WELL CONTROL MANUAL

Drilling & Workover October 2002

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INTRODUCTION AND RESPONSIBILITIES

Table of Contents

Introduction.......................................................................................................... 2
1.0 Responsibilities of Drilling Staff ........................................................ 3
1.1 Well Planning................................................................................... 3
1.2 Drilling Program............................................................................... 3
1.3 Geological Information..................................................................... 3
1.4 Area Drilling Experience .................................................................. 4
1.5 Casing Design and Depths of Setting .............................................. 4
1.6 Equipment Selection........................................................................ 4
1.7 Hiring Contract Rigs. ........................................................................ 4
1.8 Specification of Rig Equipment ....................................................... 4
1.9 Contract Responsibilities................................................................. 4
1.10 Training of Company and Contract Personnel ................................. 5
1.11 BOP Equipment ............................................................................... 5
1.12 BOP Testing ..................................................................................... 5
1.13 Well Control ..................................................................................... 5
1.14 Pre-recorded Data Sheet ................................................................. 5
1.15 Slow Pump Rate Data....................................................................... 5
1.16 Blowout Prevention Training ........................................................... 6
1.17 Information to be Posted.................................................................. 6

Current Edition: October 2002 1 3rd Edition

Previous Revision: October 1998
WELL CONTROL MANUAL
Drilling & Workover October 2002
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INTRODUCTION AND RESPONSIBILITIES

Introduction

The single most important step to blowout prevention is closing the blowout preventers when the
well kicks. The decision to do so may well be the most important of your working life. It ranks with
keeping the hole full of fluid as a matter of extreme importance in drilling operations.

The successful detection and handling of threatened blowouts (‘kicks’) is a matter of maximum
importance to our company. Considerable study and experience has enabled the industry to
develop simple and easily understood procedures for detecting and controlling threatened
blowouts. It is extremely important that supervisory personnel have a thorough understanding of
these procedures as they apply to Saudi Aramco operated drilling rigs.

The reasons for promoting proper well control and blowout prevention are overwhelming. An
uncontrolled flowing well can cause any or all of the following:

• Personal injury and/or loss of life

• Damage and/or loss of contractor equipment
• Loss of operator investment
• Loss of future production due to formation damage
• Loss of reservoir pressures
• Damage to the environment through pollution
• Adverse publicity
• Negative governmental reaction, especially near populated areas

This manual describes Saudi Aramco’s policies and equipment standards for well control/blowout
prevention. It has been designed to serve as a reference for company and contractor personnel
working in drilling and workover operations.
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Changes in this 3 Edition of the Saudi Aramco Well Control Manual are indicated by a bold
vertical line in the right margin, opposite the revision.

Current Edition: October 2002 2 3rd Edition

Previous Revision: October 1998
WELL CONTROL MANUAL
Drilling & Workover October 2002
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INTRODUCTION AND RESPONSIBILITIES

1.0 Responsibilities of Drilling Staff

The Drilling and Workover Organization includes an office drilling staff comprised of the
Drilling Operations Manager(s), Drilling Engineering Manager, Drilling Superintendent(s),
and Drilling Engineer(s) in addition to the onsite Drilling Foreman. Their responsibilities
include:

1.1 Well Planning

Planning for maximum efficiency and safe operations is primarily the office drilling
staff's responsibility. They must, with concurrence of the Drilling Operations
Manager, use all known information and good judgment to make the best possible
well plan for a particular area.

1.2 Drilling Program

This program should include the casing program, mud program, consideration of
special equipment that will be required and specific well problems that may be
encountered, and any other information pertinent to the safe and efficient drilling of
the particular well. The drilling program is written by the Drilling Engineer (assigned
to the rig) and approved by the Drilling Superintendent and/or Drilling Operations
Manager.

A directional program is also required to avoid existing holes, or when the target
location is different than the surface location, or in case a relief well is needed. The
amount of detail required depends on the depth, pressure, presence of H2S,
crookedness, etc. In high angle holes, singleshot readings should be taken on two
instruments, and an ellipse-of-uncertainty calculated. It is very important, especially
in offshore operations, to know accurately the surface and subsurface locations of
the well. In directionally drilled wells, the well course should be pre-planned, and
horizontal and vertical sections should be maintained continuously during drilling, to
insure that the well course is accurate. Deviations should be corrected early to avoid
excessive doglegs.

Often multi-shot readings are made prior to setting surface casing, so its position is
accurately known. All reasonable effort must be made to know accurately the well
position and course, from the surface to total depth. The degree of effort required
varies with the drilling operation.

1.3 Geological Information

The Drilling Engineer needs all available geological information for the area to
prepare a good drilling program. This requires good communication with the
geologists to explore possible drilling problems, and preparing a method of handling
each.

Current Edition: October 2002 3 3rd Edition

Previous Revision: October 1998
WELL CONTROL MANUAL
Drilling & Workover October 2002
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INTRODUCTION AND RESPONSIBILITIES

1.4 Area Drilling Experience

Each area has characteristic drilling problems that experienced personnel can
handle most efficiently and safely. The Drilling Superintendent and Manager should
be primarily responsible for seeing such assignments are filled with qualified Drilling
Foremen.

1.5 Casing Design and Depths of Setting

Compliance to proper casing design and setting depths, calculated from expected
formation pressures and fracture gradients, is vital, particularly in high-pressure
areas. Isolation of fresh water aquifers must also be considered in the casing
program.

1.6 Equipment Selection

Proper equipment is necessary for an efficient and safe operation. Considerable care
must be exercised in selecting equipment with the pressure rating and design for the
specific job. This should be primarily the Drilling Superintendent’s responsibility, with
concurrence of the Drilling Operations Manager and Drilling Engineering Manager.

1.7 Hiring Contract Rigs

The Drilling Superintendent and Drilling Operations Manager will usually provide the
proper rig for the job. The rig’s experience in the area could be a factor, and rig
evaluations should include past performance and condition of equipment. Where
crews change seasonally, the decision could be based on the general performance
of the contractor.

1.8 Specification of Rig Equipment

Selecting the proper equipment to do a particular job is very important. The Drilling
Superintendent’s closeness to the operation makes him best qualified to recommend
equipment.

1.9 Contract Responsibilities

The Drilling Superintendent and Drilling Operations Manager have the responsibility
to see that the contracts between Saudi Aramco and the drilling contractor are
written clearly, defining the obligations of both contracting parties.

Current Edition: October 2002 4 3rd Edition

Previous Revision: October 1998
WELL CONTROL MANUAL
Drilling & Workover October 2002
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INTRODUCTION AND RESPONSIBILITIES

1.10 Training of Company and Contract Personnel

The Drilling Superintendent and Drilling Operations Manager should maintain a

training program for the less experienced drilling employees. The program should
pair the newer employees with experienced Drilling Foremen at the wellsite, and
include attendance at company-sponsored and external schools/seminars. Drilling
Superintendents should periodically review well control procedures with the Drilling
Foreman. The contractor shall be required to train his men in well control, either by
contract or by direction from the Drilling Superintendent and Foremen.

1.11 BOP Equipment

The Drilling Foreman must ensure that the proper BOP equipment is available and
installed correctly and in good working order. He must also verify that the equipment
is in compliance with all Saudi Aramco requirements and API specifications. ALL
SECTIONS of the BOP Test and Equipment Checklist must be completed upon
initial nipple-up.

1.12 BOP Testing

Saudi Aramco requires that the blowout preventer stack be tested once every two
weeks and before drilling out each new casing string. Accurate and complete testing
of the BOP equipment is the responsibility of the Drilling Foreman on location. The
BOP Test and Equipment Checklist should be completed after each test.

1.13 Well Control

The Drilling Foreman is primarily responsible for keeping the well under control. This
responsibility includes maintaining the proper mud properties, recognizing indicators
of abnormal pressure and executing the proper well control procedures after the well
kicks.

1.14 Pre-recorded Data Sheet

The pre-recorded data sheet should be filled out as completely as possible at all
times on drilling and workover wells. The data sheet lists critical wellbore information,
which will be needed in nearly all well control situations.

1.15 Slow Pump Rate Data

The Drilling Foreman must make sure that slow pump rates and pressures are
recorded:

• Tourly
• After a mud weight change
• After a bit nozzle or BHA change (after breaking circulation gels)
• After each 500 ft depth interval

Current Edition: October 2002 5 3rd Edition

Previous Revision: October 1998
WELL CONTROL MANUAL
Drilling & Workover October 2002
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INTRODUCTION AND RESPONSIBILITIES

• After a drilling/completion, or workover fluid type change

• Whenever mudflow properties change significantly

Slow pump pressure measurements should not be taken at the following times:

• If the mud flow properties are contaminated

• Hydrostatic imbalance exists between drill/work string and annulus
• During times of loss of circulation or washouts in the drill/work string

1.16 Blowout Prevention Training

The finest equipment and the best procedures are of little use unless the rig crews
are properly trained to use them. The Drilling Foreman must see that the crews are
properly trained and respond immediately in all well control situations. The Drilling
Foreman should make sure that the shut-in procedures while tripping and drilling are
clearly posted at several locations around the rig, and that every crewmember knows
his shut-in responsibilities.

1.17 Information to be Posted

The Drilling Foreman should know and post the following information:

• Maximum allowable initial shut -in casing pressure to fracture shoe

• Maximum allowable casing pressure
• Maximum number of stands pulled prior to filling the hole (collars,
HW, and DP)
• Volume required to fill the hole on trips (collars, HW, and DP)
• Crew responsibilities for well control drills

Current Edition: October 2002 6 3rd Edition

Previous Revision: October 1998