UNIVERSITY OF KASDI MERBAH OUARGLA

FACULTY OF HYDROCARBONS, RENEWABLE ENERGY, EARTH AND

UNIVERSE SCIENCES
DEPARTMENT OF DRILLING AND MECHANICS OF OIL WORKSITES
Field of Training: Science and techniques.

Advanced well control

Material: advanced well control.

Speciality: Drilling.
Level: 2nd year master.

By: Dr. Abbas Hadj Abbas

Academic year: 2022/2023.

 FOREWORD

This document contains the essential elements of Well Control. It is intended for second-year
Master Drilling students.

This document presents basic notions on:

Introduction

1 Fundamental principles of kicks control

2 Causes of kicks

3 Kicks indicators

4 Closing procedures

5 Kicks control methods

6 Kicks control equipment

7 Well Control problems

The author thanks the readers of this document in advance and hopes that this handout will
provide master students with the information necessary to understand the “Well control”
module.

The author
 WELL CONTROL MANUAL

CONTENTS

SECTION

Introduction

1 Fundamental principles of kicks control

2 Causes of kicks

3 Kicks indicators

4 Closing procedures

5 Kicks control methods

6 Kicks control equipment

7 Well Control problems

APPENDIX

A Trouble shooting

B API RP 53 Recommendations

C API RP 59 Recommendations

D API 6A Recommendations

E Terminology and formulae

 WELL CONTROL MANUAL

INTRODUCTION

The petroleum industry is often faced to technical challenges related to drilling in

deep formations containing fluids under high pressures which may put in hazard
human life, equipment and environment.

The main objective of this manual is to provide a comprehension mean of

fundamental principles to control kicks and their application.

This manual is intended to Sonatrach staffs and partners who are in charge to
conduct the well operations.

This manual describes the standards and practices recognised by the Petroleum
Industry in terms of prevention and control of kicks.
 SECTION 1: FUNDAMENTALS OF KICKS CONTROL

Page

1.1 INTRODUCTION 2

1.1.1 Primary control 2

1.1.2 Secondary control 2

1.1.3 Tertiary control 2

1.2 PRESSURES IN WELL 2

1.2.1 Hydrostatic pressure 3

1.2.2 Bottom hole dynamic pressure 5

1.2.3 Gas behaviour 8

1.3 FORMATIONS PRESSURES 8

1.3.1 Definition 8

1.3.2 Formation pressures 8

1.3.3 Normal pressures 9

1.3.4 Abnormal pressures 10

1.4 FRACTURE PRESSURE 16

1.4.1 Definition 16

1.4.2 Leak-off test 16

Maximum Allowable Annular Surface
1.4.3 19
Pressure
1.4.4 Kick size tolerance 20

1.5 WORK SHOPS 24

 WELL CONTROL MANUAL
SECTION 1 : FUNDAMENTAL PRINCIPLES OF KICKS CONTROL

1.1 INTRODUCTION

In this section the fundamental principles of kicks control are covered.

The control of a well is divided in three main categories which are the primary
control, the secondary control and the tertiary control.

1.1.1 Primary control

The prevention of the fluid intrusion from the formation into the well is ensured by
keeping a hydrostatic pressure of the drilling mud at a value slightly greater than
the pore pressure without however exceeding the fracture pressure of the weakest
formation.

1.1.2 Secondary control

When the bottom pressure becomes less than the pore pressure, there is an
intrusion of the formation fluid into the well. This intrusion can be stopped only
after closing the well-in by using the safety equipments.

The well is put again under control by using the conventional control methods i.e.
the Driller's Method or the Wait & Weight Method.

1.1.3 Tertiary control

The tertiary control describes the third defence line for the kicks control which
consists to use unusual methods and procedures to face with particular situations of
kicks, which are:

a) bit ioff bottom

b) drill string plugged

c) Drill string out off the hole

d) Drill string washing out

e) Circulation losses

f) Annular pressure greater than the maximum allowable pressure

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g) Drill string sticking

h) Gas migration without expansion

1.2 PRESSURES ALONG THE WELL

1.2.1 Hydrostatic pressure

The hydrostatic pressure is defined as the weight of a true vertical fluid column by
unit area.

Hydrostatic pressure = fluid density × true vertical depth

The hydrostatic pressure depends on the true vertical height or depth of a fluid
column. The shape of this column is not important.

Fig 1.1 Different types of columns

If the depth is measured in meters and the fluid density in kg/L, the
pressure is expressed in bar and the conversion factor is equal to 1/10.2

Pressure gradient (bar/m) = fluid density (kg/L) × 1

10.2

Hydrostatic pressure (bars) = density (kg/l) × vertical depth (m) × 1

10.2

The conversion factor 1 is derived as follows :

10.2

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1m3 contains 1000 L and the fluid density is 1 kg/L.

The pressure exerted by 1m of this fluid height on a surface of 1m2 is equal to :

1000 × 0.981 (daN/cm2) = 0.0981 bar = 1 bar

10000 10.2

Fig 1.2 Cube of 1m unit side

The hydrostatic pressure formula (Ph) can be expressed differently in function of

the units used.

Ph = Z × d where Ph : hydrostatic pressure (bars)

10.2 d : fluid density (kg/L)
Z : true vertical depth of the fluid (m)

Ph = ρ×g×Z where Ph : hydrostatic pressure (Pascal)

ρ : weight per unit volum (kg/m3)
g : gravity acceleration (m/s2)
Z : true vertical depth of the fluid column (m)

Ph = Z × d where Ph : hydrostatic pressure (kg/cm2)

10 d : fluid density (kg/L)
Z : true vertical depth of the fluid column (m)

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Ph = 0.052 × MW ×TVD where Ph : hydrostatic pressure (psi)

MW : mud density (ppg)
TVD : true vertical depth (ft)

Units conversion of pressure

The pressure unit in the SI system is the Pascal

1 Pascal = 1Newton / 1m2

The multiples are :

1 bar = 105 Pa = 102 kPa = 0.1 MPa = 1.02 kg/cm2

1 Psi = 1 lb/in2 = 0.06897 bar = 6.897 kPa

Note : In this manual, the bar is selected as the pressure unit.

1.2.2 Dynamic bottom hole pressure

The pressure losses in a pipe describes the resistance of the fluid to flow, this
resistance is essentially due to the internal and external fluid friction forces.

The pressure losses distribution in the drilling circuit is as follows :

 in surface lines (PLS)

 in drill pipes (PLDP)

 in drill collars (PLDC)

 across bit nozzles (PLBN)

 in annulus (PLA)

The pumps discharge pressure P is the sum of all the pressure losses in the mud
circuit.

P = PLS + PLDP + PLDC + PLBN + PLA

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The pressure applied on the bottom hole (BHP) is the sum of the pressures in the
annulus.

BHP = Ph + PLA

Equivalent circulating density (E.C.D)

Z × deqv
BHP = PLA + Ph =
10.2

Then deqv = 10.2 × (PLA + Ph)

Z

deqv = da + 10.2 × PLA

Z
Where da : mud density in annulus (kg/L)

Variations of pressure losses with different parameters

PL = K× d × L × FR2
Φ5

where K : constant
L : length of the pipe
d : fluid density
FR : flow rate
Φ : pipe diameter

a) Pressure losses variation with the density

PL2 = PL1 × d2
d1

where PL2 : pressure losses with the density d2

PL1 : pressure losses with the density d1
d1 : initial mud density
d2 : new mud density

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b) Variation of pressure losses with flow rate

2 2
PL2 = PL1 × FR2 = PL1 × SPM2
FR1 SPM1

where FR2 : new circulation flow rate which corresponds to the new
pump rate (SPM2)
FR1 : original circulation flow rate which corresponds to the
original pump rate (SPM1)

c) Variation of pressure losses with length

PL2 = PL1 × L2
L1

where L2 : new drill string length

L1 : original drill string length

d) Variation of pressure losses with pipe diameter

5
PL2 = PL1 × Φ1
Φ2

Where Φ1 : initial pipe diameter

Φ2 : new pipe diameter

Application examples :

EX1 :

Pump pressure = 120 bars, d1 = 1.20 SG

What is the new discharge pressure with the density d2 = 1.25 SG ?

P2 = P1 × d2 = 1.20 × 1.25 = 125 bars

d1 1.20

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EX2 :

P1 = 100 bars with 50 spm. What will the new discharge pressure be at
60 spm ?
2 2
P2 = P1 × SPM2 = 100 × 60 = 144 bars
SPM1 50

1.2.3 Gas behaviour (Boyles- Mariotte Law)

PV = n R T

Where:
P : Pressure
V : Volume
n : Mole number
R : Constant
T : Temperature

The effect of temperature variations along the well will be neglected, so

PV = Constant

1.3 FORMATIONS PRESSURES

1.3.1 Definition

It is the fluid pressure contained in the pores of the formation. It is also called pore
pressure or reservoir pressure.

1.3.2 Formation pressure

The formation pressure at a given depth is the exerted pressure by the weight of
overlying sediments. As it is not a fluid pressure, we often prefer to make the
distinction fluid/matrix, using the term ''formation constraint''. It can be expressed
like this :

S= ds × Z
10.2

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Where ds : apparent density of the overlying sediments (kg/L)

S : formation constraint (bars)
Z : true vertical depth of sediments (m)

1.3.3 Normal pressure

The normal pore pressure at a given depth corresponds to the hydrostatic pressure
of the fluid at its true vertical depth Z.
This implies a pore to pore connection until the atmosphere independently of the
fluid path (fig 1.3)

fresh water

Fig 1.3 Normal pressure

The following table shows examples of normal formations pressures in some areas.
However, in absence of accurate data, the value 1.07 kg/L is assumed as the
density of the fluid contained in normal pressure formations

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 WELL CONTROL MANUAL
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Formation Density Pressure gradient Area

water kg/l bar/m
Rocky mountains and mid
Fresh water 1.00 0.098
continent USA
most sedimentary basins
Salt water 1.02 0.100
worldwide
Salt water 1.04 0.102 North sea and south China
Salt water 1.07 0.105 Golf of Mexico, USA
Some areas of Gulf of
Salt water 1.10 0.108
Mexico

1.3.4 Abnormal pressure

In absence of a permeability barrier, the formation weight increase due to

sedimentation represents the essential force of the fluid expulsion.
If during the sedimentation process the expulsion is impeded by a permeability
barrier or by a sedimentary rate greater than the fluid expulsion rate, then the pore
pressure becomes abnormal.
When the formation fluid withstands a part of the formation constraint under-
compaction takes place and will be characterized by increase in porosity and a
reduction in density.
A study carried in the laboratory in 1948 by TERZAGHI & PECK has established
a compaction model which is the following (fig 1.4)

plate
water

Fig 1.4 – Scheme of the TERZAGHI compaction model

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Case A : Valve closed (absence of draining)

Under the application of the load S simulating the formation compressive force,
the pressure increases inside the cylinder.
This case illustrates a real case of the abnormal pressure, the fluid can at the limit,
withstand the weight of all the overlaying sediments, which can be taken
equivalent to densities from 2.3 to 2.4 kg/L.

Cases B and C : Valve opened

There is a possibility to drain water; one fraction of the load S is held by the
springs (matrix), the water pressure decreases until the load S is supported solely
by the springs, in this situation the fluid pressure becomes hydrostatic.

Examples of abnormal pressures:

 Artesian wells

a) The anomaly of formation pressure comes from the fact that the level of
atmospheric contact is greater than the rig site level (fig 1.5)

Fig 1.5

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b) The pressure anomaly comes from the fact that the reservoir contacts the
surface at an altitude less than the rig site level, it is also the case of the
depleted reservoirs (fig 1.6)

Fig 1.6

 Hydrocarbon column

The presence of a gaseous formation can cause a pressure anomaly

characterised by an overpressure at the reservoir cap by the fact that the
hydrostatic pressure of the water is transmitted to the interface (fig 1.7)

Fig 1.7 Hydrocarbon column

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 Lateral tectonic forces

The lateral forces can create additional horizontal compression which increase
the shale compaction rate; this will cause a reduction in the water expulsion rate
and establishment of an abnormal pressure (fig 1.8).

Fig 1.8 Abnormal pressures resulting from tectonic forces

 Relief and structuring

Under the tectonic forces, the upward movement of formations containing

fluids in presence of an impermeable cap rocks, followed by the erosion of the
overlaying materials may lead to set up of abnormally high pressures at shallow
depths.

 Salt and shale banks

During the sedimentary process, the salt and shale deposits play the role of a
cap rock preventing then the fluid movement of the formations below. The
material weight increases in presence of this type of formation characterised by
a reduced permeability or almost null can generate pressures abnormally high.

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 WELL CONTROL MANUAL
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 Faulting

The faults resulting from combined compressive forces (vertically and

laterally) have typically a draining effect making the communication
between a deep and a less deep formations. However, the presence of a
permeability barrier impedes the fluids to displace and consequently leads to
create overburden pressures (fig 1.9).

Fig 1.9
A hydrocarbon trap caused by
from a fault in the right bloc
is lifted relatively with the
left one.

 Salt or shale diapirism

The salt or shale diapirism results of an upward intrusion of salt or shale to

form a dome under the effect of tectonic movements.
The upward intrusion of formations at less depth is always accompanied by
keeping of pore pressures in existence of a permeability barrier
(fig 1.10).

Fig 1.10

Often the salt domes cause

the deformation of the upper sediment
layers

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 WELL CONTROL MANUAL
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Trapped pressure

Non sealed faulting

Poor cementing Corrosion of casings

Precautions:

To prevent uncontrolled flow between zones or trapped pressures between casings:

 Control the cement job CBL, VDL ...

 Wait on cement set with pressure bled off (microannulus)
 Supervise the annulus casing pressures
 Install fluid packer with corrosion inhibitors

Others causes of abnormal pressures

 Clay diagenesis Montmorillonites transforms to illites. When it

comes out as free water, interlayer water increases in volume.

 Rehydration of anhydrite to gypsum (CaSO4 2 H2O) an anhydrite

formation in contact with water can to transform to gypsum by
physic–chemical link witch can generate up to 40% increasing
volume. If anhydrite is under impervious formation and in permeable
communication with a water reservoir, it can develop high pressures
by its tendency to increase in volume.

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1.4 FRACTURE PRESSURE

In general, the less deep formations have fracture pressures relatively low
compared to the deepest ones; this is due to the increasing weight of overlying
rocks and the compaction of the underlying sediments.

1.4.1 Definition

The fracture pressure is the pressure at which there will be a rupture of the rock
matrix, this fracture is associated with mud losses.
In the case of a drilling, the formation under the shoe represents, in general, the
weakest point of the open hole. In another way,
drilling of deep layers requires higher mud densities to maintain the borehole
stability and to prevent intrusions of unwanted formations fluids.
The knowledge of the fracture pressure is of a vital importance for the drilling and
casing programs.

1.4.2 Leak-off test (LOT)

The theoretical calculations based on estimated sediments densities gives

approximate values of the fracture pressure.
A leak-off test is a pressure test which measures the real value of the pressure to
apply on a formation to initiate injection of drilling fluid into it ( leak off pressure).
In kicks control, the leak off pressure is essential for to determine the maximum
allowable pressure at surface (MAASP) in order to prevent fracture at the weakest
point in the open hole.

Leak-off test procedure

Using a low output /HP pump and accurate pressure gauges are necessary to record
exact pressure values of the leak-off test (LOT). The steps to follow are :

 Ensure the casing column sealing

 Drill 1 to 3 meters below the shoe

 Circulate and condition the mud to homogenise mud density (in/out)

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 WELL CONTROL MANUAL
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 Pull the bit inside the shoe and connect the pumping line
 Test the pumping line

 Close the preventer

 Start pumping inside drill pipes or annulus with a flow rate of 40 to 80

l/mn (0.25 to 0.50 bbl/min) and plot on a graph the pressures that
correspond to each pumped volume increment.

 Stop the pump as the deviation from linearity is noticed. The pressure
at the deviation point represents the leak-off test pressure (LOT)

 Bleed off the pressure and measure the return volume

The leak-off test result in consolidated formations differs from those of a non
consolidated formation because the mud loss at low pressure is likely in the latter
and the pressure drops as the pump is stopped (fig 1.11)

Line up for Leak off Test

Open: 1,3,5,6,7
Close: 2,48,9,10,11,12,13,14,15,16

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 WELL CONTROL MANUAL
SECTION 1 : FUNDAMENTAL PRINCIPLES OF KICKS CONTROL

Fig 1.11

The fracture pressure is given by the following formula:

Pfrac = PLOT + Zs × d
10.2

where : Pfrac : fracture pressure at the shoe (bars)

PLOT : surface pressure of the LOT (bars)
Zs : true vertical depth at the shoe (m)
d : mud density over the shoe (kg/L)

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 WELL CONTROL MANUAL
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Application example

PLOT = 70 bars
Zs = 2500 m
d = 1.20 SG

Pfrac = PLOT + Zs × d
10.2

Pfrac = 70 + 2500 × 1.20 = 364 bars

10.2

Then dfrac = 10.2 × 364 = 1.48 SG

2500

1.4.3 Maximum Allowable Annular Surface Pressure (MAASP)

The maximum allowable surface pressure is the limit casing pressure not to exceed
to prevent the fracture at the weakest formation.

MAASP = Pfrac – Zs × d = (dfrac – d) × Zs

10.2 10.2

Note : The allowable pressure must be recalculated each time the mud density is
changed .

In any case, the maximum allowable pressure should not be reached when the
effluent is circulated below the weak point (shoe), it becomes without significance
while the effluent is displaced above this point.

We define the maximum pressure MAASP as being the limit casing pressure, this
limit depends on the working pressure of the surface equipments and the casing
burst pressure.

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1.4.4 Kick tolerance (Gmax)

The maximum admissible gain is defined as being the maximum volume of the
kick after the well closing which can be safely circulated without fracturing the
formation.

1) While drilling

In case of a kick there are two critical cases that can lead to the fracture:

a) When the kick is at the bottom hole, just after the well is closed-in, we
must calculate the maximum height of the kick (Hmax) corresponding to
the shut in casing pressure ( SICP = MAASP).

Hmax = 10.2 × (MAASP – SIDPP)

(d1 – deff)

with: V1 = Hmax × Va

where: Hmax : maximum height of the kick at bottom (m)

MAASP : maximum allowable pressure (bars)
SIDPP : stabilised DP pressure, after the is well shut-in (bars)
d1 : original mud density (kg/L)
deff : effluent density (kg/L)
V1 : kick volume at bottom (L)
Va: open hole - DC annulus capacity (L/m)

2) While circulating the kick from bottom up to the weak point, there is an
expansion of the effluent causing an increase of its height until it reaches Hmax .

For the calculations we consider that the top gas is at the weak point and its
pressure is equal to the fracture pressure.

We calculate the kick volume in the bottom conditions which gives the maximum
height (Hmax) at the weak point during the circulation.

We apply Boyle’s law between the two states :

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 WELL CONTROL MANUAL
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 Bottom conditions : Ppore , V2

 Weak point conditions : Pfrac , Vs (volume at shoe) with Vs = Hmax × Va

V2 = Pfrac × Vs = 10.2 × Pfrac × Va × (MAASP – SIDPP)

Ppore Ppore × (d1 – deff)

Note : The G max is equal to the smallest value of V1 and V2

Application example :

Phase 8” ½ Z = 2800 m
Casing 9” 5/8 Zs = 2200 m
DC 6” ½ L = 140 m
DP 5” 19.5 # E
Mud density d1 = 1.50 kg/L sg
Balance density deql = 1.60 kg/L sg
Fracture gradient Gfrac = 0.18 bar/m
Effluent density deff = 0.23 kg/L

Solution :

Pfrac = Gfrac × Zs = 0.18 × 2200 = 396 bars

SIDPP = Z × (de – d1)

10.2

SIDPP = 2800 × (1.60 – 1.50) = 28 bars

10.2

MAASP = Pfrac - Zs × d1
10.2

MAASP = 396 - 2200 × 1.5 = 73 bars

10.2

Ppore = Z × deql
10.2

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Ppore = 2800 × 1.6 = 439 bars

10.2

Then Hmax = 10.2 × (73 – 28) = 361 m

(1.5 – 0.23)

Hmax › Ldc then :

V1 = 140 × 15.2 + (361 – 140) × 23.3 = 7277 L

V2 = 10.2 × 396 × (73 – 28) × 23.3 = 7596 L

439 × (1.5 – 0.23)

Therefore Gmax = V1 = 7277 L

2) While tripping out

While pulling out off hole, a swabbing may induce a fluid intrusion from the
formation into the well, this is due to the decrease of bottom hole pressure.

If fluid intrusion takes place, we note that after closing the well-in the same
pressure is recorded at the DP and casing (kick below the bit). When the bit is run
back to bottom we read nil pressures at DP and casing. We must then determine
the maximum gain (Gmax) to avoid the fracture at the weak point.

We apply the following relation :

Hmax = 10.2 × MAASP

d1 - deff

and Gmax = Hmax × Va

then Gmax = 10.2 × MAASP × Va

d1 - deff

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Application example :

Total true vertical depth Z = 3500 m

Shoe true vertical depth Zs = 2000 m
Maximum allowable pressure MAASP = 80 bars
Mud density d = 1.60 sg
Effluent density deff = 0.3 kg/l
Drill collars length LDC = 140 m
Capacities :
drill collars/open hole = 15 L/m
drill pipes/open hole = 24 L/m

Solution :

Hmax = 10.2 × MAASP = 10.2 × 80 = 628 m

d1 – deff 1.60 - 0.3

Hmax = 10.2 × 80 = 628 m

1.60 - 0.3

Hmax › LDC then

Gmax = 140 × 15 + (628 – 140) × 24

Gmax = 13812 l = 13.8 m3

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 SECTION 2 : CAUSES OF KICKS
Page

2.1 INTRODUCTION 2

2.2 PRIMARY CONTROL PARAMETERS 2

2.2.1 Mud density 2

2.2.2 Tripping procedure 2

2.2.3 Safety margin during tripping (trip margin) 5

2.2.4 Well observation (flow checks) 6

2.2.5 Short trips 6

2.2.6 Pumping Slug of heavy mud 6

2.2.7 Mud logging unit 7

2.2.8 Communication 7

2.2.9 Alarms 7

2.3 CAUSES OF KICKS 7

2.3.1 Failure to fill during a trip 8

2.3.2 Swabbing and surging 9

2.3.3 Circulation losses 10

2.3.4 Insufficient mud weight 10

2.3.5 Abnormally high pressure formations 11

2.3.6 Gas-cut muds 12

2.4 WORK SHOPS 13

 WELL CONTROL MANUAL
SECTION 2 : CAUSES OF KICKS

2.1 INTRODUCTION
The primary control of a kick consists of using a drilling fluid of a sufficient
density which can supply a bottom pressure slightly greater than the formation
pressure, without exceeding however the fracture pressure.
It is extremely important to maintain this overbalance all the time while drilling, if
this is lost, even temporarily, the formation fluids will enter the well.

Definition of a kick

A kick is defined as being an unwanted fluid intrusion from a permeable formation

into the well, when the bottom hole pressure becomes less than the pore pressure.

2.2 PARAMETERS EFFECTING THE PRIMARY CONTROL

To be sure that the primary control is effective at any time, the following
precautions and procedures must be scrupulously followed.

2.2.1 Mud density

For an effective well control, make sure, at all time, that the mud densities in and
out are maintained at the required value. These densities are maintained at a
correct value during the drilling by the use of mechanical treatments (shale shaker,
desilter, mud cleaner …).
The frequency of density measurements during drilling must be 30 minutes or less
depending on operations and each company procedure. These values must be
normally recorded on a register.

2.2.2 Tripping procedure

Tripping operation, whether it’s pulling out or running in, requires a particular
preparation which consist of :

 The use of a trip sheet to monitor the volumes to fill during the POOH or to
be recovered when RIH. This sheet should be filled by the driller (fig 2.1)
The use of a trip tank to measure accurately the recovered or pumped
volume during tripping (fig 2.2)
 Make sure that the gray valve , the safety valve and their appropriate subs
are available on the rig floor (fig 2.3)

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During POOH, the volume to be filled must be equal to the metal volume
extracted; in case of anomaly, tripping must be stopped to identify the problem and
to take the correct actions.

Fig 2.3

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 WELL CONTROL MANUAL
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SONATRACH
DRILLING TRIP SHEET

Well : Rig : Date and time :

Well depth : Bit depth : Hole diameter

DP 1 DP 2 HW DC 1 DC 2
Diameter (inch)
Liters/meter
Liters/ stand

Nbre of DP stands : Bottom- Casing Shoe : …………… Total nbre of DP stands: …………

Trip tank Measured volume Calculated volume Difference

Stand Number
volume By nbre of Cumulated By nbre of Cumulated By nbre of Cumulated Remarks
Nber of stands
(L) stands (L) (L) lengths (L) (L) stands (L) (L)

Figure : 2.1

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drillstring

flow line

fill up
float

centrifugal
pump
centrifugal
pump

Fig : 2.2 Trip Tank

2.2.3 Safety Margin (Trip margin)

Before stopping the circulation and start pulling out of the hole, ensure that we
have an overpressure (trip margin) able to compensate the annular pressure losses
and to overcome the effects of swab pressures during a trip out of the hole

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SECTION 2 : CAUSES OF KICKS

Trip margin = 10.2 × PLa

Z

where : PLa : annular pressure losses during drilling (bars)

Z : vertical depth (m)

2.2.4 Well observation (flow check)

The well stability at any time is imperative before any trip out operation is going to
take place. The flow checks must be carried out, with the pumps stopped, at the
minimum following places :

 On bottom
 At the casing shoe
 Before the BHA is pulled into the BOP's
2.2.5 Short trip

In particular circumstances a short trip from 5 to 10 stands should be carried out

before starting the trip in order to check the bottom conditions (swabbing). The bit
is run back to bottom and the annular volume is circulated monitoring the mud
return.
2.2.6 Heavy mud slug

It’s a common practice to pump a slug to prevent mud losses at surface while
tripping out that enables to monitor accurately the hole.

The following equation permits to calculate the heavy mud volume to pump into
the drill string prior to trip out .

Vd = Vs × ds _ 1
di

Vd : dry volume inside pipes

Vs : slug volume
ds : slug density
di : mud density
In practice, the slug volume is few cubic meters and is calculated to maintain
dry at least two (02) stands of pipes.

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 WELL CONTROL MANUAL
SECTION 2 : CAUSES OF KICKS

2.2.7 Mud Logging Unit

The use of a recording cabin (Mud logging) is a mean which permits to carry out
recordings of parameters at real time, in particular with respect to well control
considerations for a rapid detection of any kick.
Some of these information are :

 drilling parameters (WOB, RPM, …)

 Rate of penetration (ROP)
 mud levels and volumes at surface
 flow rates in and out
 mud density in and out
 cuttings analysis
 gas detection and analysis
 “d” d exponent

2.2.8 Communication

A good communication between all the members of the drilling team (driller, mud
engineer , mud logger…) is essential to survey and follow the drilling procedure.
For example, prior to transfer mud or to add chemicals to the active tank all the
members of the team must be informed.

2.2.9 Alarms

The available alarms devices on the drilling rig must be calibrated, well maintained
and activated. Among these devices, two are essential for the detection of an
eventual kick :
 Differential flow meter alarm ( % of return flow)
 Mud tanks level alarm (Pit / Gain and Loss in m3 or bbl )

2.3 CAUSES OF KICKS

The kicks and influx prevention is a process which must first start by the
comprehension of its causes .The detection of the early signs and the right
interpretation of the observations will determine the correct action to take.

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 WELL CONTROL MANUAL
SECTION 2 : CAUSES OF KICKS

The most frequent causes of kicks are :

 Failure to keep the hole full during a trip.

 Swabbing upwards and downwards during the tripping
 Circulation losses
 Insufficient mud weight
 Special situations (DST, adjacent wells… )

According to statistics, the majority of kicks occur during trips because of the BHP
reduction essentially due to:

 Loss of ECD as the pumps are stopped

 Mud level drop in the annulus during the trip out
 Swabbing effects

2.3.1 Failure to fill while tripping

The mud level decrease in the annulus will cause a reduction of the BHP which can
cause a kick if the well hasn’t been filled with a mud volume equal to the extracted
metal volume.

The following formulae are to calculate the BHP reduction due to level decreases
when the pipes are pulled dry and wet.

 Pipes pulled dry

∆P = H × Gm × Cm pipe
(Ci casing – Cm pipe)

 Pipes pulled wet

∆P = H × Gm × [Cm pipe + Ci pipe]

Ci casing – [Cm pipe + Ci pipe]

2-8
 WELL CONTROL MANUAL
SECTION 2 : CAUSES OF KICKS

Where : ∆P : BHP reduction (bars)

H : length of pulled pipes (m)
Gm : gradient mud (bar/m)
Cm pipe : capacity metal pipes (L/m)
Ci pipe : capacity internal pipes (L/m)
Ci casing : capacity internal casing (L/m)

The use of a trip tank and a trip sheet are essential to prevent influxes by detecting
filling volumes anomalies.

2.3.2 Swabbing and surging

Swabbing

The swabbing is a phenomenon which occurs during a POOH by causing a

depression on the bottom hole.

This depression is however more important that :

 Pulling speed is high
 Mud density and rheology (viscosity, gel strengths…) are high
 Hole geometry (clearance between hole and BHA )
 Bit is balled up

A swabbing effect can be detected by a proper monitoring of return volumes with

the trip tank.

To minimise the swabbing effect, we should :

 Condition the mud

 Insure, prior to trip, that the trip margin is available
 Select a proper pulling rate
 Circulate while tripping if necessary
If a swabbing is suspected, the tripping must be stopped and the following
procedure will be performed :

a) if the well doesn't flow :

 Install the gray valve

 Run back to bottom monitoring the mud returns after each stand
 Circulate the bottom up through choke

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 WELL CONTROL MANUAL
SECTION 2 : CAUSES OF KICKS

Some companies prefer to strip to bottom rather than to re run with the well open

b) If the well flows:

 Install the safety valve

 Close the well in following instruction procedures
 Install the gray valve
 Strip to bottom
 Circulate through choke and evacuate the kick

Surgging
The surging is the phenomenon which occurs when running in hole by causing a
sur-pressure effect on the bottom.
If this overpressure is important, the BHP can become greater than the leak off
pressure or fracture pressure. Consequently, a total loss will take place inducing a
drop of mud level in the well and can be sufficient to cause well invasion by a
formation fluid.

2.3.3 Circulation losses

During a total circulation loss, the hydrostatic pressure decreases and if it becomes
less than the pore pressure so, intrusion of a formation fluid will take place.

The maximum dry height from which the kick starts to take place is given by the
following formula :

H = ∆P × 10.2
dm

where H : depth of static level (m)

∆P : trip margin (bars)
dm : mud density (kg/L)

2.3.4 Insufficient mud density

The mud density is a primordial factor for the primary well control. If this density
becomes less than the balance density of a porous and permeable formation so,
there will be a kick.

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 WELL CONTROL MANUAL
SECTION 2 : CAUSES OF KICKS

An insufficient mud weight can be due to :

 An underestimation of the pore pressure

 An inadvertent decrease of the mud density at surface
 A mud contamination by a formation fluid

Reduction of the mud density at surface

 Settling of weighted materials

 Accidental dilution of the mud
 Adding chemicals , oil...
 Removing solids with centrifuges
 Foaming

Reduction of hydrostatic pressure

 Drilling into abnormal pressure zone

 Failure to fill while tripping
 Settling of solids during round trips
 Expansion of swabbed gas
 Gas cut muds
 Entering of influx in particular gas
 Total losses
 After cementing while waiting on cement set
 Temperature effect s on liquids (HP/HT wells)

2.3.5 Abnormally high pressured formations

Abnormally high pressured permeable zones already treated in the previous section
are often met in many regions at various depths. These formations are often one of
the kicks causes.

A formation is at an abnormally high pressure when its pressure gradient is greater

than the normal gradient.

Abnormal gradient › 0.105 bar/m

The abnormally high formation pressures are often predicted and detected by a
detailed analysis of the seismic studies before starting drilling. While drilling, this
type of formations can be detected by supervising directly the tendencies of the
following recorded parameters:

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 WELL CONTROL MANUAL
SECTION 2 : CAUSES OF KICKS

 Penetration rate (ROP)

 “d” exponent
 Mud temperature at the flow line
 Torque and drag
 Shale densities

2.3.6 Mud contamination by gas

During drilling of formations containing gas, this gas is mixed with mud causing a
density reduction. This reduction can be more significant when the gas approaches
the surface (Boyles’ law).

The gas quantity contaminating the drilling mud depends on :

 Rate of penetration (ROP)
 Bit diameter
 Porosity
 Bottom hole conditions (pressure and temperature)

The pressure reduction due to the mud contamination by the gas is approximately
given by the Strong formula :

∆P = 2.3 × di – do log Ph
do

where: ∆P : pressure reduction on the bottom (bars)

di : mud density in
do : mud density out
Ph : hydrostatic pressure (bars)

For the well safety the mud must be degassed at the surface before being re-
circulated.

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 SECTION 3 : KICK INDICATORS
Page

3.1 INTRODUCTION 2

3.2 EARLY SIGNS OF KICKS 2

3.2.1 ROP increase (drilling break) 2

3.2.2 Torque and drag increase 3

3.2.3 Shale density decrease 3

3.2.4 Size, form and volume of cuttings 4

3.2.5 Mud properties change 4

3.2.6 Flow line temperature change 5

3.2.7 d-exponent decrease 7

3.2.8 Presence of gas in mud 8

3.3 POSITIVE SIGNS OF KICKS 9

2.3.1 While drilling 9

2.3.2 While tripping 10

2.3.3 Situations can mask a kick 10

3.4 GAS BEHAVIOUR IN OIL BASED MUDS 10

3.5 WORK SHOPS 12

 WELL CONTROL MANUAL
SECTION 3 : KICK INDICATORS

3.1 INTRODUCTION

A rapid detection of a kick and immediate correct action are the key elements for
the success of a well control.
Several signs can anticipate an imminent risk of a kick, these warning signs are
analysed in the following.

3.2 EARLY SIGNS OF KICK

The well safety depends essentially on the rapid detection of precursor signs of a
kick. However the detection of only one sign can not be a definitive indicator of a
kick, it’s for this reason that it is important to observe the other indicators detailed
in the following.

3.2.1 Drilling rate increase (Drilling break)

The ROP is function of a certain number of parameters which are :

 Weight on the bit WOB

 Rotary speed RPM
 Formation type
 Hydraulics
 Bit type
 Differential pressure P
 Formation porosity

An increase of ROP in abnormally high pressured formation could be mainly due

to differential pressure reduction and to porosity increase if all other parameters are
kept constants.

3-2
 WELL CONTROL MANUAL
SECTION 3 : KICK INDICATORS

R
R0
R0V0 = ROP we would have with ∆P = 0

Fig 3.1

Then it's necessary to control immediately the wellbore stability as soon as we

record a rapid increase of the ROP (drilling break)

3.2.2 Torque and friction increase

The increase of the torque and friction

compared to their normal tendencies during
drilling may indicate the penetration in a high
pressured zone (fig 3.2) As the result of this,
the differential pressure decreases and the
fluid in the shale expands causing cracking ,
spalling and sloughing of the shale into the
wellbore.This can cause a build up of cuttings
in the annulus and eventually stuck pipe

Fig 3.2
3.2.3 Shale density decrease

As normal tendency the shale density increases with depth illustrating the
compaction effect. The penetration in an abnormal high pressure zone will show a
porosity increase which corresponds to a shale density reduction.

3-3
 WELL CONTROL MANUAL
SECTION 3 : KICK INDICATORS

The measurement of the discard between the shale density measured at surface and
the normal trend (density /depth) is used to detect abnormal zone prior taking a
kick (fig 3.3)

LOG POROSITY SHALE LOG DENSITY SHALE

NORMAL NORMAL
COMPACTION COMPACTION

HYDROSTATIC HYDROSTATIC
ZONE ZONE

TOP TRANSITION
ZONE
ABNORMAL
PRESSURE ZONE

DEPTH DEPTH

Fig 3.3
3.2.4 Size, shape and volume of cuttings

The cuttings with larger volumes can be produced in the transition and abnormal
zones following a negative differential pressure. The cuttings analysis can show
that cuttings are more angular, sharp, and splintery and then enable to predict
entering in a high pressure zone.

3.2.5 Changes in mud properties

The intrusion of a lighter fluid into the wellbore causes a decrease of mud weight,
and generally followed by a variation in viscosity in function of type of both mud
and effluent.

3-4
 WELL CONTROL MANUAL
SECTION 3 : KICK INDICATORS

For example, an intrusion of a pore water into oil based mud will increase
viscosity; on the opposite, the effect will be inverse for a saturated salt mud with
low PH.

The chlorides concentration change in mud is among the indicators predicting a

kick. Usually formation fluids are more salty than drilling muds

An important task of the mud engineer is to establish the normal tendency of the
mud properties keeping attention to any significant changes.

3.2.6 Change of mud temperature at flow line

The variation of temperature trends is characterised by a decrease when drilling

comes close to a transition zone; at the entry of this zone the temperature gradient
increases to about twice the rate of the normal temperature gradient (fig
3.4).increase of mud temperature at the flow line can indicate the top of abnormal
pressure zone.
The temperature measurement at the surface must be corrected to take into
consideration the influence of the following parameters:
 Drilling flow rate
 Type and volume of circulated mud
 Time elapsed since the last trip
 Surface temperature

3-5
 WELL CONTROL MANUAL
SECTION 3 : KICK INDICATORS

Mud temperatures at the flowline

Fig 3.4

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 WELL CONTROL MANUAL
SECTION 3 : KICK INDICATORS

3.2.7 d-exponent decrease

The “d” exponent method has been introduced to normalise the ROP in order to
eliminate the variation effect of the drilling parameters to obtain a representative
measurement of the formation drillability (fig 3.5).

d = 1.26 – Log (ROP / RPM)

1.58 – Log (WOB / D)

Where d : d- exponent
ROP : rate of penetration (m/h)
RPM : rotary RPM (revolutions /min)
WOB : weight on bit (tonnes)
D : bit diameter (inches)

The “d” exponent must be corrected according to the mud density.

dc = d × d1
d2

Where dc : corrected “d” exponent

d : “d” exponent measured
d1 : formation fluid density corresponding to the gradient of the
normal hydrostatic pressure (1.00 to 1.07 kg/L)
d2 : equivalent mud density

3-7
 WELL CONTROL MANUAL
SECTION 3 : KICK INDICATORS

The graphical representation of

the “d” exponent versus depth in a
shale zone permits to :

 Define a basic line “normal trend”

 Follow their compaction evolution
 Detect abnormally high pressures
zones

Fig 3.5
3.2.8 Gas cut mud
Dispersion of gas in the mud can result from one of the following causes :
 During drilling of a permeable formation containing gas with an
sufficient mud density, the gas contained in the drilled rocks will enter the
mud (gas cut mud).It should be noted after the bottom up time.50% gas cut
mud at surface changes the BHP at 20 000 ft by only 100 psi.
The gas percentage in the mud is depends on:
- bit diameter
- pump flowrate
- rate of penetration
- pore pressure
- formation porosity
High volume of gas-cut mud in the annulus should be dangerous to decrease
sufficiently the hydrostatic pressure to take a kick.
 When making up a connection, gas can enter the well (connection gas)
by reducing BHP to become less than pore pressure either by the removing
annular pressure losses or/and by swabbing-in effect.
When gas of this origin is detected at surface, it is necessary to increase
mud weight prior to trip.

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 WELL CONTROL MANUAL
SECTION 3 : KICK INDICATORS

 After a tripping-out operation , a gas-cut (trip gas) is sometimes detected

during circulation of the bottom up if the BHP becomes less than the pore
pressure for the following reasons :
- the swabbing-in effect
- the failure to fill

Flow checks

Flow checks should be performed as following:

 In case of drilling break

 On bottom prior to start tripping out.
 At the casing shoe
 When DC’s on slips
Procedure:

 Stop rotary
 Space out
 Shut down pumps
 Observe flow return

If negative resume drilling operations

If positive shut the well in according to company procedures.

Remark:
If OBM is in use, the drilling break should be checked by circulating a bottom up
through choke in respect of the Driller’s Method.

3.3 POSITIVE SIGNS OF KICKS

A positive sign of kick means a sure intrusion of a formation fluid into the well
which requires to close the well in immediately.

The positive signs listed in the following can occur during drilling or tripping.

3.3.1 While drilling

The positive signs during the drilling are :

- Flow rate increase at the flow line

- Tank level increase

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 WELL CONTROL MANUAL
SECTION 3 : KICK INDICATORS

- Flow rate continues at flow line, pumps stopped.

The differential flow rate indicator and the mud volumes totalizer are essential for
kick detection.

3.3.2 While tripping

The positive signs during a trip out are:

- Difference between the mud volume to fill and the metal volume
withdrawn
- Difference between the metal volume introduced and the mud volume
recovered when running in.

The use of a trip tank and a trip sheet are necessary for a rapid detection of a
foreign fluid intrusion during tripping operation

3.3.3 Situations that can mask a kick

In certain situations, the positive signs can be unseen by :

- Mud density adjustment during drilling

- Surface mud transfer during drilling
- Partial circulation loss
- Leaks on surface equipments
- Use of solids control equipments an degassing mud
- start up and shut down mud pumps
- drain back

3.4 GAS BEHAVIOUR IN OIL BASED MUDS

In case of kick entering while drilling with an oil based mud, the gas dissolves into
the oil phase of the mud forming a mixture.
When the mud with dissolved gas is circulated up in the annulus the gas remains in
solution until it reaches its bubble point when close to surface where it will expand
rapidly.
During the circulation of an effluent volume from bottom hole to the surface in an
open well, the kick detection is more difficult in case of an oil based mud than a
water based mud (fig 3.6)

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 WELL CONTROL MANUAL
SECTION 3 : KICK INDICATORS

Oil based mud Water based mud

Fig 3. 6

3-11
 SECTION 4 : SHUT- IN PROCEDURES
Page

4.1 INTRODUCTION 2

4.2 SOFT SHUT-IN PROCEDURE 2

4.3 HARD SHUT-IN PROCEDURE 5

4.4 FAST SHUT-IN PROCEDURE 5

4.5 SOFT VERSUS HARD SHUT-IN PROCEDURES 9

4.6 DIVERTING PROCEDURE 10

4.7 SHUT-IN PROCEDURE WHILE WIRELINE LOGGING 12

4.8 WORK SHOPS 14

 WELL CONTROL MANUAL
SECTION 4 : SHUT-IN PROCEDURES

4.1 INTRODUCTION

The rapid detection of a kick and the immediate well shut-in are the key elements
to put the well under control successfully.

The well shut-in procedures are established in order to:

 Secure the well

 Minimise the kick volume

The kick size and severity depend on :

 Differential pressure at the bottom of the well

 Formation permeability

 Time spent to perform the procedure to shut the well-in

 Type of intruding fluid

The objective of this section is to describe the different procedures to close the
well-in in case of a kick, agreed by the petroleum industry.

The following procedures relative to land rigs are just general recommendations.

 The soft closing procedure

 The hard closing procedure

 The fast closing procedure

4.2 SOFT SHUT-IN PROCEDURE

4.2.1 Surface line up

During drilling the control flow path must be lined up as follows (fig 4.1)

 Choke line manual valve opened

 Choke line hydraulic valve closed

4-2
 WELL CONTROL MANUAL
SECTION 4 : SHUT-IN PROCEDURES

 Hydraulic choke opened

 All valves downstream the HCR valve passing by the hydraulic choke,
towards the separator must be opened
 Other valves on choke manifold closed

4.2.2 Closing procedure while drilling

The soft closing procedure in case of a kick during the drilling consists of:

 Stop rotating and give alert

 Raise the drill string with pumps running and position the first tool joint
above the rotary table
 Stop mud pumps and check for flow

If positive :

 Open the HCR valve on choke line

 Close a preventer (annular in preference)
 Close the hydraulic choke and warn the supervisor
 Note the gain, read DP pressures and casing pressures and plot it in
function of time

4.2.3 Shut-in procedure while tripping

If there is an indication of a kick while tripping, the well must be closed-in as

follows:

 Set the drill string on slips with top tool joint at 1 meter
 Stab the safety valve fully opened on drill pipe
 Close the safety valve
 Open the HCR valve at choke line
 Close a preventer
 Close choke and call supervisor
 Record gain and pressures versus time

4-3
 WELL CONTROL MANUAL
SECTION 4 : SHUT-IN PROCEDURES

LINE UP FOR SOFT SHUT-IN

4-4
 WELL CONTROL MANUAL
SECTION 4 : SHUT-IN PROCEDURES

4.3 HARD SHUT- IN PROCEDURE

4.3.1 Line up

During drilling operations the surface flow path should be lined up as follows (fig
4.2) :
 Manual valve at choke line opened
 HCR valve at choke line closed
 Choke closed
 All valves downstream the HCR valve through choke towards
separator are opened
 Other valves at chokes manifold closed

4.3.2 Closing procedure while drilling

The hard closing procedure while drilling consists of :
 Stop rotating the drill string
 Raise the drill string with pumps on until spaced out
 Stop pumping and check for flow
If positive:
 Close a preventer
 Open the HCR valve at the choke line and call supervisor
 Note the pit gain, plot a graph of DP pressures and casing pressures
with times (fig 4.4)

4.3.3 Shut- in procedure while tripping

If a kick is suspected during tripping, proceed as follows :
 Set top tool joint in the slips
 Install the full opened safety valve on the DP
 Close a preventer
 Open the HCR valve at the choke line and call supervisor
 Note the gain and plot casing pressures versus times

4.4 FAST SHUT-IN PROCEDURE

4.4.1 Surface line up

The line up is same as described for the hard closure procedure

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 WELL CONTROL MANUAL
SECTION 4 : SHUT-IN PROCEDURES

4.4.2 Shut-in procedure while drilling

The fast closing procedure when drilling consists of :

 Stop rotating the drill string

 Raise the drill string with pumps on until spaced out
 Stop pumping and check for flow, if positive :
 Open the HCR valve at the choke line
 Close a preventer and call supervisor
 Note the pit gain, plot a graph of DP pressures and casing pressure versus
times

4.4.3 Shut-in procedure while tripping

If a kick sign is observed while tripping, the well will be closed-in as follows:
 Set top tool joint in the slips
 Install the full opened safety valve on the DP
 Close the safety valve
 Open the HCR valve at the choke line
 Close a preventer and call supervisor
 Note the gain and plot casing pressures versus times

NOTE: For the all procedures, it is recommended to line up the flow line to the
trip tank to detect any leakage at the preventers.

Shut in procedure while tripping w/TDS

 Set the string in the slips

 Lower the TDS and spun up on the string
 Close the lower FOSV
 Open HCR valve
 Record casing pressure and pit gain
If decided to strip in:

 Back out lower safety valve

 Keep subs to connect upper and lower safety valve on drill floor

Note : Once the well has been shut in , it is recommended that a pup joint or a
single be installed between the top drive and the FOSV stabbed on the string, then

4-6
 WELL CONTROL MANUAL
SECTION 4 : SHUT-IN PROCEDURES

open valve .If flow through the string prevented installationof the sfaty valve , the
top drive may be stabbed and muk up directly o the DP

Shut in procedure while out of the hole.

Soft method
 Open HCR valve
 Close Blind rams
 Close choke.
 Read and record casing pressure and times .Check pit and trip volumes
for pit gain.

Hard method
 Close blind rams
 Open HCR
 Record casing pressure and pit gain

Main options are available:

 Stripping into the hole

 Bullheading down the kill line
 Volumetric method

Shut in procedure while running casings

Hard method
 Close the casing rams
 Open HCR
 Record casing pressure and pit gain

Soft method
 Open HCR
 Close the casing rams
 Record casing pressure and pit gain

Note: Prior to close, It is recommended to install the circulating head in case of

float equipment failure and to chain it to the substructure to prevent from lifting
forces.

4-7
 WELL CONTROL MANUAL
SECTION 4 : SHUT-IN PROCEDURES

LINE UP FOR HARD AND FAST SHUT-IN

4-8
 WELL CONTROL MANUAL
SECTION 4 : SHUT-IN PROCEDURES

4.5 ADVANTAGES AND DISADVANTAGES OF THE DIFFERENT

CLOSE-IN PROCEDURES

4.5.1 Soft procedure

Advantages:

 Allows monitoring casing pressure providing more sensitive control of

pressure build up during closure. Permits initiation of low choke pressure
method if pressure is likely to exceed MAASP.
 Avoids pressure surge at the open hole section while operating HCR
valve.

Disadvantages:

 Additional time spent to perform the procedure causes additional influx.

 Somewhat more complicated

4.5.2 Hard and Fast procedures

Advantages :

 Allows the well to be closed in the shortest possible time.

 Minimise influx volume.
 Performed by one man on a same panel.

Disadvantages :

 Doesn’t permit casing pressure control during pressure build up.

 Larger kick volume will be taken.
 Possible pressure surge at the open hole after opening HCR valve at
choke line.

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 WELL CONTROL MANUAL
SECTION 4 : SHUT-IN PROCEDURES

4.6 DIVERTING PROCEDURE

While drilling surface formations subject to contain gas, it's necessary to

install a diverter. This equipment can ensure a kick evacuation without
closing the well-in to prevent any formation breakdown.

Drilling Top Holes

While drilling top hole special care should be exercised because of difficulty in
early detection of gas influx and the shallow nature of the hole .The gas upon
entering the well bore, expands and reaches the surface rapidly with little warning.

Where shallow casing string or conductor pipe are set, fracture gradients will be
low and it may be impossible to close the BOP without breaking down the
formation at the shoe.

 Float valve should be in use to prevent gas entering drill string if a kick is
taken while making connection.
 Pilot hole: a pilot hole can be drilled as it will improve the capability of
controlling shallow gas kick .Caution should be taken while POOH due to
the possibility of swabbing.
 Heavy mud: a minimum of 50 m3 must be ready in the reserve pit (2 ppg
more than the active mud)
 Restricted drilling rates the ROP should be controlled to prevent excessive
build up of solids which could cause fracturing or lost circulation .It is also
necessary to prevent accumulation of gas in the annulus which could induce
the well to flow
 Flow checks : flow check will be made every time a problem is suspected
.Each connection will be systematically flow checked while drilling in
potential shallow gas zone
 Mud losses large bit nozzles should be used to allow pumping of LCM and
to permit high flow rates should diverting be required

a) In case of a kick
At the least sign of a kick during drilling, flow check is inadvisable and the
following procedure must be applied immediately (fig 4.3) :
 Maintain high pumps flow rate pumping the stored heavy mud.
4-10
 WELL CONTROL MANUAL
SECTION 4 : SHUT-IN PROCEDURES

 Position the lower kelly cock above the rotary table

 Open the diverter line
 Close the return valve towards the shale shaker and the trip tank
 Close the diverter
 Shut down all unnecessary equipments.
NOTE :

1. In case of an exhaust of the kill mud, pumping should be

maintained by attempt to achieve the well control by injecting
fresh water.

2. If the diverter is fitted with two flare lines, close the valve of
the line opposite to the wind direction

Safety precautions

 An abandon rig exercise is to be conducted to review all escape routes

and muster point (with alternatives established for different wind
directions).
 No hot work or preventive maintenance work to be done without
permission of company man.
 The guard at the gate stops all truck entries to rig site. Entry permission
will be given to each truck by the company representative.
 Prior to drilling the hole section where shallow gas is expected hold a
safety meeting and the company man and the Tool Pusher to explain
procedures.
 At start of each shift, driller/tool pusher explains procedures with the
crew. If anybody is in doubt/not sure, stop working and communicate the
concern to either the tool pusher or company man then go to the
established Muster point.
 All non essential personnel to be off the drill foor
 Drilling of potential shallow gas horizon should only take place during
day light hours.

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SECTION 4 : SHUT-IN PROCEDURES

DIVERTER INSTALLATION SCHEME

4.7 SHUT-IN PROCEDURE WHILE WIRELINE LOGGING

In case of a kick during a wireline operation, it is advised to proceed as follows:

 Stop the wireline operations and close the annular preventer

 Open the HCR valve at choke line and warn the supervisor

 Record pit gain and shut-in pressures

 Decide on a program to kill the well

NOTE : It is recommended to strip out the wireline. If necessary cut the

cable and close the blind rams preventer .

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PRESSURE READINGS

1 / Pressures records

Time DP Casing Time DP Casing

(mn) pressure pressure (mn) pressure pressure
1 11
2 12
3 13
4 14
5 15
6 16
7 17
8 18
9 19
10 20

2/ Graph plot

Pressures

Time (mn)
Fig 4.4

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Page

5.1 INTRODUCTION 2

5.2 PRE KICK DATA 2

5.3 CONTROL METHODS

5.2.1 Driller’s Method 2

5.2.2 Wait and Weight Method 3

5.2.3 Concurrent Method 3

5.2.4 Volumetric Method 4

5.2.5 Lubricating Technique 4

5.4 STRIPPING PROCEDURE 9

5.5 CONTROL OF KICKS IN HORIZONTAL WELLS 10

5.6 ABANDONMENT PLUGS

5.7 WORK SHOPS 12

 WELL CONTROL MANUAL
SECTION 5: WELL CONTROL METHODS

5.1 INTRODUCTION

The kicks control is implementation of some operations which can allow to

evacuate the effluent and to set up a kill mud producing a hydrostatic pressure in
balance with the formation pressure. The kick control must be carried out so to
prevent any secondary intrusion or fracture at the weakest formation.

5.2 PRELIMINARY CALCULATIONS

A kick can occur at any time during drilling operations, for this reason a some of
parameters must be selected in advance, measured and regularly updated. Others
will be calculated later on the basis of the recorded shut-in data.

5.2.1 Selection of slow pump rates

The kick is generally circulated at relatively low flow rates compared to those
while drilling. In practice the flow rate for the control is generally selected between
a half and a quarter of the drilling flow rate. This is done on the basis of some
criteria as :

 To minimise the discharge pressure while circulating the kick.

 To give time to operate choke to set the desired pressures and in the same
time to enable efficient reaction if any trouble can take place while
circulating the kick.
 To consider the capacity of the mud gas separator.
 To give time to weight up the mud to the required density.
 To prevent a wash out at the choke while circulating.

5.2.2 Dynamic Pressure losses (PL)

The theoretical calculus of the dynamic pressure losses at slow pump rates being
approximate, a direct measure becomes necessary to obtain an exact and actual
value. These values must regularly be updated by frequent measurements:

 at every crew team change

 at every BHA change
 at every change of mud density and rheology
 after drilling a supplementary section of 100 to 200 m

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NOTE : Reading of pressures at slow pump rates ( PL) must be at the gauge on
the choke panel.

5.2.3 Calculus of Maximum Allowable Annular Surface Pressure (MAASP)

The knowledge of the maximum allowable casing pressure is of a vital importance

to avoid fracture at the weakest formation during a well control operation.

The MAASP is gotten from the Leak-Off Test records using the following
formula :

MAASP = Pfrac - d1 × Zs
10.2

or :
MAASP = Zs × dfrac – d1
10.2

where MAASP : maximum allowable annular surface pressure (bars)

Pfrac : fracture pressure (bars)
d1 : current mud density (kg/L)
Zs : shoe vertical depth (m)
dfrac : mud density to fracture (kg/L)

5.2.4 Pit gain measurement (G)

The mud gain at the surface corresponds to the kick volume who has taken place
prior to close the well-in; then it is measured by the increase of mud level at the
active tank. However, if this is valid for the water based mud, it wouldn't valid for
the oil based mud which needs to be corrected.

5.2.5 Observation and records of surface pressures

As soon as the well is closed-in after a kick, the stand pipe pressures and casing
pressures must be registered each minute until the stabilisation. The necessary time
for the pressure build up to stabilise depends on the following parameters:

 The differential pressure at the bottom hole

 The reservoir permeability
 The effluent type
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In the case of a gas kick, the determination of the stabilised pressures head seems
difficult and delicate due to the gas migration effects in the annulus. For this
reason in practice, any pressure increase over a certain limit is considered as being
due to the gas migration (fig 5.1).

Re-compression Gas migration

of reservoir without expansion

DP Pressure

SIDPP

Closing time
Fig 5.1

The stabilised shut-in DP pressure (SIDPP) represents only the difference between
the pore pressure and the hydrostatic pressure of mud exerted from inside drill
string; on the contrary, the annular pressure value depends on :

 The pores pressure

 The kick volume

 The effluent type

In general, the stabilised casing pressure value (SICP) is greater than the SIDPP.
The difference will be as higher as the kick volume is important and the density of
effluent is smaller (fig 5.2)

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The value of SICP will be affected by the annular mud density which should be
loaded with cuttings if the kick is taken while drilling inducing an error on the
calculation of influx density if not taken in account.

If the density of the influx is greater than mud weight SIDPP should be greater
than SICP and in any cas the difference between SIDPP and SICP is equivalent to:

Height of influx ( mud density – influx density )

SICP - SIDPP =
10.2

SIDPP SICP1 SICP2 Pressure (bars) SIDPP SICP1 SICP2 Pressure (bars)

h2 d1 d2

h1

Pore pressure Pores pressure

Depth Depth
(m) (m)
kick height h1 < h2 kick density d1 > d2

Fig : 5.2
The presence of a back pressure valve (float valve) in the drill string doesn't allow
direct reading of SIDPP. To read the pressure needs to proceed as following:

 Pump mud through DP at a very low flow rate and observing the casing
pressure
 Stop the pump as the annular pressure starts to increase
 Note the pressure at the stand pipe, it corresponds to SIDPP.
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5.2.6 Determination of kill mud density (KMD)

The required density to kill a well is defined as being the mud weight producing a
hydrostatic pressure equal to pore pressure.

After the well is closed-in, the pore pressure is equal to the sum of the pressures
through inside drill string or to the sum of the pressures through annulus

SIDPP SICP

SIDPP + HPi SICP + HPa+ HPeff

PORE PRESSURE

Fig 5.3

Ppore = SIDPP + HPi = SICP + HPa +HPeff

where SIDPP : stabilised shut-in DP pressure (bars)

HPi : hydrostatic pressure on bottom /inside drill string (bars)
SICP : stabilised casing pressure (bars)
HPa : mud hydrostatic pressure in the annular (bars)
Pheff : hydrostatic pressure of effluent in the annulus (bars)
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The ignorance of the exact density of the intruded fluid makes the pore pressure
calculation via annulus uncertain. On the contrary, its calculus by inside drill string
gives more accurate value from the fact that this space is filled by homogeneous
mud of known density.

Ppore = Z × KMD = SIDPP + Z × CMD

10.2 10.2

or :
KMD = CMD + 10.2 × SIDPP
Z

Where: KMD : kill mud density (kg/L)

CMD : current mud density (kg/L)
SIDPP : stabilised shut-in drill pipe pressure (bars)
Z : vertical depth (m)

The necessary quantity of barite to weight up the mud from its original density to
its kill value (CMD to KMD) is given by the following formula:

B = 4.2 × V × KMD – CMD

4.2 - KMD

where B : mass of barite to add (tonnes)

V : total mud volume to weight up
KMD : kill mud density (kg/L)
CMD: current mud density (kg/L)

5.2.7 Volumes and circulation times calculus

 Drill string internal

a) Drill string internal volume (Vi)

Vi = Vint pipes + Vint BHA

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b) Number of pump strokes internal (Si)

Si = Vi = Vi × SPR
Pdis KR

where Vi : drill string internal volume (L)

Pdis : pump displacement (L/str)
SPM : slow pump rate (str/min)
KR : Kill rate (L/min)

c) Circulation time (Ti)

Ti = Vi
KR

where Vi : drill string internal volume (L)

KR : Kill rate (L/min)

 Open hole annulus

a) Open hole annulus volume (Voha)

Voha = Va (BHA/hole) + Va (pipe/hole)

b) Number of pump strokes open hole annulus (Soha)

Soha = Voha = Voha × SPR

Pdis KR

where SPR : slow pump rate (strokes/min)

Pdis : pump displacement (L/stroke)
KR : Kill rate (L/ mn)

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c) Circulation time (Toha)

Toha = Vd
Qr

 Total annulus volume

a) Total annulus volume (Va)

Va = Voha+ Van casing

b) Total strokes annulus (Sa)

Sa = Va = Va × SPR
Pdis KR

c) circulation time annulus (Ta)

Ta = Va
KR

5.2.8 Calculus of the initial circulating pressure (ICP)

During control at the constant flow rate, the initial circulating pressure necessary to
maintain a constant bottom hole pressure equal to the pore pressure is:

ICP = SIDPP + PL

where ICP : initial circulating pressure (bars)

SIDPP : shut-in DP pressure (bars)
PL : dynamic pressure loss (bars)

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5.2.9 Calculus of the final circulation pressure (FCP)

To maintain a constant BHP while pumping kill mud inside drill string, the
discharge pressure must decrease from the initial discharge pressure (ICP) until the
final discharge pressure (FCP). This final pressure corresponds to the pressure
losses inside string when the heavy mud reaches the bit.

FCP = PL × KMD
CMD

where FCP : final circulating pressure (bars)

PL : dynamic pressure loss at slow pump rate (bars)
KMD : kill mud density (kg/L)
CMD : current mud density (kg/L)

5.3 CONTROL METHODS

Several control methods have been developed throughout the years to treat various
kick situations.

These control methods have the same basic principle which consists to maintain a
bottom hole pressure constant and equal or slightly greater than the pore pressure
during all the control duration. They vary from one to other by the procedure used
to apply this principle.

5.3.1 Driller’s Method

The Driller’s method is the oldest used method, it is considered as being the
simplest one to perform by the fact that the control can be undertaken immediately
after closing the well-in without special preparation.

This method consist of :

- First : circulate and evacuate the kick with the current density
mud.

- Second : replace the original mud by the kill mud to balance the pore
pressure.

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Driller’s Method application procedure

1) Close the well-in as soon as positive sign of kick is noticed.

2) Record gain , SIDPP and SICP

3) Complete the kill sheet fig 5.9 and 5.10

4) First circulation

 Open slightly the choke and start progressively the mud pump until
reaching the control flow rate by adjusting the choke to retain constant
the casing pressure and equal to the value of the SICP
When the control flow rate is attained, the discharge pressure must be
equal to the calculated initial circulating pressure (ICP).

 Continue to circulate at the same constant flow rate until the complete
evacuation of the kick by adjusting choke holding the discharge pressure
steady and equal to initial circulation pressure (ICP).

At the end of the control or at any time the kill operation will be shut down, the
control point is again the casing pressure. It must be held constant as the pump rate
is reduced. Pumps should be slow down slowly, or in stages (use steps of 05 SPM).
This process should have been discussed between pump and choke operators prior
to pump shut down.

Stop the circulation and close the well-in when the heavy mud is ready. Then, we
must read the same pressures at the stand pipe and casing SICP = SIDPP

5) Second circulation

 The kill mud being ready, open slightly the choke and bring the pump up
progressively until to reach the kill rate by adjusting the choke to hold
constant the casing pressure and equal to the SIDPP (CP = SIDPP).

 Continue to circulate at this constant flow rate adjusting the choke to

maintain the casing pressure constant until pumped the number of strokes
corresponding to internal volume Si (kill mud at bit)

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 When the heavy mud starts to move up in the annulus, continue to

circulate at a steady discharge pressure equal to the final circulation
pressure (FCP) until the kill mud reaches the surface.
So,we should note that any casing pressure is present while the choke is
fully open

 Stop the circulation, close choke and observe the pressures at stand pipe
and annulus which must be null.

NOTES :

1. During circulating kick in the open hole, the casing pressure should
not exceed in any case the maximum allowable annular surface
pressure (MAASP) to prevent fracture at the shoe or at the weakest
point. As the kick enters the casing, the fracture risk does not exist
anymore if the bottom hole pressure is maintained steady.

2. After the Driller's method is achieved, the kill mud should be weighted
up to the density including the trip margin ( 10 to 15 bars ).

Advantages and disadvantages of the method

Advantages :

 Start up circulating the kick just after the pressure the build up is
stabilised.

 Simple to undertake

Disadvantages :

 Induces higher pressures in the annulus which can lead to fracture at

the weak point.

 Keeps equipments under more high pressures .

 Needs more time to be achieved.

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FIRST CIRCULATION

ICP CP CP=
SIDPP SICP SIDPP
Ct rises SIDPP

Expansion Gas evacuated

of gas Well full of
original mud

Gas at
bottom
well shut-in after taking kick circulating kick well shut-in after evacuating gas

SECOND CIRCULATION

SPP CP
CP FCP
decrease decrease
Ct Ct

Pumping kill mud into string kill mud moves up in annulus well shut-in full of kill mud

Fig 5.4

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Evolution of pressures at stand pipe and surface annulus

DRILLER’S METHOD FIRST CIRCULATION

Start of STAND PIPE PRESSURE End of

circulation circulation
Constant pressure = ICP

PL

SIDPP

Total annulus strokes (Sa)

Start of CASING PRESSURE End of

circulation
circulation
Gas beneath BOP’s

evacuation
of gas
Gas kick

Water kick
SICP

Total annulus strokes (Sa)

Fig 5.5

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DRILLER’S METHOD SECOND CIRCULATION

Start of STAND PIPE PRESSURE End of

circulation circulation
ICP

FCP Constant pressure = FCP

PL

Heavy mud at bit.

SIDPP

Si Sa

Start of CASING PRESSURE End of

circulation circulation

CP=SIDPP=Cte

SIDPP

Si Sa

Fig 5.6

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5.3.2 Wait and Weight Method

The Wait and Weight Method is another kick control technique having the same
basic principle as the Driller’s method. The procedure of this method consists to
evacuate the kick with a mud of a required density in only one circulation.

Wait and Weight Method application procedure

1) Close the well once a positive kick indicator is noticed.

2) Record pit gain and stabilised pressures at stand pipe and annulus.

3) Complete the kill sheet and mud of the required weight is made up .

4) When the heavy mud is ready, open slightly the choke and
progressively brigs the pump up to the kill rate by operating choke to
hold the casing pressure steady and equal to the shut-in casing pressure
SICP.

When kill rate is reached at constant casing pressure, the stand pipe
gauge must indicate a discharge pressure equal to the initial circulation
pressure (ICP).

5) While pumping kill mud down the drill pipe at the same kill rate, the
discharge pressure is allowed to drop steadily accordingly to the
established graph from the initial circulating pressure (ICP) to the final
circulation pressure (FCP) when kill mud reaches the bit.

6) While the heavy mud is circulated up in the annulus, hold steady the
discharge pressure equal to the final circulating pressure (FCP) by
adjusting choke until to evacuate completely the kick and to observe the
kill mud return at surface.

7) Stop the pump, close the choke and observe head pressures at DP and
annulus which must be zero.

8) Open the well and continue the normal drilling operations after
conditioning mud for trip margin.

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Advantages and disadvantages of this method

Advantages :

 Less fracture risk specially for long open holes

 Less casing pressure while circulating

 Time spent to achieve kill operation is less, then less risk to cause a
choke washout.

Disadvantages :

 Important waiting time to prepare kill mud, then risk to stick and plug the
drill string.

 difficulty to condition mud for important volumes

 Gas migration takes place when waiting

 Behaviour of the gas in the annulus would be difficult to predict

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 WELL CONTROL MANUAL
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SPP CP FCP CP
ICP SICP decrease increase increase
Cte

Gas
expands in
annulus
Gas at
bottom

Start circulate with kill mud Pumping kill mud into DP Kill mud at bit

CP FCP CP
FCP FCP
Max Cte decrease
Cte Cte

Kill mud moves up in Kill mud moves up in annulus

annulus gas arrives at choke with gas completely evacuated Well full of kill mud

Fig 5.7

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Evolution of head pressures

WAIT AND WEIGHT METHOD

Start of STAND PIPE PRESSURE End of

circulation circulation
ICP

FCP Ct pressure = FCP

PL

Heavy mud at bit.

SIDPP Well killed by inside string

Si Sa

Start of CASING PRESSURE End of

circulation circulation
Gas at BOP’s

Original mud
SICP circulated out
Gas evacuated
CP =0
Si Sa

Fig 5.8

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Fig 5.9

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Fig 5.10

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Trapped pressures

Any time the circulation is stopped and the choke is closed during a kill operation,
there is a risk to dynamically trap pressure in the well. Before the operations are
resumed, it is important to remove the trapped pressure in order to ensure that the
BHP is equal to the formation pressure, so that no additional pressure is maintained
on bottom.

Other circumstances that can result in trapped pressures include influx migration
and stripping drill string without bleeding mud.

While circulating a kick the operator at the choke should be aware about the
correct new Shut-in Drill Pipe Pressure to be displayed while closing the choke to
stop the circulation;

 New SIDPP remains the same as SIDPP if the Driller’s Method is in use
 New SIDPP should be a ratio of the initial SIDPP if W&W method is in
use (it corresponds to the remaining SIDPP).

To determine the remaining SIDPP:

 Initial Shut In Drill Pipe : SIDPP

 Number of Strokes at counter when decide to stop kill circulation : S
 Reduction of pressure per 100 strokes pumped : ∆P /100 str
 Number of strokes surface to bit : Si
 Remaining drill Pipe pressure= SIDPP - SIDPP x ∆P /100 str( S/Si )

During drilling or well control operations, when need to change line-up, pressures
could be trapped. To avoid trapping pressures it is a good practice to first open the
valves before to close others. It also important to check the pressure gauges prior to
decide to actuate valves. In presence of trapped pressure it may be necessary to
pressure up the other side of the valve to balance pressures on the both sides prior
to operate the valve.

Otherwise it is advisable to not open the BOP after killing and closing a well
before to bleed by opening the choke to ensure that any pressure is not trapped
under the BOP.

Failing to comply with these rules, may damage the valves and auxiliary
equipment (hammer effect) with possible effect o n the well pressures inducing
risks of blowing out, explosions and hazards for the crews.

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5.3.3 Concurrent method

This method is also known as “Slow Weight-up Method” or “Engineering

Method”, it is generally practiced in cases where the means to weight up the mud
are restricted.

This method consists to start up control after pressures build up stabilisation. The
mud is weighted up by steps while circulating. It is more complicated than the
conventional control methods because of the presence of various densities inside
the drill string. That makes complicated to follow up the discharge pressure
variations during the kick circulation.

5.3.4 Volumetric Method

The volumetric method is a conventional control method which consists to let a

gas bubble to migrate up to surface without circulation but allowing it to expand
under control.

This method is used in some particular situations where the circulation of the
intruded fluid becomes impossible such as :

 Drill string out off hole

 Drill string stuck

 Drill string plugged

 Power failure

 Drill string washed out or twisted off

Two possible situations could appear when performing the volumetric method:

1st case : No possibility to circulate but annulus and internal string are
communicating

Every time that reading of stand pipe pressure is possible, the bleed off method
controlled by DP pressures will be selected.
This consists to bleed appropriate quantity of mud at intervals while gas migrates
up in the annulus by holding stand pipe pressure steady and equal to shut-in drill
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pipe pressure (SIDPP) until gas reaches the BOP's. This procedure insures the
control of the BHP.
In practice, a safety margin is taken in consideration of pressures fluctuations while
operating the choke.

2nd case : No possibility to circulate and no pressure communication

between annulus and internal string

When the pressure reading at DP is not possible, the BHP control must be done by
the annular manometer.

a) Selections and calculus

1) Select working pressure (∆P)

The working pressure (∆P) is defined as being the predetermined increase of

annular pressure before bleeding off a certain volume of mud to keep the
bottom hole pressure constant. Working pressure is selected generally
between 5 and 10 bars.

The casing pressure increase is induced by the gas migration in the well let
closed-in.

2) Select safety margin (S)

A safety margin of 10 to 15 bars is taken to palliate to pressures variations

due to the choke handling.

3) Calculus of the volume to bleed off (Vb)

The volume Vb is the mud volume to bleed off in the trip tank giving a
hydrostatic pressure in the annulus equal to the selected working pressure
(∆P). The calculus of this volume is obtained by the following formula:

Vb = 10.2 × ∆P × Ca
d1

where Vb : mud volume to bleed (L)

∆P : working pressure (bars)

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d1 : mud density (kg/L)

Ca: annular capacity at gas position (L/m)

4) Calculus of the gas migration rate (Rm)

If a kick is taken while drilling and the well is shut-in, the intruded fluid will
be located at bottom of the annulus. After a certain time, the migration of the
gas will take place inducing higher and higher pressures along the well.

The gas migration rate is estimated from the pressure increase recorded after
a certain elapsed time. To determine the gas position at any moment in the
annulus, the following formula can be used:

Rm = 10.2 × ∆P
d1

where Rm : gas migration rate (m/h)

∆P : pressure increase per hour (bars/h )
d1 : mud density (kg/L)

Volumetric Method application procedure

1) Note the stabilised shut-in casing pressure SICP

2) Let the casing pressure to increase up to :

Pa2 = SICP + S +∆P
3) Bleed off in the trip tank at constant casing pressure equal to Pa2 the
calculated mud volume Vb corresponding to the gas position in the annulus
by using the manual choke preferently.

4) Let the annular pressure to increase with a quantity equal to the

selected working pressure. The casing pressure will have a new value
Pa3 = Pa2 + ∆P
5) Repeat the sequences 3 and 4 until the gas reaches the surface, then it will
be evacuated using the lubricating method.

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Well shut-in Casing pressure Casing pressure Casing pressure Gas reaches
after taken increase by increase after increase after the BOP's
a kick migration bleed off bleed off

Fig 5.11

Application example:
Data :

Z = 3700 m
SICP Zs = 2450 m
d1 = 1.40 kg/L
dgas = 0.30 kg/L
mud LDC = 200 m
SIDPP = 0 bar (drill string plugged)
SICP = 50 bars
Gain = 1500 L

kick Capacities : OH/DC = 15.20 L/m

OH/DP = 23.90 L/m
CSG/DP = 24.90 L/m

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We take a safety margin S = 10 bars and a working pressure ∆P = 5bars.

The casing pressure is equal to:

Pa2 = SICP + S + ∆P
Pa2 = 50 + 10 + 5 = 65 bars

If the raise of pressure is 10 bars in 30 min, the gas bubble has migrated on a
distance of h from the bottom as :

h = 10.2 × ∆P
d1

h = 10.2 × 10 = 73 m
1.40

and the migration rate is :

Rm = 10.2 × ∆P
d1

Rm = 10.2 × (10 × 2) = 146 m/h

1.40

The gas bubble is next to the DC.

The mud volume Vb to bleed off in the trip tank and corresponding to working
pressure (∆P) of 5 bars is equal to :

Vb = 10.2 × ∆P × Ca (OH/DC)
d1

V = 10.2 × 5 × 15.2 = 554 liters

1.40

The mud volume Vb to bleed off when the bubble is next to the
DP is equal to :

Vb = 10.2 × ∆P × Ca (OH/DP)
d1

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Vb = 10.2 × 5 × 23.9 = 871 liters

1.40
The mud volume Vb to bleed off when the gas is inside casing is equal to:

Vb = 10.2 × ∆P × Ca (CSG/DP)
d1

V = 10.2 × 5 × 24.9 = 907 liters

1.40

The application of the volumetric method is described as follows :

1) after closing, let the casing pressure to rise up to the value

Pa2 = 65 bars, then bleed at constant casing pressure the volume
Vb = 554 L
2) let the casing pressure to rise up to the value Pa3 = 70 bars and bleed
at constant casing pressure the volume Vb = 871 L
3) repeat the sequence 2 by letting the annular pressure to increase from the
value ∆P and bleed off the volume Vb corresponding to the position of the
kick in the annulus until the kick reaches the preventers.

Casing pressure (bars)

∆P

Pa1
Bled volume (L)

554 L 871 L 871 L 907 L 907 L

Fig 5.12

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SONATRACH KILL SHEET

VOLUMETRIC METHOD

Well : Rig : Date :

Well depth : m Bit depth : m Surface pressure limit : bars
SICP : bars Gain : L V hole : L/m
Van OH/DC : L/m Van OH/DP : L/m V an CSG/DP : L/m
Safety S = bars Working pressure ∆P = bars
Working pressure ∆P = bars Vea CSG/DP : L/m
V1= 10.2 × ∆P × Vea(OH/DC) = 10.2 × × = L
d1
V1= 10.2 × ∆P × Vea(OH/DP) = 10.2 × × = L
d1
V1= 10.2 × ∆P × Vea(CSG/DC) = 10.2 × × = L
d1
Pa2 = SICP + S + ∆P = + + = bars

Time (hr) Operation Casing Pressure Bled volume Total bled

pressure increase (bars) (L) volume (L)
(bars)

Fig 5.13

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5.3.5 Lubricating Technique

It is a technique used to evacuate a gas volume located beneath the preventers by

replacing it by mud.

The technique principle consists of maintaining a constant bottom hole pressure by

pumping in a determined volume of mud through kill line and bleed a quantity of
gas to reduce the casing pressure with a value equal to hydrostatic pressure of the
pumped volume.

Lubricating Method application procedure

1) Note the casing pressure Pa

2) Select a working pressure level ∆P which is generally between 5 and

10 bars

3) Calculate the mud volume V giving a hydrostatic pressure in the

annulus equal to the selected working pressure level ∆P

V = 10.2 × ∆P × Ca
d1

where V : mud volume to pump through the annular space (L)

∆P : chosen working pressure level (bars)
d1 : mud density (kg/L)
Ca : annular capacity casing-DP (L/m)

4) pump into annulus (kill line) the calculated mud volume V

5) let the mud settle down through the gas

6) bleed the gas using manual choke to reduce casing pressure with a value
equal to the selected working pressure ∆P plus the overpressure due to
the mud injection.
7)
8) repeat the sequences 4, 5 and 6 until the complete evacuation of the
gas.

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NOTE : In case of a swabbed gas while tripping ,the casing pressure must be
null at the end of the lubricating operation and increasing the density would
lead to a circulation loss .

Application example:
Data :

d1 = 1.40 kg/L

SIDPP = 0 bar (string plugged)

SICP = 100 bars

Annulus capacity :CSG/DP = 24.90 L/m

We select a working pressure ∆P of 5 bars.

The calculus of the mud volume to pump corresponding to the working

pressure ∆P is :

V = 10.2 × ∆P × Ca
d1

V = 10.2 × 5 × 24.9 = 907 litres

1.40

The casing pressure evolution versus pumped mud volume is represented as

follows on figure 5.14

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Casing pressure (bars)

100
95

90

85
80

75

907 1814 2721 3628 4535 V pumped

(L)

Fig 5.14

In this case where drill string is assumed plugged, to achieve the control will need
special operation to establish circulation or to perforate after the complete
evacuation of the kick.

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SONATRACH KILL SHEET

LUBRCATING TECHNIQUE

Well : Rig : Date :

Well depth : m Bit depth : m Surface pressure limit : bars
SICP : bars Gain : L Mud density : kg/L
Working pressure ∆P = bars Ca CSG/DP : L/m
V1= 10.2 × ∆P ×Ca(CSG:DP) = 10.2 × × = L
d1

Time (hr) Operation Casing Pressure Volume Total volume

pressure decrease (bars) pumped pumped (L)
(bars) (L)

Fig 5.15

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5.4 STRIPPING PROCEDURE

In case of a kick while tripping, several options should be considered:

a) if the well doesn’t flow, run string back to bottom with the well opened
keeping an eye on the mud return at flow line.

b) if the well is closed in while the drill string is far from bottom and the
hole conditions don’t allow to run back, the Volumetric Method will be
used to control the kick.

c) if the well is closed in and the hole conditions will permit to

strip in, it is recommended to run back the bit to bottom and
evacuate the kick by circulation (first circulation of the Driller’s
Method).

Knowing that the kick control while tripping will be effective only if the bit is at
bottom, efforts must be provided to run back to bottom performing the stripping
procedure.

In fact, the stripping is a technique which permits in case of a kick, to run back in
hole (well shut-in), by keeping the bottom hole pressure steady.

To maintain the bottom hole pressure constant, the stripping operation consists to
bleed at constant casing pressure a measured mud volume equal to the introduced
drill string external volume, plus a certain volume corresponding to the casing
pressure rise due to the gas migration.

The practical realisation of such operation seems delicate for the following reasons
:

 Pressure growth at the annulus due simultaneously to the gas migration

and the drill string introduction into the well.

 Difficulty to know the exact position of the gas in the well.

 Equipment used must be suited to the operation (trip tank, strip tank and
BOP’s).

 Lack of training and communication.

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Stripping requires surface equipment which simultaneously:

 Permits pipe to be pulled from or run into a well,
 Provides a means of containing and monitoring annular pressure, and
 Permits measured volumes of fluid to be bled from or pumped into the
well.
Subsurface equipment is required to prevent pressure entry or flow into the pipe
being stripped.

For stripping operations, the primary surface equipment consists of blowout

preventers, closing units, chokes, pumps, gauges, and trip tanks (or other accurate
drilling fluid measuring equipment).

Often the blowout preventer stack installed for normal drilling is suitable for low
pressure stripping if spaced so that tool joints or couplings can be progressively
lowered or pulled through the stack, with at least one sealing element closed to
contain well pressure.

Ram type preventers or combinations of ram and annular preventers are employed
when pressure and/or Configuration of the coupling could cause excessive wear if
the annular preventer were used alone. Ram preventers must be opened to permit
passage of tool joints or couplings. When stripping between preventers, provision
should be made for pumping into and releasing fluid from the space between
preventers. Pressure across the sealing element should be equalised prior to
opening the preventer to reduce wear and to facilitate operation of the preventer.

Adjustable chokes which permit fast, precise control should be employed. Parallel
chokes which permit isolation and repair of one choke while the other is active are
desirable.

A trip tank, or preferently a strip tank , accurately measuring the drilling fluid bled
off, leaked from, or pumped into the well within an accuracy of one-half barrel is
required.

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Stripping operation application procedure

1) Record the pit gain (G) and the stabilised casing pressure (SICP)

2) Prepare the kill sheet for the stripping.

3) Select a working pressure ∆P which is generally between 5 and 10 bars

4) Calculate the mud volume V1 to bleed corresponding to this working

pressure

Vb = 10.2 × ∆P × CaOH/DC)
d1

where Vb : mud volume to be bleed (L)

∆P : selected working pressure (bars)
d1 : initial mud density (kg/L)
Ca: annulus capacity hole-DP (L/m)

5) Select a safety margin (S) in consideration of pressure variations while

handling the choke .Its value is generally between 10 and 15 bars.

6) Calculate the safety margin (SDC) to compensate the hydrostatic

pressure drop while introducing the BHA in the kick.

SDC = d1 – dgas G - G
10.2 Ca(OH/DC) Chole

where d1 : current mud density (kg/L)

dgas : effluent density (kg/L)
G : pit gain measured at surface (L)
Ca(OH/DC) : annulus capacity OH/DC (L/m)
Ca (hole) : hole capacity (L/m)

7) Line up choke manifold on trip tank and reduce the regulation

pressure of the annular preventer until obtaining a slight leakage.

8) Increase the casing pressure (by stripping) at a pressure Pa2 equal to

the value :

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 WELL CONTROL MANUAL
SECTION 5: WELL CONTROL METHODS

Pa2 = SICP + S + SDC + ∆P

9) Continue to strip by introducing the drill string slowly at a speed of 0.3

m/s (1 ft/s) and by purging at constant casing pressure equal to Pa2 .

10) After every stand introduced, record the total bled volume Vb and
calculate the difference between this latter and the total external
volume of the introduced drill string at the beginning of bleeding Vext

11) Continue to running in hole by bleeding at steady casing

pressure equal to Pa2 until the difference between the total bled
volume Vb and the total external introduced volume from the
beginning of bleeding Vext is equal to the calculated volume.

Vb = V - Vext

12) Close the manual choke and continue to strip by letting the casing
pressure rise of ∆P up to the value Pa3 with :

Pa3 = Pa2 + ∆P

13) Repeat the sequences 11 and 12 until bit reaches the bottom and
prepare to evacuate the kick by circulating.

Recommendations for the stripping operation

 Fill in the drill string at least every five (5) stands.

 The run in hole speed must be reduced during the passage of the tool-
joints through the annular preventer.

 Remove the casing protectors and grease the tool-joints when running in
hole.

 The use of graduated trip tank of a low capacity is essential for a good
volumes monitoring.

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 WELL CONTROL MANUAL
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 Installation of an accumulator bottle on the annular preventer closing line

to absorb the surpressures caused while tool-joints pass through the
preventer.

Application example:
Data :

Bit 8½
Vertical depth Z 3600 m
Shoe depth 3000 m
Bit depth 3100 m
Cint DP 9.15 L/m
Cmetal 4 L/m
Ca (hole-DP) 23.3 L/m
mud
Ca (hole-DC) 15.2 L/m
C hole 36.6 L/m
Mud density 1.45 sg
kick Gas density 0.30 sg
Pit gain 3000 L

1) We select a working pressure ∆P = 5 bars and a safety margin S

of 10 bars.

2) Calculus of the volume Vb corresponding to the working pressure level

Vb = 10.2 × ∆P × Ca (OH/DC)
d1

Vb = 10.2 × 5 × 15.2 = 535 liters

1.45

3) Calculus of the drill string external volume

Cext = Cint pipes + Cmetal

Cext = 9.15 + 4 = 13.15 L/m

4) Calculus of the safety SDC of DC introduction in gas

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 WELL CONTROL MANUAL
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SDC = d1 – dgas G - G
10.2 Ca (OH/DC) Chole

SDC = 1.45 – 0.3 3000 - 3000 = 13 bars

10.2 15.2 36.6

5) Calculus of the casing pressure Pa2

Pa2 = SICP + S + SDC + ∆P

Pa2 = 10 + 10 + 13 + 5 = 38 bars

Implementation

 Increase the casing pressure by stripping up to 38 bars, then continue

to strip at steady casing pressure equal to 38 bars by bleeding off in the
trip tank.

 After each stand stripped, record the total bled volume Vb and calculate
the volume V1 = V - Vext . Continue to strip at constant casing pressure
equal to 38 bars until the volume Vb is equal to 535 L (without taking
into account the external volume of the string having served to raise the
annular pressure up to the value Pa2).

 Close the choke and increase the annular pressure from 38 to 43 bars by
stripping. Then continue to strip at constant annular pressure equal to
43 bars by bleeding off.

 Repeat the operations stripping / bleeding until the bit reaches the bottom
by increasing the casing pressure of 5 bars each time that a volume Vb =
535 L is recuperated.

NOTE : Close the choke when making up the stands.

The annular pressure evolution in function of the number of stripped stands in the
well is given, on the following figure.

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 WELL CONTROL MANUAL
SECTION 5: WELL CONTROL METHODS

casing pressure (bars)

53
48
43
38

0 1 5 9 13 17
stands stripped

Fig 5.16

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 WELL CONTROL MANUAL
SECTION 5: WELL CONTROL METHODS

SONATRACH KILL SHEET

STRIPPING PROCEDURE

Well : Rig : Date :

Well depth : m Bit depth : m Number of stands to strip :
SICP : bars Pit Gain : L Mud density : kg/L
C exter DP L/m External vol./ /stand : L Ca OH/DC : L/m
Safety S = bars Working pressure ∆P = bars
V1= 10.2 × ∆P ×Ca(OH:DC) = 10.2 × × = L
d1

SDC = d1 – dgas × G - G = × - = bars

10.2 Ca OH/DC) C hole

Pa2 = SICP + S + SDC + ∆P = + + + = bars

Step Stand P casing Bled volume Cumul V1 =V-Vext Remarks

N° N° (bars) Vb (L) Vext DP (L) (L)

Fig 5.17

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Losses while killing

With partial loss two courses of action are possible:

 Continue to maintain kill rate to control the BHP despite the losses until
the gas is within the casing shoe .Then pressures will decrease along the
open section and the lost return problem may solve itself.
 Add lost circulation materials to the kill mud if possible.
 Stop pumping and shut in. Give the hole time to cure itself .Observe
pressures
 If the losses become heavy the low choke pressure method can be
performed .If the returns are insufficient then close the well in and treat
as for severe or total losses.

Severe and Total losses (tertiary control)

 Pump LCM down the annulus that further helps to reduce influx and to
avoid bit plugging , since the total fluid head is greater
 Placing a heavy slug of mud in bottom
 Set barite, cement or gunk plug.

Total lost circulation while drilling

When lost circulation occurs, the drilling fluid level will drop and a reduction in
hydrostatic pressure in the wellbore may cause the loss of primary well control and
kick is taken.

When this type of kick occurs, it may rapidly become very severe since a large
influx can occur before a rising annulus mud level is seen, for this reason, it is
recommended that the annulus should be filled with water to maintain the best
possible hydrostatic head in the well

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 WELL CO
CONTROL MANUAL
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Underground blowout

Underground blow out can occurs after a breaking down caused by a casing
pressure exceeding the MAASP:
MAASP

- While closing the well in on an excessive kick size

- While the gas is let to migrate without to bleed off the well.

As the MAASP is reached the fracture occurs at the weakest

weakest point ( casing shoe).
The mud enters into the fractures allowing the gas to expand and the well to get
underbalanced. The kick zone will produce without any control and escape
escapes from
the fractures; the underground blowout is then triggered.

The remedialial action will need important operations of tertiary control including the
drilling of a relief well.

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5.5 KICK CONTROL IN HORIZONTAL WELLS

The kick behaviour in a highly deviated or horizontal well is different from the one
in a vertical well. In fact, a gas kick can be trapped and more difficult to evacuate
from the horizontal drain.
In a horizontal well, the kick volume due to swabbing during pulling out of hole is
relatively more important than in a vertical well. The confirmation of such a kick
by a flow check or by pressure readings after closing the well is impossible as long
as the gas is in the horizontal drain.

5.5.1 Detection of kicks while drilling

The detection of a kick in a horizontal section is more difficult compared to

vertical well. Swabbed influxes can be also hard to detect in horizontal sections.
However the surest indicators remain the same that are:

 Return flow rate increase at flow line

 Pit level increase

To permit a good tracking of volumes during drilling of a horizontal section, the

operations such as, adding chemical products or mud even at low volumes in the
active system are to be avoided.
 Gas will not migrate if hole angle is 90 ° or greater
 Gas may be trapped in undulations or wash outs in hole sections which are
equal or greater than 90°
 Slow circulating rates which gives a flow rate greater than 130 ft/ mn while
circulating gas out of horizontal section should be considered. Flow rates
lower than this may not remove the gas from the horizontal section
 SIDPP & SICP will be the same and the nature of the influx cannot be
known

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In high deviated or horizontal sections kicks and losses it is common having kicks
and losses concurrently.:

 Heterogeneous kick zones along the drain particularly in permeability

 Annular pressure losses are greater at the bottom than at the entry in the
horizontal section
 The well can crosss a fractured zone in the drain particurly in depleted
reservoir .

900
V ertical W ell

800 H o rizo nta l W e ll

700

600

500

400

300

200

100

0
20 40 60 80 100 120 140 160 180
D is p la c e m e n t T im e (m in )

Fig xx
3,250
Vertical W ell
3,230 Horizontal W ell

3,210

3,190

3,170

3,150

3,130

3,110

3,090

3,070

3,050
20 30 40 50 60 70 80 90 100
Displacem ent Tim e (m in)

Fig xx

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 WELL CONTROL MANUAL
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5.5.2 Precautions to take while making up connections

During connections, line up the mud return to the trip tank to detect any eventual
kick due to the removal of the annular pressure losses.

5.5.3 Precautions to take while tripping

1) Reduce the pulling speed to prevent swabbing.

2) Condition the mud before POOH trip to obtain an adequate

rheology and a homogeneous mud density with a sufficient trip
margin.

3) While tripping, the slug should be pumped after the bit is removed
from the horizontal section.

4) Follow in a accurate way the pumped volumes by using a trip

tank and a trip sheet.

5) Make sure that the safety margin (trip margin) will be sufficient prior
to begin pulling out of hole.

5.5.4 Evolution of discharge pressure during the control

The discharge pressure evolution during the kick control in a horizontal well
doesn’t follow only one straight line as in the case of a vertical well, from the fact
of its geometry.

The calculus and the graph plot of the discharge pressure when injecting the mud
of kill density must be done for every section of the well.

 Vertical section : from the surface to the kick off point (KOP)

 Deviated section : from the KOP up to the end of build (EOB)

 Horizontal section : from the EOB up to the total measured depth.

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Application example

Data :

SIDPP = 40 bars
SICP = 70 bars
d1 = 1.20 kg / l
C INT DP = 3.84 L/m
CINT DC = 2.56 L/m
LDC = 150 m

Pump displacement : 18.60 L /stroke

The well profile is schemed on the following figure:

A
Shoe 18 5/8
B Shoe 13 3/8
(KOP) ZB = LB = 750 m

Shoe 9 5/8

Shoe 7’’ ZS = 3000 m LS = 4000 m

LC = 4500 m C (EOB) D ZD=3500 m
Z = 3500 m ZC = 3500 m LD=5500 m

Fig 5.18

 Internal drill string volume:

Vi = Cint pipes × LDP + Cint DC × LDC

Vi = 3.84 × (5500 – 150) + 2.56 × 150 = 20928 L

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 WELL CONTROL MANUAL
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 Number of strokes for internal volume:

Si = Vi = 20928 = 1125 strokes

pump displacement 18.6

 Kill mud density:

dr = d1 + 10.2 × SIDPP = 1.20 + 10.2 × 40 = 1.32 kg/L

Z 3500

 Initial circulating pressure ICP:

ICP = SIDPP + PL = 40 + 70 = 110 bars

 Final circulating pressure FCP:

FCP = PL × dr = 70 × 1.32 = 77 bars

d1 1.20

While pumping in the kill mud, the discharge pressure decreases from the
ICP = 110 bars to FCP = 77 bars when the kill mud reaches the bit.

The discharge pressure when the heavy mud reaches the KOP and the EOB are
calculated as follows :

1. Vertical section (from A to B)

The remaining static pressure ∆PR at point B is :

∆PR = SIDPP – ZB × SIDPP

ZD

∆PR= 40 – 750 × 40 = 31,4 bars

3500

The pressure losses at point B is :

PLB = PL + LB (FCP – PL)

LD

PLB = 70 + 750 (77 – 70) = 71 bars

5500
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 WELL CONTROL MANUAL
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The value of the discharge pressure when the mud dr reaches point B is
equal to :
∆PR + PLB = 31.4 + 71 = 102.4 bars

The number of pump strokes from A to B /

SA-B = CINT DP × LB
pump displacement

SA-B = 3.84 × 750 = 155 strokes

18.6

2. Deviated section (from B to C)

The remaining static pressure at point C

∆PR = SIDPP – ZC × SIDPP

ZD

∆PR = 40 – 3500 × 40 = 0 bars

3500
The pressure losses at point C

PLC= PL + LC (FCP – PL)

LD

PLC = 70 + 4500 (77 – 70) = 76 bars

5500

The discharge pressure when the mud dr reaches point C is

equal to : ∆PR+ PLC = 0 + 76 = 76 bars

The number of pump strokes from A to C

SA-C = CINT DP × LC
pump displacement

SA-C = 3.84 × 4500 = 929 strokes

18.6

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 WELL CONTROL MANUAL
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3. Horizontal section (from C to D)

The remaining static pressure at point D :

∆PR = SIDPP – ZD × SIDPP

ZD

∆PR = 40 – 3500 × 40 = 0 bars

3500

The pressure losses at point D

PLD = PL + LD (FCP – PL)

LD

PLD = 70 + 5500 (77 – 70) = 77 bars

5500

The t discharge pressure when the mud dr reaches point D is

equal to : ∆PR+ PLD = 0 + 77 = 77 bars

The number of pump strokes from A to D

SA-D = CINT DP × LDP + CINT DC × LDC

pump displacement

SA-C = 3.84 × 5350 + 2.56 × 150 = 1125 strokes

18.6

The discharge pressure variation when pumping the kill mud from surface to the
total measured depth is illustrated on the following graph.

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 WELL CONTROL MANUAL
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Discharge pressure

110 A

102 bars
100 B

90

80 77 bars
76 bars C D
70

Number
60 of
200 400 600 800 1000 1200 strokes

Fig 5.19

5.6 Abandonment plugs

In the event that secondary control cannot be properly maintained due to hole
conditions or equipment failure, certain emergency procedures can be implemented
to prevent the loss of control. These procedures are referred to as "Tertiary
Control" and usually lead to partial or complete abandonment of the well.

Unlike primary and secondary control, there are no established tertiary well control
procedures that will work in most situations. The procedures to be applied depends
on the particular operating conditions which are encountered, and specific
recommendations regarding appropriate tertiary control procedures cannot be
given until the circumstances leading to the loss of secondary control are
established.

However, there are two procedures that are widely used. These involve the use of:

 Barite plugs

 Cement plugs
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 WELL CONTROL MANUAL
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5.6.1 Barite Plugs:

A barite plug is slurry of barite in fresh water or diesel oil which is spotted in the
hole to form a barite bridge that will seal the blowout and allow control of the well
to be re-established.
The plug is displaced through the drill string and, if conditions allow, the string is
pulled up to a safe point above the plug. The barite settles out rapidly to form an
impermeable mass capable of shutting off high rates of flow.
The effectiveness of a barite plug derives from the high density and fine particle
size of the barite and its ability to form a tough impermeable barrier. To be
effective, the slurry must have the following properties:
- The viscosity and yield point should be as low as possible to ensure a
rapid settling rate and prevent channeling. High quality barite with
low clay content should be used where possible.
- The slurry should have a high density: at least 360 kg/m3 (3 ppg)
greater than the mud density.
- The fluid loss should be high to allow rapid dehydration of the slurry.
The high fluid loss can sometimes cause the hole to slough and bridge
itself.
A barite plug has the following advantages:
- It can be pumped through the bit and offers a reasonable chance of
recovering the drill string.
- The material required is normally available at the rig site.
- The plug can be drilled easily if required.

The main disadvantage is the risk of settling and consequent plugging of the drill
string if pumping is stopped before the slurry has been completely displaced.
Two types of barite slurries can be used:
- Barite - fresh water slurry
- Barite - diesel oil slurry

Other materials can be used if a very high slurry density is required to stop the
flow so that the slurry will settle. Ilmenite and galena have been used in the past
and micaceous hematite is potentially useful. All of these materials have a higher
density than barite.
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Regardless of the materials used, all slurry formulations should be pilot tested to
ensure settling and dehydration.

Displacement of Barite Plugs

Since the barite plug slurry contains no suspending agent for the barite, the surface
mixing facilities and plug placement must be continuous and rapid. If the mixing
or pumping is halted for even a short time, settling in the pits or plugging of the
drill string will occur. It is possible to batch mix and displace the slurry using the
rig pumps. However, it is preferable to mix and displace the slurry with a
cementing unit since normal surface rig facilities are not suitable due to their low
mixing rates. Using the cementing unit gives more accurate volume control.
A minimum final plug length of 60 meters (200 ft) and not less than 1.6 m3 (10
bbl) volume should be used to ensure a good seal and allow accurate displacement
into the wellbore.
5.6.2 Cement Plugs

A cement plug can be used to shut off a downhole flow. However, this generally
involves abandonment of the well and loss of most of the drilling tools.
Cement plugs are set by pumping a quantity of quick setting (accelerated) cement
into the annulus via the drill string. The cement is usually displaced until the pump
and choke pressures indicate that a bridge has formed. Quick setting cement
reduces the possibility of gas cutting.
If a cement plug has to be set off bottom with mud below it, then consideration
should be given to spotting a slug of viscous mud below the zone to be plugged.
This precaution should be considered in long or deviated holes or when the cement
slurry is substantially heavier than the mud.
Setting a cement plug offers little chance of recovering the drill string. It is also
likely that the string will become plugged after pumping the cement, precluding
any second attempt if the first should not succeed. Therefore, cement plugging
should be regarded as the final option.

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SECTION 6 : WELL CONTROL EQUIPMENT

Page

6.1 INTRODUCTION 2

6.2 PREVENTERS 2

6.2.1 Annular preventersv 2

6.2.2 Ram preventers 14

6.2.3 BOP stacks 29

6.2.4 Diverters 37

6.2.5 Rotating Heads 39

6.2.6 Inside BOP's 40

6.3 CHOKE MANIFOLD 46

6.4 REMOTE CONTROL UNIT 56

6.5 EQUIPMENT TEST PROCEDURES 69

6.6 GAS HANDLING SURFACE EQUIPMENT 88

6.7 MUD CONTROL AND MONITORING EQUIPEMENT 91

6.8 FLANGES AND RING GASKETS 93

6.9 WORKSHOPS
 KICKS CONTROL MANUAL
SECTION 6: WELL CONTROL EQUIPMENT

6.1 INTRODUCTION

One of the most important aspect of the kicks control is the adequate choice, the
correct use and maintenance of the special control equipment.
In this section, are described the kicks control equipments, the hydraulic control
system, the BOP stack and the test procedures of the control equipments.
In addition, a maintenance practical guide of the accumulator system is introduced
at the end of the section.

6.2 PREVENTERS

The main function of the preventers is to allow closing the well in case of a kick
and the circulation through choke during control.

A preventer is defined by:

 Its label : Cameron, Shaffer, Hydril, …

 Its type : U, SL, GK, …
 Its nominal dimension which corresponds to the minimum bore diameter,
for example: 11” , 13 5/8 , …
 Its series which corresponds to its working pressure, example: 3000 psi,

6.2.1 Annular preventers

The annular preventer is installed on top of the stack. An feedable rubber on the
packing unit enables:

 The closing and sealing on any diameter and even (not recommended) on
complete shut off of the well bore (CSO)
 Capability for stripping drill string to bottom

The annular preventers most commonly used are manufactured by :

 Hydril type (GK, GL, GX and MSP)

 Shaffer spherical type
 Cameron D type

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Annular preventers. Working principle (fig 6.1)

The working principle described here is for all annular preventers. The closure
action is carried out by applying pressured operating fluid to the closing chamber,
raising the piston and squeezing the packing unit inward to a sealing engagement
with the drill string..

Application of opening chamber pressure returns the piston downwards, the

packing assembly is decompressed and takes full open bore position. The hydraulic
fluid returns to the reservoir through the opposite side of the chamber.

Practical recommendations

 Apply a closing pressure as recommended by the manufacturer; in fact,

an excessive closing pressure reduces considerably the service life of the
seal assembly.
 Run the bit and the BHA slowly through the annular preventer to
minimise damage of the packing unit.
 While stripping, reduce the closing pressure to allow a slight leakage.
 Clean the cavities and check the sealing elements at each end of well
completion.
 Annually, remove and change the sealing parts.
 Select a natural , synthetic or neoprene rubber packing unit, in
accordance with the mud type.

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Fig 6.1 Working principle of the annular preventer

Annular preventer Hydril type GK 4”1/6 10000, 15000 and

20000 psi

Operational features

 Designed for stripping and snubbing operations.

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 The packing unit and the two operating chambers are tested at the
preventer working pressure.
 The shell is tested at 150 % working pressure.
 Can seal on open hole (full closure).
 Possibility to measure the piston stroke to determine packing unit life
without disassembly
 Available with a bolted head.
 Piston is well pressure assisted .Ensures more positive seal off
 Conform to the NACE standard specifications for H2S service.

Fig 6.2 Annular preventer type GK 4”1/6

Annular preventer Hydril type GL

Operational features

 Can be closed on open hole.

 Well pressure assisted.
 The bolted cap permits easy packing unit change.
 Designed specially for subsea service.
 Possibility to measure the piston stroke to check the packing unit life.

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 Secondary chamber permits to compensate for hydrostatic pressure

marine riser in deep water.

Fig 6.3 Annular preventer type GL

Fig 6.4 Annular preventer Hydril type GL 16 3/8- 5000 psi

Annular preventer Hydril type MSP

Operational features

 Can be closed on open hole.

 Mainly used as diverter.
 Automatically, piston can move downward to open position as the
closing pressure is released.
 The well pressure assists the packing unit to seal off.
 Greater capability to stripping service.
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Fig 6.5 Annular preventer MSP-2000

Spherical annular preventer Shaffer

Operational features

 Can be closed on open hole

 Requires higher closing pressure in subsea service.
 The well pressure assists sealing elements.
 No possibility to measure the stroke length.

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Fig 6.6 Shaffer annular preventer

The annular preventer Cameron type D

Operational features

 Quick remove top to change packing unit.

 Most of these preventers require less closing fluid volume than
conventional ( Hydril and Shaffer).
 Shorter in height than Hydril and Shaffer preventers.
 Less heavy than Hydril and Shaffer preventers except for the 11”- 10000.
 Requires 3000 psi for full closure.

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Fig 6.7 Annular preventer type Cameron D

Types of packing units (Hydril)

PACKING UNIT IDENTIFICATION TEMPERATURE COMPATIBILITY

WITH DRILLING
TYPE Colour code (°F) MUD
Natural rubber Black NR -30 to 225 Water based mud
Nitryl rubber Red NBR BAND 20 to 190 Oil based mud
Neoprene rubber Green band CR -30 to 170 Oil mud

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Volumes of hydraulic fluid required ( in gallons ) to operate the annular

preventer on open hole (full closure)

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Types of annular preventers packing units

Sealing elements for Cameron annular preventers

Fig 6.8

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Adjusting the annular closing pressure

The well pressure assists the BOP to close and causes an excessive closing force
which can collapse the tubular ( particularly casings) or damage the sealing
elements. This excess of pressure should be removed to exert finaly the required
force on the piston to seal off correctly.

- Apply the initial closing pressure to shut

the well-in and to seal off
- Reduce closing pressure following
increase of well pressure

Example of adjusted pressures

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Closing pressure for annular GL Type

The closing pressure should be adjusted in accordance with installation type

Standard (secondary chamber to opening chamber ) or Optional (secondary
chamber to closing chamber).
Using manufacturer’s data the closing pressure is selected for standard hook up. To
determine the closing pressure for optional hook up, this pressure is multiplied
by the factor shown on the annexed table.

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Optional installation

6.2.2 Ram type BOP's

These types of preventers are available in simple, double or triple body types and
can be equipped with closing rams :

 Total (blind rams)

 Total and shearing (blind shear rams)
 On a given diameter (pipe rams)
 On a range of diameters (variable bore rams)

The models most widely used are:

Cameron type U & UII, Shaffer type LWS and Hydril type X.

A) Working principle of ram preventers

Working principles of all rams preventers are similar.

To illustrate this principle, the Cameron type U is described here.

Cameron type U ram type preventer (fig 6.9 & fig 6.10)

The forged body incorporates:

 A vertical central opening.
 A horizontal borehole in which two rams can move. Each ram is set to
the operating piston rod (5).

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From each side of the body :

 An intermediate flange (2)
 A bonnet (3)

Two pistons (9) and (10) are incorporated to the body with the rods screwed on it.
There are used to open the bonnets to change out rams.

Their features are:

 The piston (10) on the closing side and its rod are provided with axial
hole communicating with the closing chamber.
 The piston on the opening side is blind. The circuit ends up behind the
piston by two openings.

 Two locking screws (8) permit to block the rams in closed position
(locking screw)

In subsea application , these screws are replaced by a hydraulic system fitted with
wedges (wedgelock). This system maintains the rams in shut-in position, even if
the closing pressure is removed.
The intermediate flange between body and bonnet in which slides the piston rod is
fitted with a lip seal at the well side and an O'ring seal at opening chamber side.
Between these seals is an atmosphere vent (permits to detect leaks) and a
secondary seal system operated by plastic injection but only usable in case of
emergency.

Fig 6.9 Cameron type U ram type preventer

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Fig 6.10 Cameron type U Blowout preventer

Operational principle:
The closing action is operated by pressured hydraulic directed to closing chamber
port, it passes inside rod and piston ram change and reaches the operating cylinder.
The operating piston moves the ram inward to seal the tubular at end of stroke. In

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same time the hydraulic fluid in opening chamber returns to reservoir expelled
through opening side by the piston motion.
Opening BOP is operated by applying opening pressure, it pushes the fluid through
the opening port, passes through the blind piston rod and enters in the operating
cylinder. The piston is pushed backwards moving the ram tightly against the
preventer body. Operating fluid in closing chamber returns to reservoir through the
closing side.
The hydraulic system of the Cameron type U preventer is designed for 1500 psi
WP. Pressures of 300 to 500 psi are normally sufficient to operate. If necessary,
applying pressures up to 5000 psi are allowed (note from the manufacturer).
Ram change out
To change rams proceed as follows:
 Unscrew bonnet bolts.
 Apply closing pressure: the bonnet moves away from preventer body
 Change rams.
 Apply opening pressure: the bonnets are drawn against preventer body.
 Screw bonnets bolts to hold it closed.

Fig 6.11 Hydraulic control system Cameron type U preventer

B) Cameron type UII double preventer

Operational features

 Onshore and subsea use

 Well pressure assisted
 Secondary seal for ram shaft
 Used in HP wells 250 °F rating temperature
 Easy to change out rams
 Automatic locking system (wedgelock) maintains the rams in close
position even if the closing pressure is lost

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Fig 6.12 Cameron type UII double preventer

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Fig 6.13 UII BOP Part Numbers

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C) Cameron type SS ram type preventer

Operational features

 Short height (Space Saver)

 Ram position not noticeable from outside
 Well pressure assisted
 Secondary seal on ram shaft

Fig 6.14 Type SS Cameron preventer

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D) Hydril type X rams preventer

Operational features

 Available for high working pressures rating

 Available with manual or automatic locking systems
 Needs more space for lateral opening of the doors
 Cavities slope prevent settling of cuttings
 Designed for capability to hang off the drill string

Fig 6.15 Type X Hydril ram preventer

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E) Shaffer type LWS poslock BOP

1. Body
2. Ram shaft seal
3. Door joint
4. Door
5, 6, 7 and 8 Liners with seals
9, 10, 11 and 12 Hydraulic fluid manifold
13. Door cap screws
14 and 15 Door hinge
17, 18, 19 and 20 Hydraulic pipe with check valve
21, 22 and 23 Shaft, piston and cylinder head

16. Shaffer model LWS rams type preventer

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Locking system of Shaffer SL poslock

 Locking
While closing the rams, the operating piston moves into the wellbore and the
spring pushes inward the secondary piston which pushes in front of it the locking
segment sliding toward the piston OD .When the piston is at fully closed position
the locking segment spreads out in the locking shoulders.
The piston is automatically locked in this postion and remains locked even the
closing pressure is lost or if necessary, it is possible to remove the closing pressure,
in the case of a momentary abandonment.

Opening pressure is required to unlock the piston

Locking
Locking segment
shoulder

Spring Locking cone

Fig 6.17 Locking piston in locked position

 Unlocking

As closing pressure is applied the operating piston is in locked position and cannot
move. But the operating fluid can enter through ports inside the secondary piston
to displace it by compressing the spring. That allows the segment to retract and
slide towards the piston ID and release the operating piston to move outwards and
open the rams.

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Pisto

Ram shaft Ram

Fig 6.18 Piston Poslock in open position

F) The rams
The rams assembly consist of three parts :
 A ram block (shapes related to the types of rams)
 An upper seal assembly (top seal)
 A front seal assembly
- Packer for closing on a fixed bore size or on a range of diameters
- Side packer and blade packer for total closing and shearing.

. Fig 6.19 Cameron Shear rams

A device collects upper and front seal each other
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Fig 6.20 Shaffer shear rams

Fig 6.21 Variable bore rams

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Fig 6.22 Pipe rams

G) Closing Ratio

To ensure that the well can close safely in case of kick, the exerted force by the
hydraulic fluid pressure on the piston area ''S,'' must be greater or equal to the force
exerted by the well pressure at the ram shaft area ''s'' (Fig 6.23).
By definition, the closing ratio R is equal to the surfaces ratio S/s given by the
manufacturer.

We have at balance : Poil × S = Pwell × s , then

Poil = Pwell
R
Example :

For a preventer series of 10000 psi and a closing ratio of 10.56, the closing
pressure must be equal to 10000 /10.56 = 947 psi .This value is rounded up to 1000
psi.

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Fig 6.23

Opening and Closing Ratios of the rams preventers

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Required volumes to operate rams preventers

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6.2.3 Preventers stacks

The selection of apreventers stack arrangement depends on :
 The maximum pressure expected at surface
 The diameters of the bits and casings to run in

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 The presence of corrosive agents (H2S)

The preventers stack must always ensure the possibilities of :
 The well shutting in with drill string in or out
 The circulating out of the kick
 The injection in the casing
 The stripping

Examples of stacks configuration

Case -1 Operational features

 If one of the rams preventer is closed, we

can use the lateral outlets of the mud cross to
control the well.

 In case of low air gap, the use of a double

preventer permits to use the preventer lateral
outlets and eliminate the mud cross.

 The well can be closed while changing the

pipe rams.

 A leakage at the mud cross cannot be

repaired.

 There are more flanges exposed to the well

pressure, the flanges are the weak points in
any stack..

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Case -2 Operational features

 The well can be closed to change pipe rams.

 In case of emergency and as a last resort we
can drop the drill string and close the well
 A reduced number of flanges are exposed to
the well pressure beneath the blind rams.
 When the pipe rams is closed, we can use the
lateral outlets of the mud cross.
 We can change or repair all the elements
above the blind rams.

Case -3 Operational features

 It’s the stack which is generally acceptable

with three rams preventers.
 With the blind rams closed, we can change
the upper pipe rams.
 The drill string being in the well, the closing
of the lower pipe rams permits to repair the
elements above.
 The drill string being in the well, we can
change the blind rams in pipe rams, the
pipes can be run in hole by stripping using
the two upper pipe rams, the lower pipe
rams will be kept in reserve.
 The blind rams closed, a leak around the
mud cross or the lower pipe rams cannot be
repaired.

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Case -4 Operational features

 We can use the lateral outlets of the

mud cross when the blind rams is
closed.

 The blind rams being closed, a leak

around the mud cross or the lower pipe
rams cannot be repaired.

 The drill string being in the well, we

can change the blind rams in a pipe
rams, the pipes can be stripped in the
well through the upper pipes rams
keeping the lower pipe rams in reserve.

 If a leak happens above the rotary table,

the pipes can be suspended on the
lower pipe rams. By closing the blind
rams the well can be circulated.

 When the blind rams is closed, there

are more flanges exposed to the well
pressure. The flanges are considered as
weak points in any stack.

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Case -5 Operational features

 The drill string being in the well, the

blind rams can be changed by the pipe
rams and the pipes can be run in the
closed well keeping the lower pipe rams
in reserve.

 With the drill string in the well, the

upper pipe rams shut-in permits
circulation through the lateral outlets of
the mud cross.

 The closing of the blind rams permits to

change and repair the upper elements.

 The drill string being in the well, the

closing of the lower pipe rams permits
to repair the upper elements.

 The blind rams being closed, leaks at

the lower pipe rams cannot be repaired.

 The closing of the blind rams doesn’t

permit the use of the lateral outlets of
the mud cross.

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Case -6 Operational features

 The well can be closed while changing rams

 A reduced number of flanges are exposed to
the well pressure beneath the blind rams.
 The blind rams closing permits the reparation
or the change of all the components above.
 As the last resort we can drop the drill string
and close the blind rams.
 The closing of the lone upper pipe rams
permits the use of the lateral outlets.
 In case of stripping, we cannot change the
blind rams by a pipe rams.

Case -7 Operational features

 The closing of the annulus or blind rams

puts more flanges to the well pressure, the
flanges are considered as weak points in
preventer stacks.
 The drill string being in the well, we can
change the blind rams in pipe rams, the
pipes can be stripped by using the two upper
pipe rams keeping the lower pipe rams in
reserve, if the distance between the rams is
sufficient to contain the tool joints.
 The blind rams closing doesn’t permit the
use of the lateral outlets.

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Case -8 Operational features

 Closing blind rams permits the

reparation of the elements above.
 A reduced number of flanges are
exposed to the well pressure beneath the
blind rams.
 The drill string being in the well, the use
of the mud cross lateral outlets is
possible by closing one of the pipe rams.
 In case of a stripping, we cannot change
the blind rams in a pipe rams.

Case -9 Operational features

 The well being under pressure, a leak
around the mud cross or the lower pipe
rams cannot be repaired.
 The closing of one of the pipe rams
permits the use of the mud cross lateral
outlets.
 The drill string being in the well, we can
change the blind rams in pipe rams, the
pipes can be stripped through the upper
pipe rams keeping the two lower pipe
rams in reserve.
 The blind rams change permits to strip
the pipes through the upper rams keeping
the lower pipe rams in reserve if the
distance is sufficient to contain the tool
joint.

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Case -10 Operational features

 The well being under pressure, a leak

on mud cross or the lower pipe rams
cannot be repaired.
 The closing of one of the pipe rams
allows to use the lateral outlets.
 The drill string being in the well, we
can change the blind rams to a pipe
rams, the pipes can be stripped through
the upper pipe rams keeping the lower
pipe rams in reserve if the distance is
sufficient to contain a tool joint

Case -11 Operational features

 A leak around the blind rams or the

mud cross cannot be repaired if the
well is pressured.
 The closing of the lower pipe rams
permits the use of the mud cross lateral
outlets.
 The change of the blind rams to pipe
rams permits stripping through the two
upper pipe rams keeping the lower pipe
rams in reserve if the distance is
sufficient between the rams to contain a
tool joint.

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6.2.4 Diverters

A diverter is annular preventer with large bore / low working pressure. At its lower
side are one or two lateral outlets with large diameter (12” or more in preference),
equipped with manual or remote control valves which open as the closing pressure
is applied.

The diverter allows evacuating a kick while drilling top hole (shallow gas) without
closing the well in.

Fig 6.24 Diverter

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MSP Diverter 28’’ 2000

 Very low pressures

 Automatically returns to the Open position when closing pressure is
released
 Sealing assistance is gained from the Well Pressure

Hydril FSP Diverter 28’’ 2000

2000
 When the Diverter is open the piston closes the vent line .
 When closing, the piston opens it…
 For jack ups & submersibles rigs.

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6.2.5 Rotating Heads

The rotating head is installed at top of the stack to seal off on the drill string during
operations such as:

 Drilling or circulating under pressure with air or gas

 Drilling with underbalanced muds
 Evacuation of effluents by diverting towards mud pit or flare line,
particularly in presence of H2S.

Normal working pressure is 500 to 700 psi.

Sealing on the drill string is assisted by the well pressure.

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Fig 6.25 Rotating Head

6.2.6 Inside BOP's

They are equipments manually operated to close quickly the drill string in case of a
drill pipe kick.

Upper Kelly Cock

It’s a fast closing ball valve installed at top of the Kelly .

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Fig 6.26 Upper Kelly Cock Omsco

Lower Kelly Cock

It is a quick closing valve, installed at the lower end of the kelly.

Fig 6.27 Lower Kelly Cock

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Kelly Cocks for TDS

Typically Top drive systems employ 2 FOSV installed in tandem.

 Lower kelly cock manually actuated

 Upper Kelly cock Remotely operated

Fig cutaway of upper splined kelly gurd

Safety valve

 Full bore opening / No restriction for flow /

 One piece design ( tension resistance)
 Fast opening and closing under high pressures
 Closing against lower seat to prevent mud losses
when making up connections

The advanyage of this type of valve is to be easier to stab

on drill pipe in case of kick coming out from inside DP

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Cross over subs should be available on the drill floor to ensure to connect the
safety valve on each tubular of the drill string and for stripping.

Gray Valve

It is a check valve, stored in open position with

incorporated device (Fig 6.28). It is screwed on the
drill string as a positive kick indicator is detected.
We must take it ready with the necessary cross over
sub for making up.

Fig 6.28 Gray valve

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Fast Shut Off Coupling (Fig 6.29)

It’s a rapid locking device used in case of uncontrolled kick through inside drill
string. It permits to pump a check valve (type drop in check valve) through the drill
string.

The drill string can be stripped after the DICV is set on the landing sub.

1- Valve
2- Body
3- Seal assembly
4- Closing wedge
5- Spring
6- Axis
7- Screw

Fig 6.29 Fast shut off coupling

Drop In Back Pressure Valve (DIBPV)

It is a check valve, pumped through DP, it sets on the landing sub allowing to
circulate mud preventing any return through the inside string.

The kick being controlled, the drop in check valve can be retrieved either by wire
line, or by tripping.

The landing sub is generally placed at the top of the drill collars.

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1- Check valve
2- Body
3- Guide
4- Ball
5- Spring
6,7,8,9 and 10- anchoring slips
11- Stop ring
12- Ring stop screw
13- Seal assembly
14- Check valve seat
15- Valve stop ring

Fig 6.30 Drop In Check Valve and Landing Sub

Float Valve

They are classical check valves installed above the bit to prevent any mud return
through inside string.

The disadvantages of these equipments are:

 Overpressure while running in hole

 Shut in drill pipe pressure not read directly
 Risk to be plugged by lost circulation materials (LCM)
 Necessity to fill in the drill string while running in hole.

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Fig 6.31 Float valves

6.3 MANIFOLD CIRCUIT

6.3.1 Choke Manifold

The choke manifold permits during the control, to apply a back pressure onto the
bottom hole well using an adjustable choke and to direct the return towards the
tanks, the separator or the flare line.

As there is a risk of plugging and washb out during the control, the choke manifold
must be equipped at least with two adjustable chokes in order to permit to isolate a
failed line and swing to a back up line to continue the control. Its working pressure
upstream the chokes must be equal or greater than those of BOP stack ; the WP in
the downstream part is generally the next lower series.

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Wast / Degaser
Transducer
Wast

Pressure gauge
Remote control choke Buffer tank

Manual valve

Cross Flare
Manual choke
HCR
Valve

Check valve

Fig 6.23 Choke manifold and choke line and kill line pipes

Several types of chokes are available:

 The calibrated choke (Positive Choke) commonly used in Production.

 The manual choke (Adjustable Choke)
 The remote control choke (Remote Choke)

Manual adjustable choke (Fig 6.33)

It includes:

 A massive body
 A lateral entry port threaded or flanged
 An outlet threaded or flanged
 A choke screwed at the body end with a seal assembly
 A cap with fast nut and stuffing box of the needle screw
 The needle and seat
 A position indicator with graduations from 0 to 64/64 of an inch

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Needle

Choke

Fig 6.33 Manual choke

Remote Control Choke

There are several types of remote control chokes with the same working principle.
The remote choke is operated from the choke panel installed on the rig floor.

Examples

Choke SWACO – 10000 psi (Fig 6.34)

The choke includes two identical concentric discs in tungsten carbide, with semi
circular opening. The bottom disc (1) is fixed; the other (2) can rotate and is driven
by the stem (3). The rotation of the mobile disc, limited to 180 °, is carried out by a
hydraulic actuator mounted on a sliding stem.

The opening of this choke varies with the rotation of the operating disc from 2.4
inches squared to complete closing.

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Fig 6.34 Choke SWACO

Choke Cameron – 10000 psi (Fig 6.35)

It consists of :

 A body with a lateral inlet fitted with a flange 3” 1/16 10000 and a
threaded or flanged outlet 4” 5000
 A seat in tungsten carbide with an O ring seal
 The obturator (sleeve) in tungsten carbide, driven by a piston rod and a
moving piston in a cylinder (bonnet)
 From each side of the cylinder, a tapered hole permits the operating fluid
to enter. The seat and the obturator are reversible.
 At the end of the operating cylinder is the choke position indicator.

A hydraulic pump operated with compressed air supplies the energy allowing the
choke to open and close.

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Fig 6.35 Cameron Remote control Choke

Remote Choke Control panel (Fig 6.36)

The choke control is provided with :

 A main hydraulic pump

 A manual emergency pump
 An operating fluid reservoir

The control panel includes:

 Air supply control

 Remote choke control marked “OPEN”, “HOLD”, “CLOSE” controls the
selected choke.
 Hydraulic regulator: controls the rate at which the mobile disc is
operated.
 Choke position indicator: gives the approximate ratio of opening position
( 240° full-scale deflection).
 Two pressure gauges (stand pipe and casing)
 Pump SPM display
 Total pump strokes display

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Fig 6.36 Choke control console

Optional remote control Methods

16E.2.6.1 Remote control from the remote panels of the hydraulic control manifold
valves may be actuated by pneumatic (air), hydraulic, electro-pneumatic, or
electro-hydraulic remote control systems. The remote control system should be
designed such that manual operation of the control valves at the hydraulic control
unit will override the position previously set by the remote controls

Pneumatic Remote Control

16E.2.6.1.1 Pneumatic remote controls employ compressed air as the medium to
operate actuators for control of the hydraulic control valves. Response time
between the actuation of the pneumatic valve at the remote panel and the actuation
of the control valve is generally a linear function of the length of the
interconnecting hose. Therefore, pneumatic controls are not recommended where
hose lengths exceed 150 feet. Pneumatic remote controls are not recommended for
use in freezing temperatures because condensate in a control line may solidify and
plug the line.

Hydraulic Remote Control

16E.2.6.1.2 Hydraulic remote control is a method to interface with the hydraulic
control manifold. This method can be used in the absence of electrical power and
can function in sub-freezing temperatures. Pilot pressure for remote control should
be supplied from a hydraulic power source separate or suitably isolated from the

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main hydraulic power source so that failure of the remote control will not affect
manual operation of the BOP control system.

Electro-Pneumatic Remote Control

16E.2.6.1.3 Electro-pneumatic controls employ electric circuits to operate
pneumatic solenoid valves that control the pneumatic actuators which operate the
hydraulic control valves. Electropneumatic controls have the advantage of fast
response and ease of running electrical cables compared to hose bundles of
pneumatic remote controls. Electro-pneuthatic controls should not be used in sub-
freezing temperatures.

Electro- hydraulic remote control

16E.2.6.1.4 Electro-hydraulic controls employ electric circuits to operate the
hydraulic control valves. Electro-hyraulic controls have the advantages of fast
response, ease of running electrical cables and are functional in sub-freezing
temperatures. The hydraulic power supply for the remote controls should be
isolated from the main hydraulic system so that a failure in the remote control
circuit will not affect the manual operation of the control valves.

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Gauge range and accuracy

Ideally, the range should be to the highest expected pressure or rated working
pressure of equipment being used, with a high degree of accuracy over the entire
range. Some operator prefer that the pressure gauge selected should have a full
scale pressure such that the operating pressure occurs in the middle half (25% to
75%) of the scale(12 o'clock position is best). The scale of the gauge should be
small enough to register small changes of pressure. In most operations, however, a
5,000 or 10,000 psi (344.74 or 689.47 bar) gauge is used.
The pressure gauge accuracy is defined by a percentage from the range of the
gauge (eg ±.25%, ±.5%, ±1%, ±1.5%). There are debates over the low pressure
accuracy of large range gauges. It is not uncommon to have inaccuracy of 0.5 to
1.5 percent or greater. On a 10,000 psi (689.47 bar) gauge, for example, the
uncertainty of pressure accuracy would therefore be +/– 50 to 150 psi (3.45 to
10.34 bar). Multiple gauges are often manifolded or kept on location to
compensate for these inaccuracies.
Values on gauges measuring the standpipe pressure should be close. If there are
large discrepancies between the readings, the incorrect gauge should be
recalibrated or repaired. Pump pressure is also measured with a gauge mounted on
the pump. This gauge shows absolute pressure to circulate at a given speed and
includes all friction pressure losses. Gauges on the rig floor and remote choke
console should read slightly less than the one on the pump due to friction between
the pump and standpipe.
Gauges measuring casing or annulus pressure are typically found on the choke
manifold and remote choke panel. This gauge may be called the wellhead or casing
pressure gauge. Most regulatory bodies require a pressure gauge to monitor
pressure between strings of casing.

6.3.2 Choke line (Fig 6.32)

The choke line links the BOP stack to the choke manifold. It must be rated at the
working pressure of the stack with an internal diameter greater or equal to 3 inches
to reduce the pressure losses effect, minimise the plugging risks and wear during
the control.

The connection line to the BOP stack is equipped with two valves in tandem. It is
recommended that the valve downstream be remote controlled for a fast opening of
the line.

6.3.3 Kill line (Fig 6.32)

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The kill line links the BOP stack to the pumping circuit, it must be rated at
working of the stack with a minimum internal diameter of 2”. It offers the
possibility to pump beneath closed preventers.

The line is equipped with two valves in tandem and a check valve which
permits to prevent the stand pipe and the drilling pumps against any pressure
coming from the well in case of a kick.

Side outlets valves

National Gate Valves are available with flanged ends in standard API bore sizes and working pressures.
Special trims are available for sour gas and oil service on request. National Gate Valves are also readily
available to accept most pneumatic or hydraulic operators. National Gate Valves meet the applicable
standards set forth by the American Petroleum Institute. When ordering, be sure to specify quantity,
size, working pressure, end connection, body and trim materials, and service conditions (such as
temperature, pressure, and composition of flow material).

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6.4 REMOTE CONTROL UNIT

The preventers and hydraulic valves at the choke line and kill line are hydraulically
operated from a remote distance like the operating principle of the double effect
hydraulic jacks
The role of the hydraulic control system is to ensure the closing and opening of
any function in an efficient, rapid and easy way and if necessary repeating these
actions without having to use external energy.

The features of the hydraulic control unit are defined in function of:

 The total hydraulic fluid volume to operate the sequence required by the
company procedure
 The maximum working pressure
 The necessary time to reload the accumulator following the API
specifications.

The KOOMEY unit described here is the most widely used in the petroleum
industry. (Fig 6.37)

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Fig 6.37 The Koomey remote control unit

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6.4.1 Remote Control Unit. Items included

1. Air supply
2. Air lubricator
3. By-pass valve (normally closed), permits to by-pass hydro pneumatic
switch 4.(if pressure higher than 3000 psi, open it).
4. Automatic hydro pneumatic pressure switch,. Set at 2900 psi cut out
pressure if air + electrical pumps are used .Set at 3000 psi cut out if air
pumps alone are used. Adjustable.
5. Air shut-off valves to open or close air supply to air operated pumps
6. Air operated hydraulic pumps
7. Suction shut-off valve / one for each air operated (normally open)
8. suction strainer/ one for each air operated pump / removable screens
9. Check valve / one on each delivery line
10.Electric motor driven triplex or duplex pump.
11.Automatic hydro-electric pressure switch: set at 3000 psi cut out and
2700 psi cut in .Adjustable
12.Electric motor starter (automatic) three positions (stop, auto, manual).
Normally in automatic position
13.Suction shut-off valve
14.Suction strainer
15.Check valve
16.Accumulator shut-off valve .Normally open / close when testing,
skidding rig or pressure greater than 3000 psi
17.Accumulators. Check recharge 1000 psi ± 10 % in Nitrogen exclusively/
every 30 days
18.Accumulator relief valve . Relieves at 3500 psi ,
19.Fluid strainer located on the inlet side of the regulation valve
20. Pressure reducing and regulating valve. Manually operated , reduces the
pressure from 3000 psi to 1500 psi (or operating pressure of ram BOP's
21.Check valve
22. 4 way Valve / air operated / air cylinder operators for remote operation
from BOP panel. Open position when control is not in use
23.By-pass valve / remote operation from BOP panel .Keep closed unless
pressure > 3000 psi (or if more pressure is required on rams)
24. relief valve / relieves at 5500 psi
25.Hydraulic bleeder valve / to be kept OPEN when precharging bottles
26.Panel- Unit Selector .3 way-valve (air from the regulator on the unit or
the panel )
27.Annular pressure regulator : permits to adjust the closing pressure of the
annular preventer from 0 to 3000, it can be operated from the BOP panel

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28.Accumulator pressure gauge

29.Manifold pressure gauge
30.Annular pressure gauge
31, 32 and 33 Pressure pneumatic transmitters towards the BOP panel
34. Air filter
35, 36, 37 and 38 Air regulators / for the pneumatic transmitters set at 18 to
24 psi
39. Air junction box / connect air lines on the unit to the air lines coming
from panel .
40. Fluid level indicator in the reservoir
41Hydraulic fluid fill hole
42. Rig skid antest line . Four way valve / accumulator position: handle to
the right / test position handle at centre position / skid position: handle to the
left position. Caution : handle to accumulator position while normal
operation
43. Check valve
44. Rig skid relief valve
45 Rig skid customer connection
46 Test line customer connection
47. Return to the reservoir when using an auxiliary line
48. Inspection plug

6.4.2 Unit operating

The remote control unit is made of six subsets:

 Air equipment
 Electrical equipment
 Accumulators
 Manifold rams& valves
 Annular manifold
 Reservoir

Air equipment

The rig air passes through a filter and a lubricator (2). Normally the by-pass valve
(3) is closed and the air passing through the hydro pneumatic pressure switch (4),
arrives to each air operated hydraulic pump (6)
The hydro pneumatic pressure switch (4), manually adjustable, opens when the
hydraulic pressure drops to 2700 psi (in general) and closes at 2900 psi.

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If we desire to pump up the accumulators for more than 3000 psi we just need to
open the by-pass valve (3) and remember to close it again when the desired
pressure is reached.

If an air operated pump (6) has failed, we can isolate it by the valve (5) to repair.

The hydraulic fluid stored at atmospheric pressure in the reservoir is aspirated by

the air pump through the suction line equipped with shut off valve (7) and a
strainer (8) then discharged at 3000 psi towards the accumulator bottles.

The 3000 psi delivery line is equipped with a check valve (9).

Electric equipment

The motor driven pump (10) has the same use as the hydro pneumatic pump seen
previously and the suction lines are normally equipped with a valve (13) and a
strainer (14) and on the discharge line at 3000 psi, with a check valve (15).
In the same way for the electric pump, the automatic principle at 2700 psi cut in
and 3000 psi cut out is respected. The decrease in pressure is recorded by the
pressure switch (11) which actuates an electric automatic starter (12) normally on
the auto position. The manual position will be selected if we want exceed the
pressure of 3000 psi.

Accumulator part

The accumulator system is protected by a relief valve (18), set at 3300 psi or 3500
psi.

The accumulator shut-off valve (16) must be opened except during the movings

The fluid at 3000 psi arrives in 2 pressure regulators: the regulator (27) for the
annular preventer manifold and the regulator (20) for the other manifold for
preventers and remote control valves...

The by-pass valve (23) permits to pass up the regulator (20) and directs the
accumulator pressure to the manifold.

The accumulator pressure gauge (28) indicates the pressure in the bottles.
More, the circuit is provided with a relief valve (24) set at 5500 psi, which protects
the system if the accumulator shut off valve valve (16) is closed and a bleeder
valve (25) into the reservoir.
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Manifold for Rams and Valves

The fluid at pressure of 3000 psi enters in the pressure regulating valve (20) where
it delivers at 1500 psi.

The manifold includes:

 A pressure gauge (29), which must indicate 1500 psi
 A panel/ unit selector (26) to operate, either from the unit, or from the rig
floor
 A by-pass valve (23) to apply directly 3000 psi in the manifold in case of
emergency,
 Different 4 ways valves (22) each one connected to a preventer and or a
valve

Annular manifold
The system is similar to the other manifold where the fluid at pressure of 3000 psi
enters the regulator (27) which permits to adjust the delivery pressure read on the
gauge (30) from 0 to 3000 psi depending on the dimensions of the tubular and the
operations.

The control of the regulator (26) permits to adjust the annular pressure, either from
the unit or from the rig floor panel. in accordance with the selector position
Some regulators keep their settings in case of a failure of the remote control device
(fail safe).
On the side of the unit, there are 3 pressure transmitters which convert the
hydraulic pressures in pneumatic pressures that can be read at different places of
the rig.

Reservoir
The reservoir of a rectangular section is used to store the operating fluid at
atmospheric pressure. Its capacity must be in minimum equal to twice the
necessary operating fluid volume to ensure the required sequence. ( usable volume)

6.4.3 Control panel (Fig 6.38)

Several models exist in the industry following the type of control. The operations
can be actuated from a remote control console placed on the rig floor or in the dog-
house. An emergency auxiliary panel can be placed in a safe distance area.

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To operate remotely a function, the air master valve must be pressed at the same
time as the control of the function is handled on the panel. That activates a 4 way-
valve on the main unit.
The position of the 4 ways valves of the unit is indicated by green or red lights.

A
traduire

Fig 6.38 Remote Control Panel

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Operating Sequence : Close Function

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Functional problems during Stack operations

Current Acc. P. Manif. P. Ann.P Red Green Causes

operation psi psi psi light light
Drilling ↑↓ 1500 1000 Leak on hydraulic lines 3000psi
Drilling 2600 1500 850 Default on setting for automatic
starting / pump switch on Off position
Drilling 2800 2800 900 By pass open or leaking / Malfunction
of Manif.Regulator
Drilling 2800 1500 900 All OK

Closing a 3000→ ↑↓ 1000 lights Goes All OK

ram BOP 2850 off
Closing ↑↓ 1500 ↑↓ Not Goes Problem on the red lamp circuit (
annular lights off grilled lamp, contact default...)
BOP
Closing a 3 000 1 500 1 000 lights Goes The 4 way valve works normally but
ram BOP off the hydraulic does’nt flow from the
unit to the BOP’s ((plugging)
Drilling - Leaking on the 4 way valve,
w/ Valve on - Not connected
Neutral Postion
0 psi air
pressure
on
Driller’s
Panel

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6.4.4 Accumulator Unit selection

To select unit system, we must determine:

 The usable volume to meet the customer's operational criteria

 The accumulator volume
 The atmospheric reservoir capacity
 The pumping capacity

Example:

Determine the number of accumulator bottles required on the Unit to meet the
following customer's specifications :
- Stack includes: Well head 13 5/8 5000 psi, an annular preventer Hydril
type GK, a double preventer Cameron type U.

- Operational criteria:
The usable fluid volume must carry out: closing and the opening of all the
functions + a reserve of 25 % of this volume which remains in the accumulator at a
minimum pressure of 1200 psi.

Stack configuration Opening volume Closing volume

gallons gallons
Annular Hydril GK 14.16 17.98
Pipe rams Cameron U 5.46 5.54
Blind rams Cameron U 5.46 5.54
HCR choke line valve 1.00 1.00
Total 26.08 30.06

The usable volume required by the sequence is:

Vu = (26.08 + 30.06) × 1.25 = 70.175 Gallons

Total bottles volume needed :

P1 : precharge pressure (1000 psi) and V1 the accumulator volume

P2 : the minimum pressure (1200 psi)

V2 : the nitrogen volume at P2

P3 : the Unit working pressure (3000 psi)
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V3 : the nitrogen volume at P3

Vu : the usable fluid volume (70.175 Gallons)

We apply the BOYLE’s Law :

P1 × V1 = P2 × V2 = P3 × V3

then : V2 = V3 = Vu
P3 P2 (P3 – P2)

V2 = Vu × P3
P3 – P2

V1 = V2 × P2 = Vu × P2 × P3
P1 P1 × (P3 – P2)

then: V1 = 2 × Vu = 140 Gallons

We need 14 bottles of 10 Gallons each.

For the given pressures, the volumetric capacity must be equal to twice the usable
volume.

Reservoir capacity :
Following the API recommendations, the reservoir must have a minimum capacity
equal to twice the usable volume. In this example the reservoir capacity must be at
least 140 Gallons capacity.

Pump capacity requirements

a) The pumping system must pump up the accumulators from the minimum
pressure of 1200 psi to the maximum pressure of 3000 psi in a maximum
lapse of time of 10 min.
In this example usable volume = 70 gal then Q = 70 /10 = 7 GPM (gal/mn)

b) The accumulator removed from service, pumps must permit to close the
annular preventer on the DP being used and open the HCR valve in 2 mn
maximum and keeping a final pressure of 1200 psi on the closing unit
manifold.

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If we consider the greatest annular dimension used on the field, MSP 20”3/4
the closing volume is 31.05 Gallons and the HCR opening volume is 1
Gallon, let the flow rate pump Q ≥ (31.05 + 1)/2

Therefore each pump must deliver a flow rate greater or equal to 16 Gallons per
minute.

6.4.5 Control of the hydraulic Unit

- A complete inspection of the unit will be performed at every moving
- Operating tests will be carried out:

 At every BOP test with a minimum once per week

 Alternatively from each control panel
 All the results (time, volumes, pressures) must be recorded on the test
report sheet.

7 parameters have to be checked:

1) Elapsed time to load the bottles

The two groups must compress the bottles from 1000 psi to 3000 psi in less
than 15 minutes.

2) Cut-in / cut-out sets

Each pump must start up when the pressure decreases of 10 % (2700 psi)
and must cut out when it increases back to 3000 psi.

3) Reservoir fluid level

The oil level must be at the middle of the reservoir.

4) Precharge pressure

Measure the recovered volume after bled off the bottles from 3000 psi to
2000 psi and calculate the precharge pressure P1

P1 = 6000 × Vrecoverd/ Vaccumulator

5) Pump capacity

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Bottles removed from service, the group must in less than two minutes and
with at least a final pressure of 1200 psi :

 Close the annular preventer at the required pressure

 Open the HCR valve

6) Accumulators capacity (API 16E)

Pumps removed from service, the bottles must satisfy two conditions:

 Closing all the preventers with a safety usable volume of 50 %

 When the preventers are closed, the final pressure must be greater than
the calculated pressure corresponding to the closing of any rams
preventer (except the shear rams) with a well pressure equal to the rated
stack working pressure.

Example :

1400 psi for a working pressure of 10000 psi and a closing rate of 7/1.

7) Response time

The closing time (from the initial action to the complete closing) must be
less than 30 seconds for all the ram and annular preventers smaller than 20”.
For annular preventers with size equal or greater than 20” the pumps must be
capable to close them within 45 seconds or less.

Note : The choke and kill line valves must close within a delay less to those of
ram preventers.

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6.5 Testing and Inspection of Well Control Equipment

Between Wells
After each well, the well control equipment should be cleaned, visually inspected,
preventative maintenance performed, and pressure tested before installation on the
next well. The manufacturer's test procedures, as prescribed in their installation,
operation, and maintenance (IOM) manual, should be followed along with the test
recommendations of Table 1. All leaks and malfunctions should be corrected prior
to placing the equipment in service.
Visual Inspection—Flexible Choke And Kill Lines
A visual external inspection of flexible chokes and kills lines through the entire
length of the line.
Major Inspections
After every 3-5 years of service, the BOP stack, choke manifold, and diverter
components should be disassembled and inspected in accordance with the
manufacturer's guidelines. Elastomeric components should be changed out and sur-
face finishes should be examined for wear and corrosion. Critical dimensions
should be checked against the manufacturer's allowable wear limits. Individual
components can be inspected on a staggered schedule.
A full internal and external inspection of the flexible choke and kill lines should be
performed in accordance with the equipment manufacturer's guidelines

Preventer inspection

Before hydraulically testing a preventer, check the following:

1. Verify wellhead type, rated working pressure.

2. Check for wellhead bowl protector (wear bushing).
3. Verify the preventer type and rated working pressure.
4. Verify drilling spool, spacer spool and valve types and rated working
pressures.
5. Verify ram placement in preventers and pipe ram size.
6. Verify drillpipe/tubing connection size and type in use.
7. Open casing valve during test, unless pressuring the casing or hole is
intended.

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8. Test pressure should not exceed the manufacturer's rated working pressure
for body or seals of assembly being tested.
9. Verify the type and pressure rating of pump and preventer tester to be used.

Rams and spool inspection

At a minimum the inspections and tests should include the following:

1. Visually inspect the body and ring grooves (vertical, horizontal or ram bore)
for damage, wear and pitting.
2. Check studs and nuts for correct size/type.
3. Check size/type of ring joint gaskets.
4. Visually inspect ram preventer.
 Wear, pitting and/or damage to bonnet or door seal areas or grooves,
ram bores, ram connecting rods and operating rods.
 Packer wear, cracking, excessive hardness.
 Measure ram and ram bore to check for maximum vertical clearance
according to manufacturer's specifications. The clearance is dependent
on type, size and trim of the preventers.
 inspect secondary seals and remove plugs to expose plastic injection
ports used for secondary sealing purposes. Remove the plastic
injection screw and check valve in this port. (Some rams have a
release packing regulating valve that will need to be removed.) Probe
the packing to

EQUIPMENT TEST PROCEDURES

All the safety equipments (preventers, rig manifold, chokes manifold and the
casings suspensions) must undertake a test program.

These tests are of two types :

 Operating tests : It concerns the safety equipments to make sure that, at

any time, the closing and opening of preventers and valves will be quick
and effective as operated.

Function test procedure

Frequency At each round trip

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 Max : once / day

 Min : once / week

Condition: Just bit into casing

Procedure

 Install drill pipe safety valve

 Operate the choke line valves
 Operate adjustable choke
 Open each choke and pump through to ensure it is not plugged
 Operate all pipe rams ( blind rams when out of the hole)
 Operate annular preventer
 Return all valves and preventers to their original position .
 Record test results and continue normal operations.

Function test for diverter:

Typically only function and flow-through tests are performed .However a optional
pressure integrity test (200 psi) may be made on the diverter system on installation.

- Record hydraulique pressure and air supply air pressure with the
accumulator fully charged and the controls in normal drilling position

- Actuate the diverter close and open sequence with drill pipe or mandrel and
record response time

- Pump water or drilling fluid through the diverter at low pressure and high
flow rates and check vent line (s) for returns

- In cold climates vent lines should be protected from freezing

 Hydraulic tests : they are conducted under pressure on the preventers,

surface equipments and inside BOP's. We must make sure that at any
time, they will withstand the maximum expected pressures.

6.5.1 General recommendations

 All the elements should be tested at their rated working pressure or at the
wellhead working pressure taking into account the smallest value.

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 For developing wells the test pressure could be reduced.

 To minimise pack-off element wear or damage, the annular preventer
should be tested at 50 % of its rated working pressure
 The test must be conducted for15 mn for the preventers and for 10
minutes for the valves.
 The preventers must be tested applying the hydraulic pressures at the
sides they would contain the kick.
 The pressure tests will be performed by a testing unit.
 The maximum allowable test pressure decrease is 5 % for a tests up to
5800 psi and 300 psi for the tests more than 5800 psi.
 The pressures should be recorded on the periodic test sheet.
 The tests must be conducted with water.
 If the tests are performed with a tester cup (figure 46), the test pressure
should not exceed 70 % of the minimum internal yield pressure of the
upper part of the casing string (API RP53).
 Take the necessary arrangements to prevent the consequences of a fluid
leakage.

Tests periodicity

 At the equipment receipt

 After every nippling up / down
 Before a formation test
 Each time judged it necessary
 At the minimum : one operating test once a week, completed by a
hydraulic test every two weeks
 Before entering a reservoir

6.5.2 HydraulicTest procedure

 Circulate with water to clean up the lines to test

 Fill in the space to test until water returns at the flow line and close the
preventer
 Open the line downstream the components to test
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 Conduct the tests at the low pressure of 30 bars, prior to test at high
pressure
 Increase the pressure by steps of 30 bars until reaching the test pressure
 Wait for 10 min while testing valves and 15 min while testing preventers
 Bleed off at zero from the test pump or from the choke manifold

NB) The tests can be carried out in masked time

The following pages show the different circuit configurations corresponding to the
components to test following the Sonatrach procedures.

derating of BOP equipment

Factors causing the derating of BOP equipment

When well control equipment fails to pressure test at its MWP, if the repair cannot
be accomplished quickly, the equipment may be down rated or removed from
service. There are a number of factors that are known to cause reduced
performance of BOPs:

- Using BOP at pressure in excess to their MWP

- Use of Non-OEM (Original Equipment Manufacturer) Replacement Parts
- Special drilling operations, like milling
- Effects of Various Compounds On BOP Elastomers (drilling fluid, H2S etc)
- Effects of temperature on BOP Elastomers
- Special use of BOP (Hang-off, stripping, shearing)

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Tested : Pipe rams & Valves

CHOKE MANIFOLD

TEST
UNIT

VALVE OPEN HYDRAULIC MANUAL

CHECK VALVE
VALVE CLOSED VALVE CHOKE

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Tested : Pipe rams & Valve 4

CHOKE MANIFOLD

TESTING
UNIT

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Tested : Pipe rams & Valves 3, 6, &7

CHOKE MANIFOLD

TESTING
UNIT

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Tested : Valve 1

CHOKE MANIFOLD

TESTING
UNIT

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Tested : Valve 2

CHOKE MANIFOLD

TESTING
UNIT

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Tested : Annular preventer

CHOKE MANIFOLD

TESTING
UNIT

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Tested : Blind Rams & Check Valve

CHOKE MANIFOLD

TESTING
UNIT

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Tested : Valves 12, 13, & 14

CHOKE MANIFOLD

TEST ING
UNIT

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Tested : Valves 9, 10 & 11

CHOKE MANIFOLD

TESTING
UNIT

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Tested : Valves 15 ,16 & 20

CHOKE MANIFOLD

TESTING
UNIT

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Tested : Valves 17 , 18 & 21

CHOKE MANIFOLD

TESTING
UNIT

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Tested : Lower Kelly Cock

TESTING
UNIT

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Tested : Upper Kelly Cock

TESTING
UNIT

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The tools used to perform a hydraulic test are :

Fig 6.39

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6.6 GAS HANDLING SURFACE EQUIPMENTS

These equipments are used downstream of the choke manifold to extract gas out
from the mud and prevent lost of drilling fluid.

There are two types of gas handling surface equipments:

Mud Gas Separator (fig 6.40)

The gas-fluid enters into the separator to be separated by flowing on baffles. The
degassed mud is recovered at the bottom of the separator while the gas escapes
from the top part through the vent line.
If the separator capacity is exceeded, we must direct the gas to the flare line to
prevent blowing the mud from the bottom and discharging gas into the mud tank .
The pressure inside the separator is equal to the pressures losses generated along
the vent line.
The mud return to the mud tank is equipped by a U tube system (mud seal), in
general of a height between 2 and 7m.
The maximal pressure in the separator is equal to the hydrostatic pressure of the
mud seal. If this maximal pressure in the separator is reached, there is a hazard of
gas blowing into the mud tank.
.
The minimal recommended diameter of the separator is 30”. Figure 40

A vertical separator is characterised by:

- The length and the diameter of the separator

(L = 10 ft, OD = 30” mini)
- Baffles arrangement
- Diameter and length of the vent line
(ID = 6” mini, L = variable)
- The mud inlet orientation to minimise the erosion and to
allow inspection of the wear area.
- The U tube height to maintain a mud column in the separator.

Typically, a separator of 30” diameter and minimum height of 16 ft, lets to have an
efficient degassing in the majority of the cases. The internal diameter on the mud
inlet line to the separator must be equal to those of the choke line (generally 4”).

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Fig 6.40 Mud Gas Separator

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Degassers (fig 6.41)

If the gas ratio in the mud is low, either because the kick size is low, or because
there is a residual gas after separation in the poor boy separator, the gas-cut mud is
passed in the degasser installed downstream the shale shaker.
The mud is aspired in a chamber where it is submitted to a partial vacuum to break
out completely the gas. The mud is degassed by flowing on baffles and returns in
the circuit.
A vacuum pump produces a depression into the tank and aspires the gassed mud.
An other auxiliary centrifugal pump ensures circulating of the degassed mud
towards the tanks.
In general, this type of equipment is used with heavy and viscous muds where the
gas extraction in the vertical separator only is not effective.

If operating limits are being reached :

- Direct the gas to flare line / Close the separator isolation valve
- Switch to a slower kill rate
- Stop the circulation and shut the well in .Then the Lubricate method can be
performed to remove the gas from the annulus.

Fig 6.41 Degasser

1- Vacuum pump
2- Water trap
3- Valve 1” on vacuum line
4- Pressure regulator

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6.7 MUD CONTROL AND MONITORING EQUIPEMENT

Pit Volume Totalizer (fig 6.42)

The mud levels in the tanks are continuously monitored. A set of floats (one per
tank) permits to measure and record mud levels in the pits. The tank dimensions
being known, a conversion level/volume is then performed.
This equipment is completed with audible and visual alarms for a rapid indication
of an abnormal level variation.

ALARMS

JUNCTION BOX

MUD

FLOATS AGITATORS

TANKS

Fig 6.42 Mud levels recordings

Differential flow meter (Fig 6.43)

At the flow line, a differential flow meter (flapper system) gives the return flow
rate fluctuations in percentage.

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If the inlet and outlet flow rates are not exactly the same, there is immediately a
gain or a loss indication and warning by an audible and visual alarms activated
before at the driller's station.

Fig 6.43 Return Mud Flow System

Trip Tank (Fig 6.44)

It is a tank with sufficient capacity accuracy enabling to measure a metal volume

of a stand. This measure is carried out by a float which directly displaces a pointer
in front of a graduated rule.
There are also other measuring devices such as the potentiometers which directly
give the total volume, pit gains and pit losses.

The trip tank permits then to make a precise monitoring of volumes while tripping
in and tripping out.

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Fig 6.44 Trip tank

6.8 FLANGES AND RING GASKETS

6.8.1 Flanges

They serve to connect the different components of the wellhead. A flange is

designated by: its type (6B or 6BX), its nominal size in inches (bore of flange) and
its rated working pressure in psi. Example: 11” – 5000 psi

There are two types of flanges (Fig 6.45) :

 The 6B flanges up to the nominal size of 11”.for working pressures of

2000, 3000 and 5000 psi

 The 6BX flanges for the working pressures of 5000 psi from the
dimension of 13 5/8, 10000, 15000 and 20000 psi (as with working
pressures of 2000 and 3000 psi of nominal diameter 26 ¾ ).

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These two types of flanges are mainly different because of the metal to metal
sealing system which uses the stand off between the two flanges.

Fig 6.45 Type s of flanges

6.8.2 The ring gaskets

They are elements made in steel, which serve to ensure the sealing between two
flanges of the same nominal dimension and same series.
It is manufactured in mild iron (symbol D stamped on the seal), or in mild steel
(mark S).

The ring gasket is identified by:

 One or two letters for its type

 A number indicating a reference corresponding to a nominal dimension
but can be used for several series (example: R57 is used for flanges 12”
2000 and 12” 3000).
From this number we can extract dimensions of the groove and the ring
gasket.

There are three main types of ring gaskets: R, RX and BX (Fig 6.46)

 The ring gaskets types R and RX are used on 6B flanges type. The R type
has an oval or octagonal section. The RX has an octagonal asymmetric
section.

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For these two types of seals, tightening will be effective when the seal clearance
between flanges approaches the dimension S called stand off. This clearance must
be the same around the entire circumference.

 The ring gaskets type BX are used on 6BX flanges, they have a
symmetric octagonal section with axial holes to allow the pressure to be
active radially by energising the seal on the external sides of the groove
and ensure the sealing. For this type of seal, the flanges come in face-to-
face contact as the joint is tightened at the recommended make up torque
(S = 0).

Remarks

 An ring gasket should never be re-used

 The flanges grooves must be perfectly clean

 The seal must be inspected before its installation and should not have any
choc marks

 The ring must be installed dry or slightly lubricated with oil

 The RX and BX rings are pressure assisted for sealing (pressure

energized)

 It is recommended to tighten periodically the flange bolting (standard is

weekly) in consideration that vibrations and load of the wellhead can
deform the ring and the groove during drilling operations

Fig 6.46 Types of ring gaskets

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Nominal Series
size 2000 3000 5000 10000 15000 20000
1 13/16 BX 151 BX 151 BX 151
2 1/16 RX 23 RX 24 R-RX 24 BX 152 BX 152 BX 152
2 9/16 RX 26 RX 27 R-RX 27 BX 153 BX 153 BX 153
3 1/16 BX 154 BX 154 BX 154
3 1/8 RX 31 RX 31 R-RX 35
4 1/16 RX 37 RX 37 R-RX 39 BX 155 BX 155 BX 155
5 1/8 RX 41 RX 41 R-RX 44 BX 169
7 1/16 RX 45 RX 45 R-RX 46 BX 156 BX 156 BX 156
9 RX 49 RX 49 R-RX 50 BX 157 BX 157
11 RX 53 RX 53 R-RX 54 BX 158 BX 158
13 5/8 RX 57 RX 57 BX 160 BX 159
16 3/4 RX 65 RX 66 BX 162 BX 162
18 3/4 BX 163 BX 164
20 3/4 RX 74
21 1/4 RX 73 BX 165 BX 164

API Flanges and matching ring gaskets

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Page

7.1 INTRODUCTION

7.2 DOWHOLE PROBLEMS

7.2.1 Bit Nozzle or string Plugging

7.2.2 Bit Nozzles Washed out

7.2.1 String Washed Out

7.2.2 Annulus blockage / collapse

7.2.1 Lost Circulation during a Kill

7.3 SURFACE PROBLEMS

7.3.1 Pump related issues

7.3.2 Pressure gauge failure

Chock/ kill manifold and downstream

7.3.3
problems

7.3.4 BOP failure

7.3.5 Plugged or washes chokes

7.3.6 Hydrate Formation

7.4 PRE-PLANNING AND DRILL

7.5 TOP DRIVE

 KICKS CONTROL MANUAL
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7. Introduction
During well control operation surface and downhole problems can occur.
7.2. Downhole problems

7.2.1 Bit Nozzle or string Plugging

Plugging can occur in the surface lines, string or bit nozzles; it could be partial or
total.
Plugged nozzle(s)or string indicated by sudden increase in circulating drill pipe
pressure with no corresponding increase in casing pressure.
If absolutely sure that a blocked nozzle is the problem, it is acceptable to continue
holding the new drillpipe pressure because it will not affect the U-Tube
communication. But it will affect only the circulating pressure at kill rate (increase
in drill pipe pressure).
In most circumstances, the safest option is to shut down, discuss and restart
if new surface pressure exceed casing shoe fracture pressure, the reduction of the
Stroke Per Minute (SPM) should be considered by shutting in the well.
To reduce the kill pump rate (SPM) to avoid excessive drill pipe pressure by the
following steps:
 Shut-in the well keeps the casing pressure constant.
 Read the new SIDPP and SICP.
 Compare the new SIDPP with the old SIDPP.
 Bring the pump up to kill rate keeping the casing pressure constant, and new
DP pressure should be kept constant if kill mud has passed the bit.
 If kill mud has not reached the bit yet, the new DP pressure schedule should
be computed and followed.

Sudden fall of the DP pressure later may indicate the nozzles have become
unplugged, so original pressure schedule has to be followed.

7.2.2 Bit Nozzles Washed out

Washed bit nozzles indicated by Sudden decrease in circulating drill pipe pressure
with no corresponding decrease in casing pressure.
Similar to the partially plugged nozzles case, It will not affect the U-Tube
communication.
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Suggested actions:
 Shut-in the well, Keep the casing pressure constant
 Read new SIDPP and SICP
 Compare the new SIDPP with the old SIDPP
 Bring the pump up to kill rate keeping the casing pressure constant, and new
DP pressure should be kept constant if kill mud has pass the bit
 If kill mud has not reached the bit yet, the New DP pressure schedule should
be computed and followed

7.2.3 String Washed Out

A drill string washout is indicated by Sudden decrease in circulating drill pipe

pressure with no corresponding decrease in casing pressure, and an increase in
pump strokes.
Depending on the killing methods used and the position of the influx in relation to
the washout
The position of the washout may dictate what actions will follow. Actions should
be taken to prevent the washout from enlarging. In a well control activity,
maintaining bottomhole pressure is paramount. Maintaining circulating pressure
according to plans may increase or decrease pressures in the annulus, depending on
where the washout is located and its severity. Perhaps the best course of immediate
action is to shut the well back in and monitor pressure. If the shut in pressures (on
string and choke) are essentially the same, the washout is above the influx. When
the shut in pressure on the string is lower than pressure on the choke, the washout
is below the influx.
Circulating to kill the well is a judgement call. If washout is below influx, an
attempt may be made to circulate and kill the well. Since the circulating pressure
with washout is not known, procedures in “Kill Rate Pressure Not Available or
Reliable” in this section should be followed to establish a reliable pump pressure.
Even so, periodically the well should be shut in and new pump pressures
established if washout worsens, or existing pump pressure validated if it does not.
Trying to establish and maintain a new pump pressure when the washout is above
the influx will not take gas expansion into account and may allow bottomhole
pressure to drop.
Use volumetric techniques if it is suspected that pumping might create
complications.
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Other possible actions are stripping out of the well and replacing the bad joint,
pumping a dart down the string to isolate washout, or using a coiled tubing,
snubbing or small tubing unit to run a kill string inside damaged tubing.

7.2.4 Annulus blockage / collapse

If the annulus should become totally blocked or collapses during well control
operations, circulating pump pressure will begin to increase while choke pressure
decreases. If pumping continues, pressures below the blockage will pressure the
wellbore, thereby increasing the risk of formation fracture. The pump should be
shut down and the choke closed.
There are many possible solutions to this problem. But well control should be the
primary concern. It may be possible to cut the pipe above the pack off, controlling
the well to that point with heavier fluid. Although not killed, the well may be
static, allowing other fishing or wash over activities until full circulation may be
possible.

7.2.5 Lost Circulation during a Kill

Lost circulation may occur as partial or total loss of returns during well control
situation, Lost circulation can be caused by poor cementing, formation fracture due
to pressure surge, heavy mud weight, excess back pressure due to a large kick
volume or mishandled kicks.
There are a number of signs which, taken together, indicate that losses are
occurring. The most reliable of these is the pit level, which may either drop or,
more probably, fall below an expected trend of increase as gas expands. Another
indication of loss is choke movement. Most choke adjustments in a usual kill are
towards the open position. If a gradual closing down is needed to hold pressure,
lost circulation is a possibility, since this results in casing and drillpipe pressure
dropping, with the casing pressure reduction being more pronounced.

Partial Losses
With partial loss of returns, two possible courses of action are:
 Maintain kill rate pump speed and drillpipe pressures to keep a constant
bottom hole pressure, while attempting to keep up with the losses until the
gas is within the shoe. Once the gas is within the casing shoe, the lost return
problem should stabilise.

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 If the losses become increasingly heavy, the ‘low-choke’ method should be

adopted. If this does not allow sufficient returns, then close the well in and
treat as for severe or complete losses.

Severe or Total Losses

Where losses are too severe to maintain or are total, several options remain:
 Pump lost circulation material down the annulus.
 Placing a heavy slug of mud on bottom
 Set barite, cement or gunk plugs.

7.3. Surface problems

7.3.1 Pump related issues

Pump rate and volume are important. If the pump fails or is not operating correctly
during well control operations, change to another pump using the following steps.
1. Slow down and stop the pump, while holding the casing pressure constant.
2. Shut the well in.
3. Switch to the alternate pump and bring it up to the desired kill rate.
4. When second pump is up to desired kill rate, and casing pressure is the same
as when shut in the second time, record the circulating pressure.
5. This value will be the new circulating pressure. Pressure may be higher or
lower than first pump’s pressure because of efficiency or output differences.
Depending on stage of well control operation, circulating pressure may be
initial, final or some intermediate pressure.
In the event of sudden pump failure the well should be shut back in and volumetric
techniques implemented until it can be repaired or another brought on line

7.3.2 Pressure gauge failure

Pressure gauge is rare problem, it is possible for a gauge to malfunction or fail
during any well control operation. Most units contain several pressure gauges that
can be used to read shut in and circulating pressures. In addition to the set of
primary gauges that will be used, it is advisable to identify and record pressure
values from all the gauges that may be used during a well control operation,
Remember that there may be variations in pressure readings from one gauge to

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another. Also, keep in mind that if a primary gauge fails, the alternate gauge may
be remotely located. This will also require a communication network to relay
pressure readings and what adjustments must be made on the choke and pump to
successfully continue the control operation. If electronic communications are not
available or malfunctions, then hand signals or runners may be required.

7.3.3 Chock/ kill manifold and downstream problems

Alternate flow routes are usually provided on the choke/kill manifold in the event
of plugging or washouts. This may require that flow be redirected through a
different choke. Common sense and observing the sequence is vital to troubleshoot
these problems. The pressure gauge on the kill manifold gives a good indication
whether the problem is upstream or downstream of this gauge. For example, if
choke pressure rapidly bleeds off, even with the choke operator trying to maintain
correct pressure, the plugging problem is upstream of the pressure sensor. Or, if
pressure begins increasing and not responding to choke adjustment, the blockage
may be downstream of the choke. Once the problem is identified an alternate flow
path may be chosen.

If the mud gas separator becomes plugged, flow may have to be redirected to the
flowline and bypass the line to the mud gas separator until it can be unplugged.
Caution should be used, as the flow may be flammable. Consideration should be
given to shutting the well back in until the necessary repairs are completed.

7.3.4 BOP failure

Both contingency plans and emergency response plans (ERPs) should include
action plans for BOP failure. BOP failure can result in additional formation influx
and escape of formation fluids at surface resulting in the loss of the well and rig.
Hence the reason the BOPs should be monitored throughout any well control
activity. If there is a leakage Both contingency plans and emergency response
plans (ERPs) should include action plans for BOP failure. BOP failure can result in
additional formation influx and escape of formation fluids at surface resulting in
the loss of the well and rig. Hence the reason the BOPs should be monitored
throughout any well control activity. If there is a leakage when the BOP is closed
the packer element may be damaged. Often increasing the closing pressure may

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stop the leak, however if the leak is severe an alternate preventer should
immediately be used.

On surface BOP stacks most rams have a weephole that indicates failure of the
main seals of the ram shaft. This can result in failure of a positive closure of the
ram around the pipe or wellbore. Several BOP manufacturers provide a temporary
means to remedy this problem. A hex screw, located upstream from the weephole,
when tightened will force packing or sealant material into the seal area to reduce or
stop the shaft seal from leaking. When the well is back under control this problem
must be repaired.

Crews should be familiar with alternate closing devices in the event of hydraulic
failure of the closing system. This may be as simple as selecting another BOP, or
manually closing a pipe ram. It may be necessary to manifold a high pressure test
or cement pump to the stack’s closing line if the closing unit fails and the rams
cannot be closed manually. If a hydraulic line fails, the function should be blocked
to avoid losing closing pressure.

The point of failure is critical. If the failure is a flange seal between two BOPs,
closing a lower ram may allow pressures to be controlled and depending on
arrangement, well control activities to continue. Dropping the pipe and closing a
blind ram is yet another possibility depending on the severity and location of the
failure. Another solution to a flange seal failure is to pump a graded sealant into
the wellhead. Pumping cement to plug the well is usually the last resort.

7.3.5 Plugged or washes chokes

3.5.1 Plugged choke

During well control operations, the choke may plug for a number of reasons
including blockage by cuttings and hydrate formation.

When this happens, both the drill pipe and casing pressure will increase. The choke
operator will start to open the choke to compensate.

This will work for a time, however once recognised, the remedy is to shut in and
reroute to another choke.

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It is possible that upon opening the choke the obstruction may clear and operations
can return to normal.

Suggested actions:

1. Stop the pump immediately (to reduce back pressure or trapped pressure at
choke and very important to prevent over pressure in open hole against
weaker formations).
2. Shut-in the well (choke follows pump).
3. Some companies prefer to close then open HCR and line up alternative
choke in between HCR actions.
4. Release the trapped pressure through the standby choke or choke manifold
bleed line by bleeding small volume at intervals till the SIDPP comes back
to normal.
5. Well control can continue with the alternate choke.
6. Bring the pump up to the required kill rate keeping the casing pressure
constant to continue well killing process

7.3.5.2 Washed choke

Due to the amount of cuttings and, in particular, sand in the returns, a choke
washing out is a definite possibility. This is recognized by a decrease in the Casing
Pressure and after time lag the Drill Pipe Pressure decrease which cannot be
corrected by choke manipulations. Once recognized the well should be shut in
immediately and The HCR or failsafe should also be closed.

Suggested actions:

1. Stop the pump immediately.

2. Isolate the defective choke line or valve.
3. Read new SIDPP and SICP.
4. Compare the new SIDPP with the old SIDPP.
5. Continue the well killing operation
6. Bring the pump up to the required kill rate keeping the casing pressure
constant

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7.3.6 Hydrate Formation

Definition
Hydrates are a complex crystalline structure of hydrocarbons and water. In simple
terms, a hydrate is a frozen gas, commonly methane.

Formation of Hydrates
The formation of hydrates is dependent upon a combination of the following
conditions:

 Presence of free water.

 Presence of hydrocarbon gas.
 Low temperature.
 High pressure.

It is aggravated by pressure drop/gas expansion (e.g., through a choke) and

pressure pulsation. Hydrates usually occur in production and drilling operations in
cold where they can be a routine occurrence.

Hydrates can cause severe problems by forming a plug in valves or chokes

completely blocking flow. The two critical areas are the passage in to the choke
line through the failsafe valves and at the choke itself. The resulting pressure drop
as the gas passes through these restrictions and the sudden increase in velocity
causes expansion cooling of the gas immediately downstream of the choke.
Prevention of hydrate formation is a great deal less difficult than removal of
hydrates once they have formed.

It may be necessary to inject methanol to suppress hydrate formation. This is

normal practice on surface choke manifolds and. If hydrates do form and plug off a
choke or line they can be very difficult to remove. Considerable heat is required for
decomposition. Such decomposition can be explosive since once the process
begins it will continue extremely quickly. The best method of decomposing
hydrates is to circulate hot brine solution.

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Prevention of hydrates
Hydrates are much easier to prevent
from forming than to remove once
they have formed. Prevention can be
achieved as follows:

 Primary good well control

practices to minimize gas
coming from the formation.
 Reducing free water by using
oil based mud or maximizing
the chloride content of a water
based mud.
 Maintaining temperature as
high as possible.
 Injecting methanol or glycol at
a rate of 2-4 liter (0.5-1 gal.)
per minute on the upstream side of a choke or line.

7.4. Pre-planning and drill

Pre-planning and drills on the rig are necessary to prepare for expected and
unexpected events. Pre-planning should take all expected operations into account
and set a well control plan of action. Unexpected events frequently occur.
Forethought must be given to unusual situations and a plan of action should be
defined. Once a plan of action is established, the crew should familiarize
themselves with it.

Drills should be designed to ensure that everyone knows their responsibilities.

Many drills cannot be performed without complications, and the drills are often
different from the actual procedure. For example, a diverter drill might require the
driller to go to the diverter console where he would not shut in the well, but rather
explain the procedure of opening the downwind diverter line and closing the

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diverter packer. Then he would to go to the pump control, and explain the process
of bringing the pump to full rate. Other drills can be initiated by raising the float in
the mud pits or the flowline sensor paddle. The elapsed time for the drill is
measured until everyone is in position to shut in the well. Drills should be
practiced as if the event were real.

Drills may be announced or unannounced and typically take place at times that will
not interfere with the current activity. Evacuation drills rarely include the driller if
the bit is in the well and are often announced so personnel will not overreact, panic
or injure themselves.

Pit Drill ( API53RP section 4 shut in procedure)

Without prior warning and during a routine operation, the rig supervisor should
simulate a gain in pit drilling fluid volume by raising a float sufficiently to cause
an alarm to be activated. If automatic equipment is not available, the drills may be
signalled by word of mouth. This, of course, diminishes the surprise element, but
the training is still effective. The drilling crew should immediately initiate one of
the four procedures discussed in Paragraph B depending on the operation at the
time of the drill. A pit drill is terminated when the crew has completed the steps up
to, but not including, closing the blowout preventers (Crews must be advised that
this is a pit drill, otherwise they should proceed with the complete blowout
preventer drill). The supervisor initiating the drill should record response time.
Crew response time should be one minute or less.

B. Blowout Preventer Drill.

This drill includes all steps of the pit drill (refer to Paragraph A) but is continued
through all the steps of closing in the well as outlined below. This drill should be
repeated on a daily basis until each crew can close in the well within a span of two
minutes. Thereafter the drill should be repeated weekly to maintain proficiency.

On-bottom Drill.

a. Signal given.
b. Stop rotary.
c. Raise kelly tool joint above the rotary, while sounding the alarm.
d. Stop pump.
e. Check for well flow.
7-11
 KICKS CONTROL MANUAL
SECTION 6: WELL CONTROL PROBLEMS

The on-bottom drill should be carried only to the point of driller recognition,
signalled by raising the kelly and pump shutdown. This is to avoid the
danger of stuck pipe.

Out of the Hole Drill

a. Signal given.
b. Close blind rams.

Tripping Drill Pipe Drill

a. Signal given.
b. Position the upper tool job above rotary table and set slips.
c. Stab full-open valve on drill pipe.
d. Close drill pipe safety valve.
e. Close blowout preventer.

Drills while tripping drill pipe should be performed after the bit is up in the casing.
A full opening safety valve for each size and type connection in the string must be
open and on the floor ready for use. Safety valves must be clearly identified as to
size and connection to avoid confusion and lost time when stabbing.

Stripping Drill.
The performance of a stripping drill by at least one crew on each well should be
considered. This drill can be conveniently performed after casing is set and before
drilling out cement. With drill pipe in the hole a blowout preventer should be
closed and the desired pressure trapped. Each crew member should be assigned a
specific position. Following an acceptable procedure, 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 assignments. In addition to
establishing equipment reliability, this will permit the training of at least one crew
on each well. Over a period of time, all crews should become proficient in
stripping operations. Stripping drills are not recommended for operations involving
subsea blowout preventer stacks.

7-12
 KICKS CONTROL MANUAL
SECTION 6: WELL CONTROL PROBLEMS

7.5 Top drive

The top drive unit has been used primarily for drilling rigs, but has also been
designed for

smaller workover operations. The traditional kelly and kelly drive bushing are not
required, as the work string is rotated directly by electric or hydraulic power. The
system is an improvement in rotating technology, as multiple joints of pipe may be
used at one time. A conventional elevator hoists and lowers the string when
tripping. With the top drive, rapid response to well kicks is always available while
tripping or drilling. The drilling shaft is never more than a few seconds away so the
driller can set the slips, stab into the string, rotate and torque the connection, so
shut in of the well does not depend upon floor crew. With a top drive, circulation
can be maintained (pump out of hole), as can the ability to back-ream during trips
out of the hole. Hazards are reduced by eliminating two-thirds of the connections,
and no bushings rotate at the floor.

Shut in on trip with top drive

The kelly is not used on rigs equipped with top drive systems. Once the well has
been shut in, it is recommended that a pup joint or a single be installed between the
top drive and full opening safety valve (FOSV) stabbed on the string. Then open
the valve. If flow through the string prevented installation of the safety valve, the
top drive may be stabbed and made up directly on the drillpipe.

Top drive systems employ a remotely operated FOSV which is always made up on
the top drive. If a kick is suspected, the pipe can be set in the slips, the top drive
lowered and spun up on the string. The FOSV is then closed. At shallow depths,
where time is especially critical, this technique offers great advantages over
conventional rotary Kelly systems.

7-13
 KICKS CONTROL MANUAL
SECTION 6: WELL CONTROL PROBLEMS

Summary of problems while well killing

Problems SPP CP BHP Risks Shut-in

String washout ↓ → → Secondary kick

Choke Washout ↓ ↓ ↓ Secondary kick Emergency
Choke plugged ↑ ↑ ↑ Fracture Emergency
Surface Equipment

Rotary Hose leaking ↓ ↓ ↓ Secondary kick Emergency

BOP failure (Static) ↓ ↓ ↓ Secondary kick (Close 2nd
BOP)
BOP failure → → → Secondary kick (Choke closed
(circulating) little more)
Hydrates ↑ ↑ ↑ Fracture Emergency
Bit nozzle plugged ↑ → → No risk on By steps
formations
Bit nozzle cut out ↓ → → No risk on By steps
formations
Drill String

Bit nozzle washout ↓ → → No risk on By steps

formations
String washout ↓ → → Secondary kick or By steps or
Overpressure Emergency
Pump failure ↓ ↓ ↓ Secondary kick Emergency
Blockage downhole ↑ ↓ ↑ Fracture Emergency

7-14
Abbreviations

bar = Bar (pressure)

bar/m = Bar per metre
bar/hr = Bar per hour
BHP = Bottom hole pressure
BOP = Blowout Preventer
kg/l = Kilogram per litre
l = Litre
l/m = Litre per metre
l/min = Litre per minute
l/stroke = Litre per stroke
LOT = Leak-off Test
m = Metre
m/hr = Metre per hour
m/min = Metre per minute
MAASP = Maximum Allowable Annular Surface Pressure
SICP = Shut in Casing Pressure
SIDPP = Shut in Drill Pipe Pressure
SPM = Strokes per minute
TVD = True Vertical Depth
10.2 = Constant factor
Calculation formula

01 Volume of tanks and pits = Volume of mud per unit height (mଷ⁄cm) × mud height (cm)

Open hole capacity per unit π

02
length (L/m)
= 4 × [open hole diameter (m)]ଶ

Annular capacity per unit π

03
length (L/m) = 4 × [hole diameter (m) − tubular diameter (m)]ଶ

04 Annular volume (L) = Annular capacity per unit length (L⁄m) × annular length (m)

05 Pump output (L/min) = Pump Displacement (l/stroke) × Pump Rate (SPM)

Pump Output (L/min )

06 Annular Velocity (m/min) =
Annular Capacity (L/m)

07 Displacement of open pipe (L) = metal displacement (L⁄m) × length of pipe (m)
 Displacement of closed pipe
08
(L) = [metal displacement + capacity of drill pipe](L⁄m) × length of pipe (m)

drill string volume (L) + annular volume (L)

09 Circulation time (min) =
pump output (L⁄min)

Annular volume(L)
10 Bottoms up time (min) = pump output (L⁄min)

Total circulating time, drill string volume (L) + annular volume (L) + active surface volume
11 =
including surface equipment pump output (L⁄min)

drill string volume (L)

12 Surface to bit time =
pump output (L⁄min)

open hole annular volume (L)

13 Bit to shoe time =
pump output (L⁄min)

Annular volume (L)

14 Bottom up strokes = pump displacement (L⁄stroke)

Drill string volume (L)

15 Surface to bit strokes =
pump displacement (L⁄stroke)
 open hole annular volume (L)
16 Bit to shoe strokes = pump displacement (L⁄stroke)

Total circulating strokes, drill string volume (L) + annular volume (L) + active surface volume
17 =
including surface equipment pump displacement (L⁄stroke)

Mud density (kg⁄L) × TVD (m)

18 Hydrostatic Pressure (bars) =
10.2

19 Formation pressure (bars) = Hydrostatic Pressure in Drill String (bar) + SIDPP (bar)

Fracture and leak-off pressure LOT density (kg⁄L) × TVD Shoe (m)
20 = LOT pressure (bar) +
(bars) 10.2

[Max Allowable Mud Density (kg/l) − Current Mud Density (kg/l) ] × Shoe TVD (m)
21 MAASP (bar) =
10.2

Mud Density With Trip Safety Margin (bar) × 10.2

22 = + Mud Density (kg/L)
Margin Included (kg/L) TVD (m)

Surface LOT Pressure (bar) × 10.2

23 Maximum Allowable Mud = + LOT Mud Density (kg⁄L)
Density (kg/L) Shoe TVD (m)
 MAASP (bar) − SIDPP (bar)
24 Kick Tolerance (m) = × 10.2
Mud Density (kg⁄L) − ϐŽ—šdensity (kg⁄L)

10.2 × pressure (bar)

25 Drilling Mud Density (Kg/L) =
TVD (m)

Mud density (kg⁄L)

26 Pressure Gradient (bar/m) =
10.2

10.2 × SIDPP(bar)
27 Kill Mud Density (kg/l) = Original mud density (kg⁄L) +
TVD (m)

Equivalent Circulating Annular Pressure Loss (bar) × 10.2

28
Density (kg/l) = Mud Density (kg/l) + TVD (m)

New Pump Pressure (Bar)

New Pump Rate (SPM) ଶ
29 With New Pump Rate = Old Pump Pressure (bar) × ൬ ൰
approximate Old Pump Rate (SPM)

New Pump Pressure (Bar) New Mud Density (kg/l)

30 With New Mud Density = Old Pump Pressure (bar) × ൬ Old Mud Density (kg/l) ൰
approximate
 ୔భ୚భ ୔భ୚భ
31 Gas Laws = PଵVଵ = PଶVଶ Pଶ =
୚మ
Vଶ =
୔మ

[Mud Density − ϐŽ—šDensity](kg⁄L) × ϐŽ—švertical Height (m)

32 SICP (bar) = + SIDPP (bar)
10.2

Pit Gain (L)

33 Influx Height (m) = Annular Capacity (L⁄m)

Mud density (kg⁄L) SICP (bar) − SIDPP(bar)

34 Influx gradient (bars/m) = ቆ ቇ− ቆ ቇ
10.2 ϐŽ—šVertical Height (m)

Initial Circulating Pressure

35
(bar) = Kill Rate Circulating Pressure (bar) + SIDPP (bar)

Final Circulating Pressure Kill Mud Density (kg/l)

36
(bar) = Original Mud Density (kg/l) × Kill Rate Circulating Pressure (bar)

(ICP − FCP)
37 Pressure drop per step = × 100 strokes
Surface to bit strokes
 Rate of Increase in Surface Pressure (bar/hr)
38 Gas migration Rate (m/hr) = × 10.2
Drilling Mud Density (kg/L)

Volume to Bleed off to Increase in Surface Pressure (bar) × Inϐlux Volume (L)
39 Restore BHP to Formation =
Pressure (litre) Formation Pressure (bar) − Increase in Surface Pressure (bar)

Baryte Required To Increase Kill Mud Density (kg/l) − Original Mud Density (kg/l)
40
Drilling Mud Density (Kg/L) = 4.2 × ൬ 4.2 − Kill Mud Density (kg/l)
൰

Volume increases due to Baryte required to increase density (kg)

41 = Iinitial mud volume (L) +
increase in density 4.2

Pressure Drop Per Metre Drilling Mud Density (kg/L) × Metal Displacement (L/m)
42 =
Tripping Dry Pipe (bar/m) [Casing Capacity (L/m) − Metal Displacement (L/m)] × 10.2

Pressure Drop Per Metre Drilling Mud Density (kg⁄L) × Closed End Displacement (L/m)
43 =
Tripping Wet Pipe (bar/m) [Casing Capacity (L/m) – Closed End Displacement (L/m)] × 10.2

Level Drop Pulling Remaining Length of Collars (m) × Metal Displacement (L/m)
44 Collars Out Of Hole Dry = Casing Capacity (L⁄m)
(metre)
 Level Drop Pulling Remaining Length of Collars (m) × Closed End Displacement (L/m)
45 Collars Out Of Hole Wet =
(metre) Casing Capacity (L⁄m)

Length of Tubular to Pull Dry Overbalance (bar) × [Casing Capacity (L/m) − Metal Displacement (L/m)]
46 Before Overbalance is Lost =
(m) Drilling Mud Gradient (bar/m) × Metal Displacement (L/m)

Length of Tubular to Pull Wet Overbalance (bar) × [Casing Capacity (L/m) – Closed End Displacement (L/m)]
47 Before Overbalance is Lost = bar
Drilling Mud Gradient ቀ ቁ× Closed End Displacement (L/m)
(m) m

Hydrostatic Pressure Loss if Mud Density (kg/L) × Casing Capacity (L/m) × Unϐilled Casing Height (m)
48
Casing Float Fails (bar) = [Casing Capacity (L/m) + Annular Capacity (L/m)] × 10.2

Slug Volume (Litre) for a Length of Dry Pipe (m) × Pipe Capacity (L/m) × Drilling Mud Density (kg/L)
49
Given Length of Dry Pipe = Slug Density (kg/L) − Drilling Mud Density (kg/L)

Pit Gain due to Slug U-Tubing Slug Density (kg/L)

50
(Litre) = Slug Volume (L) × ൬Drilling Mud Density (kg/L) − 1൰
51.Pump output from table
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