Sonatrach Well Control

Development Phase
September October 2005

abalt solutions limited - 2005
INTRODUCTION TO HYDROCARBON EXPLOITATION
Abalt Solutions
Introduction to Hydrocarbon Exploitation
2005 Abalt Solutions Limited. All rights reserved
Well Control
Section
By Pratap Thimaiah
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Kick
An uncontrolled flow of formation fluids into the
wellbore during a drilling operation mainly
arising due to the formation pressure being
greater than hydrostatic pressure imposed by
mud column.
Development Phase
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Causes of Kick
Insufficient mud weight
Low level of fluid column in annulus
Excessive swabbing
Excessive drilling rate in gas bearing formation
Diffusion of gas through mud cake
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Insufficient Mud weight
Penetration of geo pressured zone.
Accidental dilution of mud by fluid addition at
surface
Dilution of mud by influx from aquifer exposed
to open hole.
gradual decrease in mud density due to gas cut
and failure to degas.
Poor quality control
Development Phase
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Low level of drilling fluid column
Failure to fill hole during tripping
Lost circulation
Mud loss to caverns and vugs
Penetration of depleted zones
Mud loss to fractures as a result of surge
pressures, excessive hydraulics etc.
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Excessive swabbing
Reduction of bottom hole pressure caused by
upward pipe movement
Mud flows down the annulus into the open hole.
Frictional pressure loss in the direction of
surface.
Reduced BHP and instantaneous vacuum below
bit.
Development Phase
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Excessive drilling rate in Gas bearing formations
Influx reduces mud density in annulus.
Mud cut occurs from:
Swabbing
Fluid diffusion due to negative pressure
differential
Expansion of gas as it reaches the surface.
Air entrained in mud from the Kelly air trips.
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Pre-Kick Data
Maximum Working Casing Pressure
Casing and BOP are designed for different expected
pressures during each phase.
Determined during well planning-Usually maximum
rating of BOP or 80% burst pressure of last casing
string.
MAASP (Maximum Allowable Annular Surface Pressure)
Represents maximum annulus pressure permitted
while controlling a kick.
Annular pressure at surface that corresponds to
weakest point of the hole.
MAASP =0.052 x (Frac - ) x TVD
where Frac=fracture pressure at shoe
in ppg
Development Phase
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Pre-Kick Data
Pump, String and Hole configurations
Pump capacity
Hole stability
Drilling string capacity
Annular capacity
Casing data (size, weight, burst pressure, shoe
depth etc)
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Kick Detection Techniques
Positive Indicators
Mud pit level/flow increase
Incorrect hole fill up during trip
Decrease in stand pipe pressure
Increase in pump rate
Increase/decrease in drill string weight
Potential Indicators
Increase in ROP
Lost circulation
Changes in mud density and conductivity.
Development Phase
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Well Control Procedures
Control Procedures Involve the following:
1. Shut in the well-follow predefined procedures
2. Observe shut in pressures and kick volumes
3. Make kill calculations for
Formation pressure
BHP
Kill mud density
Initial and final circulation pressure
Drill pipe pressure schedules
Weighting material volume required.
4. Define weighing up and circulating procedures
Drillers method
Wait and weight method
Concurrent
Top kill method
5. Make interpretation for influx
1. Height and density
2. annular pressure behaviour while circulating
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Well Control Equipment
Wellheads
Control systems
Associated equipment
Blow out Preventers
Annular
Ram Type
Development Phase
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Well Control Equipment
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Annular Preventer
Doughnut shaped elastic
element with bond steel
reinforcement.
Extrusion of element into
wellbore is effected by upwards
movement of hydraulically
actuated piston.
Element designed to seal around
any shape or size of pipe and to
close on open hole.
Facilitates stripping of drill pipe
in and out of well, with pressure
on wellhead
BOP
Development Phase
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BOP
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Majority of annular Preventer currently in use are
manufactured by
Hydril (types MSP,GK,GL,GX)
Shaffer (spherical)
Cameron (Type D)
BOP
Development Phase
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Ram Preventers
Two Hydraulically actuated horizontally opposed rams which are
either designed to seal off an open hole or annulus against pipe of
specific diameter.
Working pressure of ram preventers should be atleast equal to
maximum anticipated surface pressures ,plus margin for pumping
to the well.
BOP
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BOP
Development Phase
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Types
Pipe Rams
Designed to centralize
and pack-off around
one specific size of drill
pipe or casing.
Variable Pipe Rams
Available in different
sizes
One set will provide
back-up for two
different pipe rams.
Have limited hang-off
capacity therefore
depends upon tool joint
size and ram range.
BOP
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BOP
Development Phase
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Hanging Rams
Pipe rams with enhanced load bearing capacities used for
floating operations.
Hardening of bearing area
Blind/shear rams
Used to cut pipe and seal as blind rams.
Pipe stub accommodated in a recess.
Care should be taken that pipe body is opposite rams and not
tool joint.
Bop control systems must be adequate to shear the pipe in use.
Offset rams
Available for dual completions
BOP
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Control Systems
Provides means of individually closing and
opening each BOP and valve conveniently,
rapidly, repeatedly and at correct
operating pressure.
Designed to operate when in
emergencies, primary rig power may not
be available.
Elements of control systems:
Power source
Control manifolds
Accumulators
Connecting pipe works/hose bundle
and wiring
Development Phase
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Control Systems
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Control Systems
Development Phase
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Control Systems -Power Source
Primary power source
Electrically driven pumps.
For a 3000 psi accumulator system, pumps should incorporate a
pressure switch set to cut in & out at 2800 psi and 3000 psi
respectively.
Diesel pumps used on land rigs
Secondary power source
Air power pumps located on control manifold.
Stand by diesel driven air compressor piped to pumps should be
provided at location away from primary power source.
Battery packs
Where electric panels are used, a battery pack is required
Manual closing
Extension arms and wheels should be considered for ram
preventers.
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Control Systems-Control Manifolds
Equipped with three control manifolds or panels
Central Manifold
Located away from the rig floor area.
All hydraulic, air-hydraulic or electro-hydraulic
Required features are
Regulator to reduce accumulator pressure to operating
pressure for ram preventers ,annular preventers and
valves.
Control handles or switches
Pressure gauges
By pass valves
Vent line for bleeding off accumulator fluid
Relief valve for pumps
Flow meters.
Development Phase
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Driller's Control Panel
Located on the rig floor within access.
Air or electric operated
Required features include:
Control for each BOP Stack and to adjust manifold
regulators.
Read-outs for accumulator pressures, manifold pressures
and flow meters.
Air supply pressure read outs.
Schematic showing kill & choke lines
Visual or audible warning devices
Remote Manifold
Located at safe distance from well access
Required features include:
Controls for BOP Stack
Interlocks and covers
Visual and audible warning systems
Schematic of BOP Arrangement.
Control Systems-Control Manifolds
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Hydraulic fluid required to operate the BOP functions is stored
in accumulators, pressurized against a nitrogen inflated
bladder.
Located near control manifold.
Stores hydraulic energy and high rate supply of fluid for BOP
functions.
Operating pressures are 3000 psi.
Control Systems-Accumulators
Development Phase
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High capacity conduits for individual functions.
For a particular function, fluid flows from accumulators,
through regulators and directly to function.
Control lines should be seamless steel tubing of 1 in
minimum nominal size and pressure rating equal to
working pressure of control system.
Control Systems-Pipe Works/Wiring
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Associated equipment
Mud control & Monitoring equipment
Mud gas separators
Drill string valves
Rotating heads
Development Phase
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Pit volume measurement
Calibrated read-out and
audio alarm installed in
Drillers station
Flow line measurements
Measures flow line mud
return rate
Trip tank
Used to fill hole during
trips, measure mud
volumes or water into
annulus when
circulation is lost or
logging etc.
Types
Gravity feed
Pump type
Associated equipment-Mud control & Monitoring
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Separates gas from drilling fluids
Provides a means for safety
venting the gas and returning
usable liquid mud to active
system.
Minimizes risk for gas influx
circulation during a kick without
having to shut down the system
Types
Atmospheric
Referred to as gas buster or
poor-boy separator.
Simple design and does not
require control valves on
either discharge lines
Pressurised
Operates with moderate back
pressure generally 50 psi or
less.
Overcomes line pressure
losses due to excessive
lengths of vent lines
Associated equipment-Mud gas separators
Development Phase
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Used to close in well on the drill pipe bore and to protect surface
equipment.
Placed on surface and may be either manual shut-off or automatic check
valve type.
Rated at same pressures as BOP & tested at same frequency.
Types
Kelly Valves
Upper kelly valve closes on drill string when kelly is down through rotary
table and cannot be lifted.
Lower kelly valve allows closing-in on drill string and removing kelly if
required
Float valves
Prevents back flow during connections and flow up drill string in the event
of a kick.
Drop-in valves
Held on surface & dropped down to a special landing sub.
Allows pipe to be stripped to bottom and preventing further circulation
Drill pipe safety valves
Installed when kick occurs, allows drill string to be closed-in.
Inside BOP
Surface installed checked valve to close drill string bore.
Available on rig floor as back up and installed above drill pipe safety valve
Associated equipment-Drill String Valves
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Installed above BOP and
provide seal on kelly or
drill pipe.
Drive unit is attached to
Kelly, locates in bearing
assembly
Applications
Drilling with air or gas
Permit drilling
Underbalance.
Diverter for surface
hole
Keep gas away from
rotary table, important
when H2S can be
expected
Associated equipment-Rotating Heads
Development Phase
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Kill Method-Drillers Method
Well shut in after the kick has occurred with appropriate shut in
procedures followed.
Influx circulated out using original mud in hole.
Once kick is out of hole, the hole is filled with the heavier kill mud.
Two circulations:
First circulation-remove influx
Second circulation-circulate kill mud
Advantages
Minimum circulation
Minimum idle time
Minimum well information required
Disadvantages
High annular pressure if kick contains gas
Maximum time with well under pressure
Maximum time spent controlling choke
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Development Phase
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Kill Method- Wait & Weight (Engineers) Method
Influx is circulated out by the kill mud in one cycle.
Requires manipulation of choke to maintain constant bottom hole
pressure as the new mud moves from surface to bottom.
The kill may require several circulation cycles with mud density raised
in stages.
Advantages
Lowest wellbore and surface pressure.
Minimum time spent on choke
Disadvantages
Idle time weighting up with gas migration possible.
Possibility of several cycles if large mud weight increase is
necessary.
Development Phase
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Development Phase
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Kill Method-Concurrent Method
Mixes the features of Drillers & Engineers Methods.
Applied in cases where surface pressures need to be kept as low as
possible and shut-in time minimum.
Circulation starts immediately after observing shut-in pressures using
current mud weight.
Mud weight is then increased in stages.
As each stage of increased mud weight reaches the bit, the driller starts
pumping next stage.
When the new mud reaches the kill mud weight, circulation continues
until new mud reaches the surface.
This method requires more choke manipulation to maintain constant
BHP like Engineers method.
Advantages
Minimum idle time
Control starts immediately
Continuous and smooth adjustment of mud density
Disadvantages
Slightly more complex calculations
Maximum time spent circulating under pressure.
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Well control -Without Circulation
If the influx is gas-drill string out of hole ?
Volumetric method to bleed off ,allowing gas to expand as it
migrate.
Most effective method when the kick occurs during swabbing.
In most cases mud weight is sufficient to prevent further influx
before the circulation of weighted mud.
Development Phase
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Well control -Without Circulation
X
X
X
Kill
Fluid
Gas
Compressed
Displace Small
Amount of
Kill Fluid
Into Well.
Kill Fluid
Settles
To Bottom
Gas Pressure
Bled Off at
Surface
(Process
Repeated)
Kill
Fluid
Gas
Gas
Kill
Fluid
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Top Kill Method
Bullheading
Injection of mud into the closed annulus to force
invading fluids back into formation.
Used in cleaning up well bore after a drill stem test in
cased holes.
Only used in kick control when no other method is
possible.
Disadvantage is that there is a high risk of failure of
casing shoe and creation of fissures to surface behind
casing.
Development Phase
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Safety
To avoid or prevent flowing of wellbore fluids!
A general rule is that at least two independent
and tested barriers should be used.
There are two types of barriers:
Mechanical
Hydrostatic
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Mechanical Barriers
Closeable Barriers:
BOP Rams
Xmas Trees Valves
SSV
Annular preventers
Closed Barriers:
Wireline stuffing box
Coiled tubing stripper
Snubbing strippers
Coiled tubing check valves
Additional Barriers:
Wireline Plugs
Cement Plugs
Overbalanced hydrostatic fluid
Bridge Plugs
Development Phase
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As their name says it all, this type of barrier is
provided by liquid.
Typical fluid barriers are:
Drilling Mud
Completion Brines
Seawater
Fresh Water
Hydrostatic Barriers
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Pressure Control Devices
Development Phase
Abalt Solutions
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BLOW OUT
When secondary control fails, then blowouts occur.
Massive influx to the wellbore and gusher to surface.
To control this, it maybe useful to close blind rams before
abandonment.
Putting blowouts under full control may require drilling of
a relief well, through which are pumped very heavy mud
or cement to plug off the well affected.
During blow outs special blow out control teams are
required.
Types
External Blowout: It is an Uncontrolled flow of influx to
the wellbore and through to the surface.
Internal Blowout or Underground Blowout: It is an
uncontrolled flow of influx to wellbore and entry into a
weak zone
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BLOW OUT

Sonatrach Well Control

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Sonatrach Well Control

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Development Phase

September October 2005

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