard 1,003 700 1,575 1,100

131 Medium 1,146 800 1,719 1,200
Soft 1,289 900 1,862 1,300
Very hard 859 600 1,432 1,000
133 to Hard 1,003 700 1,575 1,100

138 Medium 1,146 800 1,719 1200
Soft 1,289 900 1,862 1,300
Very hard 1,432 1,000 2,292 1,600
142 to Hard 1,575 1,100 2,578 1,800
147 Medium 1,719 1,200 2864 2,000
Soft 1,862 1,300 3,008 2,100
Very hard 2,292 1,600 2,864 2,000
Hard 2,578 1,800 3,150 2,200
187 to
189 Medium 2,864 2000 3,437 2,400
Soft 3,008 2,100 3,724 2,600

Note:
1. For subsequent cut-offs, total work given in the table must be reduced
by 100 ton. mile (143*103 daN.km ) for 1-1/8 inch& smaller wire
ropes and by 200 ton.mile (286*103daN.km) for other wire rope
diameters
2. The table gives work done by Improved Plow Steel drilling line
before first cut off using a factor of safety of 5. If a different factor of
safety is selected, curve below gives the correction factor to apply to
the work given in the table above
Example:
Mast height = 138 ft; Wire rope diameter = 1-1/4";Drum diameter = 28 in
Drilling difficulties = hard; Factor of safety = 3
Value of work done 1,575*103daN.kmis obtained from Table: Cumulative

Work Done before First Cut offfor factor of safety 5.
Above curve gives a corrective ton mile factor of 0.58 for factor of safety of
3.
So work done with factor of safety 3 for slip & cut is
= 1,575*103* 0.58 = 914*103daN.km before the first cutoff
Table: Cut Off Length and Wraps gives cut-off length as a function of
drum diameter and it is 25.70 m (11-1/2 wraps) for 28 inch diameter drum.
h) Attachment of U-clamps on wire rope :
1. Always use the U-clamp of the same size as that of wire rope.
2. Ensure U-bolt clamps are attached correctly and in required numbers
as shown in picture below.
3. Turn back the specified length of rope.
4. Apply first clamp one base width from the dead end of the wire rope.
5. Tighten nuts evenly to the recommended torque.
6. Apply the next clamp as near the loop as possible. Turn on nuts firmly
but doProper procedure
not tighten.
7. Spacetoadditional
fit U-Clamps
clamps if required equally between the first two.
Turn on nuts, take up rope slack, and tighten all nuts evenly on all
clamps to the recommended torque.
8. Apply the initial load and retighten nuts to the recommended torque.
Rope will stretch and be reduced in diameter. Inspect periodically and
retighten nuts to the recommended torque.
9. The number of clamps shown in Table is based upon using Right Lay
Regular Lay (RLRL), or Right Lay Lang Lay (RLLL) wire rope, 6 x
19 class or 6 x 36 class, fibre core or IWRC, IPS or EIP. If Seale
construction or similar large outer wire type construction in the 6 x 19
class is to be used for sizes 1 inch and larger, then add one additional
clamp.
10. For other classes of wire rope not in this list, it may be necessary to
add additional clamps to the number shown. If a greater number of
clamps are used than shown in the table, then the amount of rope turn
back should be increased proportionately.
Table: Wire Rope U-Clamps:
Wire rope No of Length of rope Torque,

diameter, Inch clamps turn back, Inch N-m
1/8 2 3¼ 6
3/16 2 3¾ 10
¼ 2 4¾ 20
5/16 2 5¼ 41
3/8 2 6½ 61
7/16 2 7 88
½ 3 11 ½ 88
9/16 3 12 129
5/8 3 12 129
¾ 4 18 176
7/8 4 19 305
1 5 26 305
1-1/8 6 34 305
1¼ 7 44 488
1-3/8 7 44 488
1½ 8 54 488
1
TABLE – Field Troubles & Possible Causes as per API 9B
Field Possible Cause

Troubles
Rope Overloading, kinking, damage, localized wear, weakening
broken (all of one or more strands, or rust-bound condition, loss of
strands) elasticity or loss of metallic area due to broken wires.
One or more Overloading, kinking, divider interference, localized wear, or
whole rust-bound condition. Fatigue, excessive speed, slipping, or
strands running too loosely. Concentration of vibration at dead sheave
parted or dead-end anchor.
Excessiv Lack of lubrication. Exposure to salt spray, corrosive gases,
e alkaline water, acid water, mud, or dirt. Period of inactivity
corrosion without adequate protection.
Rope damage Rolling reel over obstruction or dropping the reel. The use
by careless of chains for lashing, or the use of lever against rope instead
handling in of flange. Nailing through rope to flange.
hauling to
the well or
location
Damage Improper seizing which allows slack from one or more
by strands to work back into rope; improper method of
improper socketing or poor workmanship in socketing, frequently
socketing shown by rope being untwisted at socket, loose or drawn.
Kink Kinking the rope and pulling out the loops such as in
improper coiling or unreeling.
Permanent Improper winding on the drum. Improper tie down. Open-
bends (“dog drum reels having longitudinal spokes too widely spaced. The
legs”) or addition of improperly spaced cleats to increase the shipping
other reel diameter. Stressing while rope is over small sheave or
distorted obstacle.
places or
Damage Rope improperly used on a fishing job, resulting in damage
failure on or failure as a result of the nature of the work.
a fishing
Lengthening Allowing a wire rope to rotate (single part line or wire ropes
of lay and dead ended in a swivel) or produced by some type of
reduction of overloading, such as an overload resulting in a collapse of
diameter the fiber core in swabbing lines.
Excessive Kick over points and change of layer points on the drum.
wear in spots Kinks or bends in rope due to improper handling during
installation or service. Divider interference; also, wear against
casing or hard shells or abrasive formations in a crooked hole.
Too infrequent cut-offs on working end.
Spliced rope A splice is never as good as a continuous piece of rope, and
slack is liable to work back and cause irregular wear.
Abrasion and Damage due to slipping rope through clamps.
broken wires
in a straight
line Drawn or
loosened
strands Rapid
fatigue breaks
Reduction in Excessive heat due to careless exposure to fire, torch or
tensile strength electrical arc. All wear and deterioration of a wire rope during
its service life reduces the wire rope’s strength.
Distortion of Damage due to improperly attached clamps or wire rope clips.
wire rope Drum crushing.
High strands Slipping through clamps, improper seizing, improper socketing
or splicing kinks, doglegs, and core popping.
Wear by Lack of lubrication. Slipping clamp unduly. Sandy or gritty
abrasion working conditions. Rubbing against stationary object or
abrasive surface. Faulty alignment. Undersized grooves in
sheaves. Occurs in normal operation over time.
Fatigue breaks Normal wear mode that may be accelerated by excessive
in wires vibration due to poor drilling conditions, i.e., high speed, rope
slipping, concentration of vibration at dead sheave or dead-end
anchor, undersized grooves and sheaves, and improper selection
of rope construction.
Spiraling or Allowing rope to drag or rub over pipe, sill, or any object
curling (“pig during installation or operation. It is recommended that a
tail”) block with sheave diameter 16 times the nominal wire rope
diameter, or larger, be used during installation of the line.
Excessive Heavy load, loose winding on drum, or cross winding.
flattening or
crushing
Bird-caging or Sudden unloading of line such as hitting fluid with
core popping excessive speed. Improper drilling motion or jar action. Use
of sheaves of too small diameter or passing line around
sharp bend.
Whipping of Wire rope run at high speeds with light loads. Harmonics.
rope Running without line guides or stabilizers.
13 Safety in
Drilling
Operations
Safety is of vital importance in all drilling and well operations at rig.
Adhering to safe working practices is the responsibility of each individual who
is involved in drilling of a well. It enhances company’s image as ‘Safe &
Responsible’ organization.
Drilling of a well involves various hazardous operations and requires a

proactive Safety Management System (SMS). Safety does not mean safety of
the human beings only, but it is redefined as ‘Loss Control’. Loss Control
encompasses safety, occupational health, property damage, process loss and
consequential environmental impact. Commitment to safety is vital at all
organizational levels as it manages costs, improves overall management of
operations and fulfills statutory / regulatory requirements.
This chapter covers the safety aspects of following topics:

(a) Rotary slips
(b) Power tongs
(c) Rotary Table
(d) Cat Heads
(e) Derrick Floor Area
(f) Hot Job (Gas Welding / Cutting)
(g) Hot Job (Electric Arc Welding)
(h) Pumping & Pressure Testing Job
(i) Air hoists/winches
(j) Important Safety Points
(a) Rotary slips:

1. Never use damaged/ worn-out slips.
2. Always use proper size of slips.
3. Ensure that welding is not done on any part of the slips.
4. Always change complete set of dies.
5. Always use safety goggles while changing dies.
6. Dope should be applied regularly on outer load bearing
surface of slips to facilitate easy removal of slips.
7. Ensure hinge pins are free and segments move freely.
8. Slips should be inspected regularly using a steel scale to detect any
uneven wear on back of segments.
9. Never use slips to stop downward motion of the pipe. Use draw
work brakes instead.
10. Never kick the slips in rotary bowl while RIH.
11. Do not let the slips ride the pipe while POOH.
12. Always keep slips’ dies free from mud and dirt.
13. Hold the slips with the palms facing upward.
14. Persons working on rotary should use proper posture to remove
slips to avoid injury to the back.
(b) Power tongs:

1. Never use damaged tongs.
2. Ensure that welding is not done on any part of the tong
3. Use both the tongs for making and breaking out tubulars.
4. Tongs should always be used with safety line of proper size
and length.
5. Ensure the strength of safety line is more than break out line
strength of the tongs.
6. The ends of tongs safety line should be spliced/ secured with
recommended number of wire line U-clamps.
7. Recommended line sizes are:
o 16 mm: Tong hang off line
o 19 mm line: Pull-line of Make-up tong
o 22 mm line: Break out line
o 25 mm line: Ezy-Torq line/ Back-up line for tongs
8. The tong dies should be kept clean and checked for wear. If worn
out, replace immediately.
9. Adjust tong counter balance for easy up and down movement of
tongs.
10. Hang tongs properly by adjusting balancing screw.
11. When tongs are not in use, secure properly in the derrick.
12. Grease hinge pins regularly.
13. Line-pull gauge should be used to ensure recommended torquing.
14. No jerk should be applied to any pull line or safety line. As
these are not designed for shock loading.
15. During crack opening/ final tightening, all rig floor personnel
should be in safe position. No person should stand behind
tongs in tong swing zone.
16. Never use smaller size pin in a bigger size hole in a hinge to
prevent damage to the pin hole. Use only proper size of tong jaw
pin.
17. Tongs should be at 90 degree to pull/ safety line when final
tightening is carried out.
18. Do not apply tongs on pipe body as it may crush or damage the
pipe.
19. Inspect pull lines, safety lines, tongs hang-off lines and all pulleys
periodically and replace as and when required.
20. Do not use tongs on any mouse hole operation when Kelly is
rotating as it may lead to serious accidents.
21. Hydraulic cathead (Ezy-Torq) should be used for making up/
breaking out joints requiring torque more than make-up cathead
capacity, normally for 8” or bigger size drill collar.
22. Monkey tongs should never be used for cracking open and final
tightening of tubular joints during tripping as it is meant only for
initial tightening and opening of joints.
(c ) Rotary Table:
1. Rotary table gear, driving chains and sprockets should be secured
with proper guards.
2. Driller should start the rotary only after ensuring rotary table is
clear of all material/ personnel.
3. Check both mechanical locks are working. Never use mechanical
lock of the rotary table to stop rotary motion.
4. Rotary table should not be used for crack opening or tightening of
tubular joints.
5. Set rotary torque limit based on drill string in use.
(d) Cat Heads:

1. Crew members should be watchful and careful while operating
cat head.
2. The driller must be vigilant to stop rotation of the cat head, in
the event of any emergency.
3. Three safety rules to keep in mind when using a cat line on
cat head are :
a. Never add more than necessary wraps on the cathead.
b. Driller should always be on the controls to stop power to
cathead in case of emergency.
c. Crew member should never stand on coil of surplus cat line on
the floor.
4. Never use damaged cat lines or jerk lines on cathead.
e) Air winch:
1. Ensure rig air supply pressure of 120-125 psi for effective pull
capacity of air winch.
2. When hoisting line is spooled off the drum, at least six wraps
should be on drum to avoid complete lines removal from anchor
clamp on drum.
3. Use man rider winch for lifting rig personnel.
4. The winch operator should always be vigilant while operating
winch.
5. Winch line should be secured with an anchor/ safety line while
lifting light load to avoid winch line flying off in derrick.
6. Operate winch smoothly and without jerks. Make sure that winch
line and loads are moving with same speed.
7. Do not lower winch further if load is stuck in derrick/ mast to
avoid falling down of load in case of sudden release.
8. Ensure rig personnel operating winch are not wearing any loose
clothing.
9. Never operate winch without drum guard.
10. Periodically check winch brake shoe to ensure safe operation.
11. Load being lifted should always be visible to the winch operator
12. Winch should not be used to lift more than recommended load
capacity
13. Check winch foundation bolts regularly
14. Check wire rope regularly and replace if required
15. Check wire rope pulley mounted on crown block and grease
regularly
16. Operator should never leave the winch even in locked condition
unattended when load is on the winch
17. Use only certified shackles of proper load capacity.
18. Make sure winch line is not entangled anywhere in the derrick/
mast.
(f) Rig floor:
1. Wear PPE at all times
2. Ensure Top man safety belts are in proper condition.
3. Ensure Top man escape device is working properly.
4. All guy ropes are properly anchored.
5. Ensure fall arresting device is working.
6. Ensure Toe Board around Derrick Floor is available.
7. Check BOP Accumulator unit is charged to required pressure:
 Accumulator pressure: 3,000 psi;
 Manifold pressure: 1,500 psi
 Annular pressure: 600-1,500 (As required).
8. Ensure proper illumination of derrick floor and mast.
9. Ensure aviation light is in working order.
10. Ensure IBOP and FOSV are available on the rig floor in open
position and with required cross overs.
11. Avoid swinging of travelling block.
12. Do not lift any tubular to derrick floor when rotary is in motion to
avoid accident.
13. During casing operation, crane should be visible from rig floor
and only designated person should give signal.
14. Use balancing rubber strap on elevator for easy operation of
elevator.
15. Never use mobile phone at Derrick Floor.
16. Ensure Crown-O-Matic/ Twin Stop is functioning properly.
17. Avoid water wastage as it may lead to water logging in the site.
18. Escape routes from the rig floor should remain unobstructed at all
times.
19. Ensure that mouse hole and rotary are covered when not in use.
20. Ensure proper house keeping
 Rig floor should be kept clean and non-slippery.
 All un-wanted material should be off loaded from the rig floor.
 All drilling handling tools including power tongs, elevators, slips
etc. should be properly arranged.
 Ladders and the railings and steps of stairs should be in order.
(g) Hot Job (Gas Welding/Cutting):

1. Obtain Hot Work Permit prior to any Hot Job.
2. Use goggles, hand gloves, face shield/helmet with dark glasses and
cotton overalls with full sleeves.
3. All oxygen lines and fittings should be free of oil or grease.
4. Ensure pressure gauges are functioning properly.
5. Operate cylinder valves slowly to avoid sudden release/ pressure
surging.
6. When welding in vicinity of flammable material, beware of flying
sparks and hot slug. Keep fire extinguishers ready close by.
7. Ensure Spark Arrestor (Non return safety valve-NRV) is installed
to avoid back fire.
8. Never carry out hot job in an enclosed area/tank unless it is
properly ventilated and all necessary safety measures are in place.
9. Never use gas cylinders as work supports.
10. Store acetylene and oxygen cylinders separately with proper cap.
11. Never keep cylinders near source of heat.
12. Never weld galvanized or coated metals without taking due
precautions.
13. Use trolleys to transport cylinders to avoid crushing or damaging
hoses.
14. Only authorized and qualified welder should be allowed to carry
out any gas welding job.
(g) Hot Job (Electric Arc Welding):

1. Designate and display “Welding Area” properly.
2. Use certified electrode holder and welding cables.
3. Before carrying out any electric welding job, hot work permit should
be issued and ensure all the safety measures and precautions are in
place.
4. Ensure that shield of helmet has the correct filter glass.
5. Wear adequate personal protective gears like full-sleeve overall,
leather gloves & shock proof shoes etc.
6. Ensure that cables and connections are in good condition.
7. Make sure that the welding equipment; bench or work piece is
properly earthed.
8. Weld inside enclosed vessels only after necessary safety measures are
in place.
9. Protect welding transformer from rain/ water. Do not carry out welding
in rain/ wet conditions.
10. Only authorized and qualified welder should be allowed to carry out
any electric arc welding job.
(h) High pressure pumping & testing Job:

1. Safety meeting should be conducted prior to carry out any high
pressure pumping and testing jobs.
2. Individual job responsibility should be assigned to personnel involved
in operation.
3. Area of pressure testing should be clearly demarcated.
4. Flammable or combustible fluids are not to be stored in open tanks.
5. When pumping and carrying out pressure testing, ensure that:
a. High pressure lines are secured and anchored.
b. Pressure gauges are of proper pressure range and calibrated.
c. Safety valves are set at the recommended pressure and tested.
d. All pumping and pressure testing jobs should be recorded on
pressure-charts.
e. Only authorized personnel to be allowed in the operational area.
6. Surface pumping pressure should be limited to working pressure rating
of line and assembly parts viz union/chicksans/valves/cross-over etc.
7. After testing is over, ensure that pressure is completely bled off from
test lines before disconnecting lines.
8. Do not tighten any leaking joint without releasing pressure.
k) Important Safety Points:

1. Always conduct a safety meeting before starting a job on the rig floor to
discuss hazards involved and safety precautions to prevent untoward
incidents and accidents.
1
2. All work platforms that are 1.80 meters or more above ground level
shall be guarded by a standard railing at least 1.00 m high with toe
board of
0.15 m height.
3. Safety valve should be set at 10 % higher than the normal working
pressure. It must be calibrated and tested every year or as and when
required.
4. Air pressure vessels should be tested as per statutory guidelines.
5. All moving parts should have guards.
6. Portable Gas Detector must be calibrated every year.
7. Availability of Electrical Safety gadgets like Earth Leakage Relay
(ELR)/ Earth Leakage Circuit Breaker (ELCB), use of flame proof
equipment in classified zones, proper earthing of equipment, use of
proper PPE, rubber mats etc. should be ensured.
8. Rotary hoses must be fitted with safety lines also.
9. While working on any machinery/ equipment, ensure power is switched
off and lock-out permit is to be issued. Ensure ‘Man at Work’ signage is
displayed properly at necessary places like work place, control room
and rig floor.
10. In case BOP is closed, it should be clearly displayed at rig floor,
driller’s console and Accumulator Unit.
11. Portable Fire Extinguisher must be tested as per guidelines
12. Never allow any rig personnel under moving load at drill site.
13. Work Permit System like lock out permit, Hot and Cold work permit
should be adhered to.
14. All engines to be provided with discharge muffler and spark arrestor.
15. Engines are to be equipped with safety devices like over speed tripping,
low lube oil alarm and hot engine shut down etc.
16. Ensure dykes (bundh) around diesel tank and waste pit.
17. Fencing: around Drill site, Fire Water Tank, Oil Pit–Not less than 1.80
M in height.
18. Use certified mast pins/studs with proper lock pins/check nuts.
19. Material Safety Data Sheet (MSDS) should be made available at
operation site.
20. Ensure:
o Proper Rig Illumination.
o Good housekeeping.
o Safety Sign Boards and Hazardous Zones are displayed.
o Availability of round-the-clock emergency/ambulance.
o Availability of breathing Apparatus.
o Availability of safety torch.
o Availability of eye wash facility at hopper
o Availability of first aid kits.
o Wind socks are installed on the site to check wind direction.
o Disaster and contingency plan is displayed on site.
Availability of round-the-clock communication at rig site with alternate
means of communication.
14 Completion
1.1 Definitions Fluid
1.2 Completion Fluid Management
Completion fluid is a liquid used during completion of an oil / gas well. It is a
salt solution (clear brine) or low solid mud used during well testing,
completion
& remedial workover operations such as well killing, cleaning out or
perforating etc. It is intended to minimize formation damage, control
formation pressure and should be compatible with reservoir.
1.3 Packer Fluid
It is the fluid in the casing tubing annulus above the packer, after the packer
has been set. Packer fluid can be either the same completion fluid or any other
fluid displaced in the annulus above the packer after the completion operation.
2.1 Functions and Characteristics of Completion Fluid
2.2 Functions
1. Control the Formation Pressures.
2. Circulate and transport the solids.
2.3 Characteristics
1. Dense enough to balance formation pressure but not fracture the
formation.
2. As far as possible, should be solid free to avoid chocking of the
formation pores.
3. Non-corrosive to prevent failure of tubular and subsequent fishing job.
4. Stable for an extended period.
5. Avoid damage to the formation, down hole & surface equipment,
personnel and the environment.
6. Cost effective.
3.1 Types of Completion / Workover Fluid
The commonly used completion / workover fluid are water based fluids.
These are:
1. Clean, solids-free brines
2. Viscosified Brines
3. Conventional water base muds
3.2 Water Base Fluids
3.1.1 Clean, Solid-Free Brines
They are the most commonly used fluids in completion and workover
operations. These brines are true solutions containing only water and
dissolved salts. They may be used as single-salt brines or mixture of two or
three different salt compounds. Advantages of clear brines solution are;
1. Solids-free
2. Inhibitive
3. Available in a wide density range.
4. Capable of reuse.
5. Non damaging formation.
The most common types completion fluids used and the maximum density
which can be achieved by dissolving these salts at room temperature are listed
in Table A. & Fig A.
Table A: Commonly used Completion clear fluids and maximum

achievable density at room temperature
Max. Max.
Sol
Sl. Sp. Density
Brine Type Wt
No. Gr. Range
%
Range (ppg)
1. Potassium Chloride (KCl) 24 ≤ 1.16 ≤ 9.70
2. Sodium Chloride (NaCl) 26 ≤ 1.20 ≤ 10.0
3. Sodium Formate (NaHCO2) 50 ≤ 1.32 ≤ 11.1
4. Calcium Chloride (CaCl2) 40 ≤ 1.41 ≤ 11.8
5. Potassium Bromide (KBr) - ≤ 1.39 ≤ 11.6
6. Sodium Bromide (NaBr) 46 ≤ 1.52 ≤ 12.7
7. Potassium Formate (KHCO2) 78 ≤ 1.57 ≤ 13.1
8. Calcium Bromide (CaBr2) 57 ≤ 1.83 ≤ 15.3
Sodium Formate + Potassium Formate
9. - <1.52 < 12.7
(NaHCO2 + KHCO2)
Calcium Chloride + Calcium Bromide
10. - ≤ 1.81 ≤ 15.1
(CaCl2 + CaBr2)
11. Cesium Formate (CsHCO2) 84 ≤ 2.30 ≤ 19.2
Potassium Formate + Cesium Formate
12. - ≤ 2.20 ≤ 18.3
(KHCO2 + CsHCO2)
13. Zinc Bromide (ZnBr2) - ≤ 2.52 ≤ 21.0
Calcium Bromide + Zinc Bromide
14. - ≤ 2.30 ≤ 19.2
(CaBr2 + ZnBr2)
Max. SG at Room Temperature

2.5 2.
2. 5
3
1.
2 1. 83
1.
1. 1. 52 57
1. 41 39
1. 1. 33
1.5 16 2
0.5
KC N N Ca KB N K Ca Cs Zn
l aC a Cl r aB H Br H Br
0
H 2 r C 2 C 2
C O
Fig. A Maximum achievable density at room temperature
3.1.2 Viscosified Brines
Viscosified brines are used where additional parameters like bridging,

suspension, fluid loss control etc are required. Viscosifiers are added in clean
brine solution to attain rheological properties to hold the weighting material.
Bridging / Weighting Agents

1. Tri Manganese Tetra Oxide (Mn3O4) SG 4.8 can be used as
weighting agent to increase the density in Potassium Formate
and Calcium Bromide Brines.
2. Acid-soluble CaCO3 used both as a bridging & weighting agent. It is
available in three standard particulate sizes: Fine (F), Medium (M)
& Coarse (C).
3. CaCO3 (SG 2.7) has good temperature stability, non-toxic, non-
corrosive & least damaging, if size of particles is suitably chosen
and placed the pill properly. CaCO3 is insoluble in formations fluids
and can be completely dissolved by 15 % HCl.
3.1.3 Conventional Water- Base Muds

Conventional water-base drilling mud for completions or workover
operations is not advisable unless we are sure that it will not damage the
formation. Clays, weighting material and other additives present in these
muds can cause severe and permanent damage to producing formation.
However in recent years the non-damaging fluids have been designed &
used for drilling & completion of reservoir sections. The use of these
fluids as completions or workover fluids may prevent formation damage.
4.1 Preparation of Completion / Work over Fluid
4.2 Single Salt Brine: These brines are made with fresh water and one salt.
4.2.1 Sodium Chloride (NaCl) Density range 8.4 to 10.0 ppg (1.008 to 1.2
SG)
1. Required density is obtained by adding NaCl salt in water
2. pH must be maintain in between 8 – 10
3. Corrosion rates reasonably low and further reduced by maintaining the
pH / using corrosion inhibitor.
4.2.2 Potassium Chloride (KCl) Density range 8.4 to 9.70 ppg (1.008 to
1.164 SG)
1. Required density is obtained by adding KCl salt.
2. pH must be maintain in between 8 – 10.
3. Corrosion rates reasonably low and further reduced by maintaining the
pH / using corrosion inhibitor.
4.2.3 Sodium Bromide (NaBr) Density range 8.4 to 12.80 ppg (1.008 to
1.537 SG)
1. Required density is obtained by adding NaBr salt in water.
3. More expensive and used as an alternative to calcium base brines when
formation waters contain high concentrations of bicarbonate and
sulphate ions.
4. Corrosion rates reasonably high as compared with NaCl & KCl and can
be further reduced by maintaining the pH / using corrosion inhibitor.
5. It can be mixed with NaCl to prepare brines with densities between
10.0 to 12.5 ppg (1.2 – 1.501 SG).
4.2.4 Calcium Chloride (CaCl2) Density range 8.4 to 11.80 ppg (1.008 to
1.41 SG)
1. CaCl2 is available either as a concentrated solution or as a dry powder.
2. Required density obtained by adding solid CaCl2 in water or by diluting
the CaCl2 brine solution with water.
3. pH must be between 8 - 10
4. Liquid CaCl2 of 11.6 ppg (1.392) is available which is most economical
form.
5. The anhydrous (94 to 97 %) form of CaCl2 is used at the rig site to
adjust fluid density.
6. With addition of dry CaCl2 to fresh water, a great deal of heat is
generated.
7. Used to prepare clear fluids up to a density of 11.8 ppg. However at
higher densities, there may be operating problem in winter because of
freezing of the solution. At a density of 11.6 ppg the freezing point of
CaCl2 brine is 44 OF (6.7 OC).
8. Dry salt must be added very slowly to prevent boiling due to its
exothermic nature.
9. Dissolution in water gives high heat & the amount of CaCl2 required to
obtain the desired density should be calculated prior preparation of
solution or density measurement must be made after cooling.
10. Logistics for liquid is tough as compared to dry CaCl2 whereas powder
is being hygroscopic in nature which has risk of getting hydration.
11. Corrosion rates reasonably low & further reduced by maintaining the pH
/ using corrosion inhibitor.
4.2.5 Calcium Bromide (CaBr2) Densities ranging 8.4 to 15.3 ppg (1.404 to
1.837 SG).
1. Required density is obtained by adding solid CaBr2 salt in water or by
diluting the solution of CaBr2 brine with water.
3. CaBr2 Systems exhibit lower crystallization points. The 14.2 ppg CaBr2
has a TCT (true crystallization Temperature) around -18°C.
4. It generates heat when dissolved in water; similar precautions should be
taken care as in case of CaCl2.
5. It provides inhibition, preventing the hydration of swelling clays.
6. Corrosion rates high and can be reduced by maintaining the pH / using
corrosion inhibitor.
4.2.6 Sodium Formate (NaCOOH) Density range 8.4 to 11.1 ppg (1.008 to
1.33 SG)
1. Required density is obtained by adding Sodium Formate salt in water.
3. Better HSE characteristics than chloride and bromide brines.
4.2.7 Potassium Formate (KCOOH) Density range 8.4 to 13.2 ppg (1.008
to 1.573 SG)
1. Required density is obtained by adding Potassium Formate salt in water.
3. Better HSE characteristics compared to chloride and bromide brines.
4. Show excellent thermal stabilization effects on natural polymers & the
potassium ion provides excellent clay stabilization & swelling
inhibition of shales.
4.2.8 Cesium Formate (CsCOOH) Density range 8.4 to 19.2 ppg (1.008 to
2.30 SG)
1. Required density is obtained by adding Cesium Formate salt in water.
3. Cesium formate is being produced as a 19.7 lb/ga liquid.
4. Better HSE characteristics compared to chloride and bromide brines.
5. Show excellent thermal stabilization effects on natural polymers &
provides excellent clay stabilization and swelling inhibition of shales.
4.2 Mixed Salt Brine: When the brine densities required greater than 11.6 ppg
(1.393 SG), the use of two or more salts is usually preferred instead of
single salt due to economics.
4.2.1 Calcium Chloride - Calcium Bromide: Density range 11.7 – 15.1 ppg
(1.404 – 1.813 SG)
1. Most common two salt brine.
2. Clear brines are prepared using a combination of CaCl2 & CaBr2
available in solid & liquid form.
3. The pH range is 7.0 – 7.5.
4. CaBr2 costs approximately ten times as much as CaCl2. When TCT and
density requirements allow field prepared brines should have as much
as CaCl2 as practicable.
4.2.2 Zinc Bromide - Calcium Bromide : Density range 15.0 – 19.2 ppg
(1.80 – 2.301 SG)
It is very expensive and highly corrosive. Due to the high concentration
of dissolved salts and the low pH (1-1.5), zinc bromide brines must be
handled with maximum safety precaution. The discharge of zinc to the
environment is restricted, hence not advisable to use.
5.1 Field Testing of Brines: The Fluid Engineer on location shall monitor
the following properties:
1. Density of the brine measured with a mud balance.
2. Funnel viscosity of the brine by Marsh Funnel Viscometer
3. Plastic Viscosity , Yield point and Gel strength with Viscometer
4. Total suspended solids by Millipore filtration unit
5. Clarity of brine in NTU’s by Turbidity Meter: An NTU of 20 to 40 is
generally considered to be clean, but NTU as low as less than 10 are
most desirable
6. pH of the brine by pH meter.
7. Brine checks shall be made according to specifications.
6.1 Criteria for Brine Selection

To select brine based workover/ completion fluid, following parameters
should essentially be considered;
1. Fluid density
2. Wellbore temperature
3. Crystallization temperature
4. Formation compatibility
5. Corrosion control
1
6. Resistance to contaminants
2
7. Carrying Capacity
8. Pressure Transmissibility
9. Suspend Solids
10. Health, Safety and Environmental (HSE)
11. Economics
6.1 Fluid Density:

1. The primary criterion for fluid selection.
2. It should be enough to balance the reservoir pressure. Should be equal
or higher than the formation pressure except for underbalanced pressure
situations, where it should be enough only to control the underbalanced
portion of reservoir pressure.
6.2 Wellbore temperature.

1. The density of a brine decreases as the temperature increases. Hence
bottom hole temperature (BHT), both static and circulating, is an
important factor in selection of brine.
2. Temperature & exposure time affects the stability of various additives,
corrosion rate etc. and may use additives and corrosion inhibitors
accordingly.
6.3 Crystallization temperature
1. Crystallization point is the temperature at which salt crystals will begin
to fall out of solution.
2. The precipitation of insoluble salts can cause a number of problems like
drop in fluid density, choking of lines, nozzles and seizing of pump.
3. Unlike water, brines do not expand during crystallization. Therefore,
fluid lines, valves or pump heads will not rupture as they can when
water freezes.
6.4 Formation compatibility
The compatibility of brines with the formation is important issue as
incompatibility will lead to formation damage resulting in loss of
productivity.
1. Compatibility with Rock: Brine should have compatibility with
formation rocks so as to prevent swelling, deflocculating and/or
migration of formation clays, especially in “tight” high-clay
sandstone.
2. Compatibility with Formation Water
i. It should be compatible with formation water to avoid formation of
scale.
ii. Most common multivalent cations such as (Ca2+), (Mg2+) & (Fe3+)
are responsible for scaling.
3. Compatibility with Hydrocarbon
i. Any incompatibility between brine and hydrocarbon may result in
formation of oil/water emulsions and/or sludge, both of which cause
severe formation damage by blocking pores.
ii. Brine/crude incompatibility is especially important when low-pH,
heavy brines are used. Natural gas if rich in CO2 may cause CaCO3
to precipitate if mixed with high pH brine that contains calcium.
6.5 Corrosion control
1. The brine should not cause much corrosion to tubular and downhole
equipment.
2. Dissolved oxygen is the primary corrosive agent in sodium, potassium,
calcium, chloride or bromide-brine completion fluids. The solubility of
oxygen in these brines decreases as saturation of salt is approached.
3. Oxygen scavengers are not normally use for corrosion control.
4. High-density ZnBr2 blends are used in very high-pressure situations.
These brines have a low pH. Raising the pH would be detrimental,
causing precipitation. The acidity of the zinc can cause severe
corrosion, unless proper protection is provided with an appropriate
corrosion inhibitor.
6.6 Resistance to contaminants:
1. The brine properties should not be affected by contaminants like
cement, drilled solids, formation water, pre- flushes and mud cake over
time and temperature.
6.7 Carrying Capacity:
1. The brines viscosified by polymers should have the capacity of
carrying formation / cement cuttings when used as a work over fluid.
6.8 Pressure Transmissibility:

1. In HPHT wells, Drill Stem Test (DST) is preferred over conventional
testing because DST has got additional features like safety valves in the
string which allows the closure of valves at the bottom or at the surface.
The DST tools are operated by annular pressure and require either clean
fluids or fluids with absolute no sagging (Sag factor 0.50 – 0.52) for
effective pressure transmissibility.
6.9 Environmental concerns (HSE): Health, Safety and Environmental

1. Brine should be safe for personnel during handling and should be not
detrimental to the environment.
6.10 Economics
1. Brine which is most economical, easily available and meets the
requirements should be considered for use. The Reuse, Recover,
Recycle of these brines further improves the economics.
6.11 Suspended Solids

1. It is also critical to minimize the level of total suspended solids in the
completion / work over fluid to minimize formation damage. This can
be control by filtering the brine through fine filters. Mostly NTU
(Nephelometric Turbidity Unit) values of brines are measured because
a brine which looks fairly clean by naked eyes may not be so clean.
NTU as low as possible is preferred and in the range of 20 to 40 NTU
is acceptable. But NTU less than 10 are most desirable.
7.0 Effect of temperature & pressure on density of brine under down
hole conditions:
Operators must use brine densities sufficient to produce the required

overbalance for well control, usually 200 psi above bottom hole reservoir
pressure, depending on the operation. Engineers, therefore, need to know
down hole fluid densities accurately. High pressure, high-temperature
(HPHT) wells cause brine densities to vary significantly from measured
surface values. Calculations have shown that bottom hole pressures
predicted with constant surface densities to be in error by hundreds of psi.
A pressure-density-temperature dependent equation-of-state for different
brines is mentioned below. Workers can calculate the equation's empirical
coefficients, as functions of the brine weight concentration (W). From the
required down hole pressure and the well's temperature profile, engineers
can calculate the needed brine concentration.
Density change with temperature change:
DDH = Ds (1 + 0.000252 ( Ts – TDH))
Example : It can be calculate the down hole density (DDH) of a 16.4 ppg
surface density (DS) brine (60 OF) when down hole temperature increases
to 230 OF with above equation:
DDH = (16.4) (1+ 0.000252 (60-230)
DDH = 15.7 ppg
8.1 Facilities / Infrastructure Required for Storing, Recycling and Reuse

of Brines
The plant should be complete in respect with
1. Centrifuge
2. Brine filtration units
3. Recycling units
4. Storage of brines
5. Liquid brine Plants
6. Brine transportation
8.2 Brine Filtration System
It is a self-contained unit that emphasizes efficient particle removal &
extended filter life. The unit utilizes a three-vessel filter configuration, with
a manifold system to meet a wide variety of flow and filter requirements.
Each particular system is dependent on the particle load & the desired flow
rate of the fluid to be filtered. Filter element longevity is accomplished by
filtering the larger particles in the initial stages, which is commonly 50-
micron elements. With the stepped filter arrangement, the 2-micron
element witnesses less particle load, thereby increasing filter life.
Increased efficiency is realized due to the multi-staged vessel flow path, as
compared to conventional passage through one vessel.
8.3 Creation of multipurpose liquid Brine Plant of Assets:

1. Properly equipped and manned Brine Plant is needed depending on
Asset’s requirement for storing, preparation & processing of different
types of clear fluids.
2. The plant should be complete in respect with centrifuge, filtration units
etc.
3. As bromide brines (especially ZnBr2) are environmentally hazardous
and cannot be disposed-off. These are stored, reprocessed and reused.
4. Similar facilities are also required for use of very costly cesium
formate brine.
5. The storage tanks & handling system require special coating / lining
inside for protection against corrosion.
9.1 Assessment of Rig Preparedness: A completion Fluid engineer should

assess the following:
1. Rig Inspection
2. Preparing for Receiving Brines
3. Displacement to Brine
4. Perforating
5. Displacement to Packer Fluid
A. Rig Inspection
1. Completion fluid engineers should perform a rig survey about fluid
handling system prior to accepting brine.
2. Identify areas where surface fluid loss & contamination of completion
fluid may occur.
3. Survey report detailing the findings along with recommendations is
presented to concerned person for required action.
B. Preparation for Receiving Brine

1. The engineer should supervise the cleaning of the fluid handling
system, equipment, material & verify that all materials & equipment
required for the fluid operation are available & in operation on board.
2. All centrifugal pumps, mud pits, hopper, feed and discharge lines, gun
lines etc. to be checked.
C. Displacement of Brine
It is one of the most important operations performed during the
completion phase of a well. If the fluid handling system is not properly
managed to handle isolation of contaminated brine, the entire
displacement could be compromised contributing to increased cost in
fluid maintenance and lost rig time.
The following criteria must be considered:

1. As the well bore fluid is displaced, its disposal shall be handled.
2. Spacer / pre-flush should be used to avoid contamination.
3. The displacement rate should be as per simulation.
D. Perforation:
1. It is the first instance where the completion fluid will be exposed to the
formation & formation fluids.
2. Facility for isolation of contaminated returns from the well should be
ensured.
3. Necessary arrangement for storage of formation fluids and disposal of
contaminated fluids.
4. Lost circulation material should be on location if losses are expected.
5. If condition does not permit to spot LCM pills or density reduction is
not feasible, enough completion fluid should be available at location to
keep the hole full for completion of the operation.
E. Packer Fluid
1. The final stage of a completion involves spotting a packer fluid in the
well.
2. The packer fluid may be the completion fluid.
3. Packer fluids should be treated with corrosion inhibitors, oxygen
scavengers, bactericides, scale inhibitors, etc. These additives are added
to the packer fluid on the last circulation, prior to landing the tubing
string and should be made in a way as to minimize foaming and air
entrap.
Rig Site Fluid Operations and Fluid Maintenance:
During rig operations where brine is utilized good practices should be
followed to reduce the likelihood of losses and minimize personal
contact:
1. Solids Control – The solids content of the active system can be
minimized by use of filtration equipment.
2. Oil Contamination – The biggest impact of oil contamination on
surface is shaker screen blinding. Regular cleaning of the screen is
required. In severe cases, brushing the screens with a detergent
will reduce the problem.
3. Pit Room – Brine does not require consistent agitation in the same way
that mud does. Solid contaminated brine should be left without
agitation to let solids settle out. Brine returns from displacements
and/or well clean-ups should be isolated in a reserve pit for possible
treatment to remove contaminants.
4. Health & Safety – Although no brines (except ZnBr2) are classified as
hazardous, special precautions should be taken to minimise personal
contact.
10.1 Safely Handling Brines

1. Communicate safety aspects to plant and rig personnel, brines are not
harmful when properly handled.
2. Brine is simply a salt or a blend of salts plus water.
3. Heavy brines contain so much salt that they absorb water from
surroundings until the salt concentrations of both the brine & the source
are in equilibrium, hence avoid spillage of brines.
4. High-density brines have special chemical properties & should be
handled differently from conventional muds, especially for safety
reasons.
5. Brines cause no immediate pain when spilled on the skin unless they
are splashed into the eyes, nose, mouth, or open cuts or scratched.
Wash with plenty of water & take medical help if needed.
11.1 Safety Equipment

1. Use Personal Protective Equipment (PPE).
2. Eyewash fountains & drench showers should be installed near areas of
activity.
3. Hard hats, chemical splash goggles, rubber gloves & rubber boots
should be wear at work. Plastic or rubber coated slicker suits should
be added as chances of splashing increases. Dust / mist respirators
should be worn if misting occurs.
4. Brines make smooth, non-porous slippery surfaces. Place bristle type
floor mats (i.e. Coco mats) where the floor may remain wet with brine.
5. Tools such as tongs, pipe wrenches, chains, etc. should be periodically
rinsed to remove brine spills.
6. Pipe wipers will reduce the chance of heavy brines dripping from the
pipe on the rig floor crew. The wiper should be kept at waist level or
lower to prevent the brines from splashing on the face.
7. MSDS (Material Safety Data Sheet) must be available for all chemicals
used at site.
12.1 First Aid Measures

1. For contact with eyes & skin – flush promptly with plenty of water. Get
medical attention in the event of contact with eyes.
2. For inhalation – if illness occurs, remove the victim to fresh air and get
medical attention.
3. Remove contaminated clothing and wash before reuse.
4. See MSDS for more information.
13.1 DO’S & DON’TS

1. Select workover and / or completion fluid which is dense enough to
balance formation pressure, free of solid particles as far as possible,
non- corrosive, stable and cost effective
2. Preferably use single salt brine based work over / completion fluid of
appropriate density and characteristics as these are clean and has
minimal suspended solids.
3. To avoid any damage to the formation always remove the suspended
solids through 2-5 micron size filter.
4. When the brine densities required greater than 11.6 ppg (1.39 SG), two
or more salts brine such as CaCl2 - CaBr2 or other combination should
be used.
5. Select the packer fluid which is stable with time & temperature, non-
corrosive, remain pumpable for a long period, sufficient density to
control well pressure, capable of keeping solid suspended in it so that
they cannot settle on top of the packer.
6. Use Viscosified brines where additional properties like suspension &
fluid loss control etc. are required.
7. As fish eyes/ microgels are potential source of formation damage,
formation of fish eyes and microgels should be avoided while preparing
pill by dissolving water-soluble polymers in water.
8. While displacing mud with brine, it should be ensured that solids
cleanout is achieved in one pass using spacer.
9. Circulate as per simulation.
10. Produced oils and other hydrocarbons affect brine density & can blind
filtration units. Hydrocarbons will form a separate layer above heavy
brine and should be skimmed off at surface.
Table 1: Sodium Chloride Brines

Sl. Weight of Salt in Volume of Water Specific Gravity of
1 0 100 1.00
2 2 100 1.01
3 4 100 1.03
4 6 100 1.04
5 8 100 1.06
6 10 100 1.07
7 12 100 1.08
8 14 100 1.09
9 16 100 1.10
10 18 100 1.11
11 20 100 1.12
12 22 100 1.13
13 24 100 1.14
14 26 100 1.15
15 28 100 1.16
16 30 100 1.17
17 32 100 1.18
18 34 100 1.19
19 36 100 1.20
Table 2: Calcium Chloride Brines

1 0 100 1.00
2 2 100 1.02
3 6 100 1.04
1
4 10 100 1.06
5 14 100 1.08
6 18 100 1.10
7 22 100 1.12
8 26 100 1.14
9 30 100 1.16
10 34 100 1.18
11 38 100 1.20
12 42 100 1.22
13 46 100 1.24
14 50 100 1.26
15 54 100 1.28
16 58 100 1.30
17 62 100 1.32
18 66 100 1.34
19 70 100 1.36
20 74 100 1.38
21 76 100 1.40
Table 3: Sodium Chloride -Calcium Chloride Brines

Sl. Weight of Salt in gm Volume of Water Specific Gravity of
No. NaCl2 CaCl2 in ml Brine
1 2 - 100 1.02
2 2 2 100 1.04
3 2 10.00 100 1.06
4 2 18.00 100 1.10
5 2 26.00 100 1.14
6 2 34.00 100 1.18
7 2 42.00 100 1.22
8 2 50.00 100 1.26
9 2 58.00 100 1.30
10 2 66.00 100 1.34
11 2 74.00 100 1.38
Table 4: Calcium Bromide Brines
Sl. Weight of Salt Volume of Water in Specific Gravity of
1 69 100 1.40
2 71 100 1.41
3 75 100 1.43
4 79 100 1.45
5 83 100 1.47
6 87 100 1.49
7 91 100 1.51
8 95 100 1.53
9 99 100 1.55
10 103 100 1.57
11 107 100 1.59
12 111 100 1.61
13 115 100 1.63
14 119 100 1.65
15 123 100 1.67
16 127 100 1.69
17 129 100 1.71
18 133 100 1.73
19 137 100 1.75
20 141 100 1.77
21 145 100 1.79
22 147 100 1.81
23 149 100 1.83
Table 5: Calcium Chloride- Calcium Bromide Brines

Sl. Weight of Salt in gm Volume of Water Specific Gravity of
No. CaCl2 CaBr2 in ml Brine
1 76 0 100 1.40
2 76 2 100 1.41
3 76 6 100 1.43
4 76 10 100 1.47
5 76 14 100 1.49
6 76 18 100 1.51
7 76 22 100 1.53
8 76 26 100 1.55
9 76 30 100 1.57
10 76 34 100 1.59
11 76 38 100 1.61
12 76 42 100 1.63
13 76 46 100 1.65
14 76 50 100 1.67
15 76 54 100 1.69
16 76 58 100 1.71
17 76 62 100 1.73
18 76 66 100 1.75
19 76 70 100 1.77
20 76 74 100 1.79
21 76 78 100 1.81
22 76 82 100 1.83
23 76 86 100 1.85
24 76 88 100 1.86
Table 6: Sodium Format Brines

1 0.0 100 1.00
2 5.0 100 1.01
3 7.5 100 1.03
4 12.5 100 1.06
5 17.5 100 1.09
6 22.5 100 1.11
7 27.5 100 1.14
8 32.5 100 1.16
9 37.5 100 1.18
10 42.5 100 1.20
11 47.5 100 1.22
12 52.5 100 1.25
13 57.5 100 1.27
14 62.5 100 1.29
15 67.5 100 1.30
16 70.0 100 1.31
17 72.5 100 1.33
Table 7: Potassium Format Brine

1 0.0 100 1.00
2 4.0 100 1.02
3 8.0 100 1.04
4 12.0 100 1.06
5 16.0 100 1.08
6 20.0 100 1.10
7 24.0 100 1.12
8 28.0 100 1.13+
9 48.0 100 1.21
10 68.0 100 1.26
11 88.0 100 1.32
12 108.0 100 1.36
13 128.0 100 1.40
14 148.0 100 1.42+
15 168.0 100 1.45
16 198.0 100 1.47+
17 228.0 100 1.49+
18 258.00 100 1.51
19 288.0 100 1.53
20 308.00 100 1.54+
21 318.0 100 1.56
22 328.0 100 1.56+
23 331.0 100 1.57

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STANDARD OPERATING

PROCEDURES MANUAL FOR

Institute of Drilling Technology

S.No Chapter Page

Drilling operations need to be carried out in a safe, efficient, and

a) Preparation for spudding the well:

b) Common drilling practices for all phases:

List of Handling Tools:

List of Handling Tools:

Sequence of Drilling Operations:

e) Drilling 12 ¼”hole section:

List of Handling Tools:

Sequence of Drilling Operations:

4. Tag float collar and test 13 ⅜” casing to 70% of burst rating.

f) Drilling 8 ½” hole section:

List of Handling Tools:

Sequence of Drilling Operations:

18. Drill ahead to Phase TD.

32. Change pipe ram to casing ram.

g) Drilling 6” Hole Section

List of Handling Tools:

Sequence of Drilling Operations:

h) Casing Integrity Test (CIT):

Casing test before drilling float collar:

Casing Shoe Integrity Test (SIT):

i) Leak-off Test (LOT):

LOT is carried out to determine the competency of the formation. The

600 Pressure (psi)

2. In the second injection cycle, pumping continues for at least 1 min

3. The well then remains shut-in while pressure is monitored for at

7. If required, a fourth cycle of pumping can be undertaken to investigate

k) Recommended practices for tripping out:

m) Recommended practices for reaming:

m) Recommended practices for back-reaming:

n) Recommended practices for wiper trips in deviated hole:

• Pump-out in tight portions if required back reaming may be done.

o) Recommended practices to clear pack-off:

To avoid possible pack-off:

1. To prevent annulus loading and consequent packing-off by ensuring

p) Recommended practices for surface seepages:

Procedure for making up Core Barrel:

Procedure for coring:

This chapter deals with

b) BHA Operational Guidelines:

 Making up new drill collar:

e) Critical points while making BHA for various hole sizes:

The two basic types of jars are mechanical and hydraulic

Pump Open Force/Jar extension force

Weight indicator to be set at =Normal Hook load when lifting the

Cock the jar from full open position

Weight indicator to be set at = Hook load while lowering the string–

Re cock the jar from closed position

Weight indicator to be set at = Hook load while lifting the string–

Reason for Jar failure

General guidelines for jar operation.

The Chapter covers the following topics on bits:

a) Basics about Drill bits:

b) Bit Operating Guidelines: