Well Control Well Control Handbook Handbook: Drilling - Completion - Workover Drilling - Completion - Workover

Well Control
Handbook
Drilling | Completion |Workover
Version 1.3
Chevron's drilling and completions organization has a vision to
be the Clear Leader in every location that we operate. To
achieve that vision we must be the Clear Leader in well
control. Maintaining well control, managing influxes, and
ensuring that we always keep hydrocarbons where they need
to be ensures that we can continue to operate efficiently and
effectively. Our people are the most important part of our well
control effort. Having qualified well trained people on our
locations is the first and last line of defense against a loss of
well control. Our well control training, well control standard
and Wellsafe all work in concert to ensure that everyone in our
operations has the tools and competency to be successful. This
well control handbook is one of those tools and allows you to
have access to all of the concepts that you have learned in
training at your fingertips when you need them. I recommend
that you spend some time familiarizing yourself
yourself with the
handbook before you need it. Bookmark pages that might be
needed in an emergency and always use it as a reference in
actual well control situations.
Dave Payne
Chevron Well Control Handbook

© 2014 Chevron U.S.A. Inc. All Rights Reserved. Company Confidential.
1 PREPARATION
“Always comply with all applicable rules and

regulations.”
Tenet 7
Version 1.3 Chevron Well Control Handbook 1- 1

© 2014 Chevron U.S.A. Inc. All Rights Reserved. Company Confidential. 1 - Preparation
Introduction
Well Control Goals

Chevron’s recommended well control practices are
based on principles that guarantee containment.
DPP
Chevron operational well control goals, established CP
principally to protect people and the environment are as
follows (listed in decreasing priority):
• Maintain primary hydrostatic control of the well at all

times during well operations.
• Efficiently use secondary well control options

whenever primary control of the well is lost. By
emphasizing the need for the earliest practical
detection of a kick, followed by rapid well shut-in, the
probability of successfully controlling a kick using Drillstring
standard, appropriate procedures is enhanced. Float
• Restore primary control of the well, using acceptable

well control methods, to enhance safety and Kick
operational performance objectives (in that order of Influx
priority). Based on specific local conditions an SBU
level MOC can be put in place to select an
appropriate kill technique such as the Wait & Weight
Method, bullheading, etc.
The procedures and methods detailed in this handbook can be referenced and
used to help implement, maintain, and restore well control for all operations and
rig-work employed by Chevron.
Chevron rig-work and operations include drilling, completions and workovers, and
well intervention work. Rig types used to achieve the objectives of each
operational plan include:
• Land drilling rigs
• Offshore jack-ups and platform rigs (surface BOP)
• Offshore semis and drillships (subsea BOP)
• Pulling units, hydraulic workover rigs, snubbing units, wireline/slick line units
and coiled tubing units
Each application of this equipment requires specific operational plans but all
require sound well control practices and procedures.

Introduction - continued
Drilling Program
• Casing Depths
• MW vs Pore psi
• Bit & Hydraulics
Completion Plan
• Cleanout Run
• Perforating Details
• Frac / Gravel Pac
Common Goal: • Run Completion Assy
Well Control • Well Testing
• ND BOP, NU Tree
Workover Work
• Kill Well
• ND Tree, NU BOP
• Pull Completion Tubing
• Run Workstring
• Conduct WO Work
• ND BOP, NU Tree

D&C GTS Well Control Requirements (excerpts)
6. A Chevro
Chevronn drill/w
drill/well
ellsit
site
e manage
managerr (DSM/W
(DSM/WSM)
SM),, with a vali
valid
d Chevr
Chevron
on Well
Well
Control Certificate, shall supervise the overall well kill operation at the work
site. The Chevron DSM/WSM that oversees the well kill operation should be
the most senior and / or lead DSM/WSM.
7. Bridgi
Bridging
ng docum
document
ent for each
each rig or work
workove
overr unit
unit shall
shall identi
identify
fy the
the prim
primary
ary
choke operator, verify the choke operator’s competency, and explain the
process for confirming choke operator competency.
8. To prepa
prepare
re for
for and resp
respond
ond to pote
potenti
ntial
al well
well contro
controll situati
situations
ons,, specific
specific well
well
control procedures shall be defined and developed for non-routine
operations that require special consideration. Examples include the following:
• Gravel pack screens or perforated liners across the BOP stack and
within the well.
• Tubing with control lines across the BOP stack.
• BOP equipment failure that requires remotely operated vehicle
intervention to operate stack functions and the like.
• Multi-string completions.
9. For rigs
rigs equip
equipped
ped with
with shear
shear rams
rams and blind
blind shea
shearr rams,
rams, the BU
BU shall
shall ensur
ensure
e
that rig teams document well control procedures and operations when non -
shearable tubulars are across the stack. These procedures shall include
specific shearing instructions for any tubular, posting of specific shearing
instructions at the driller’s station, and a shear matrix (tubular shearing table)
that identifies non-shearable tubulars.
10. Well control

control procedu
procedures
res shall be
be defined
defined and develop
developed
ed for special
special
operations, such as the following:
• High-pressure/high-temperature
High-pressure/high-temperature conditions
• Managed pressure drilling
• Dual gradient drilling
• Closed hole circulating drilling
• Mud cap drilling
• Casing drilling
• Horizontal drilling
• Slim hole drilling
• Steam boiling liquid expanding vapor explosion (BLEVE)
considerations
• Air blows
• Air drilling
• Shallow Hazards

Barriers (D&C Global Technical Standard: Well Barrier Design)

In a well design, a barrier is a component or practice that contributes to total
system reliability by preventing formation fluid or gas flow.
The three classifications of barriers are:

1. Hydrostatic
2. Cement
3. Mechanical
Hydrostatic
Hydrostatic Barrier
A hydrostatic barrier is achieved through the effect of hydrostatic pressure
from a column of fluid.
Hydrostatic Barrier Examples:

• Drilling Mud
• Completion Brines
• Sea Water
• Oils
A static test is the primary means of Hydrostatic

Hydrostati c Barrier Verification. It is used
to verify that a fluid column has sufficient hydrostatic pressure to overcome
pore pressure.
Cement Barrier
A column of cement is defined as a barrier after it has reached its planned
minimum compressive strength.
Cement Barrier Verification

• Verification to prevent flow
o Positive pressure test
o Inflow test
• Verification of placement (inside the wellbore or casing annulus) is also

required. Placement of a cement plug may verified by set-down weight for
example.
Mechanical Barrier
A mechanical barrier is achieved through mechanical means. The barrier
elements may contain metal and/or elastomeric rubber or polymer.

Barriers - continued
Mechanical Barrier Examples:
• Blowout preventer (BOP) & production tree, & sub sea test tree (SSTT)
• Bridge plugs, cement retainers, crown plugs, tree caps
• Full opening safety valve (FOSV), top drive FOSV, IBOP
• Permanent packer with plug, storm packer, test packers
• Casing, tubing & liner hangers - with seal
• Back pressure valve (BPV) and two-way check valve
Barrier integrity shall be verified upon installation and at periodic intervals, as

required.
APPLICATION OF THE BARRIER STANDARD

Routine Operations
All Chevron D&C, Intervention, Environmental Management Company (EMC),
and Base Business (BB) case operations shall
sha ll have a minimum of two
independent barriers available within or on a well to prevent uncontrolled flow
from the wellbore.
Long-term Suspension & Abandonment

Two barriers shall be in place (neither of which shall be hydrostatic).
Deepwater Recommendation – One of the two barriers should be a mechanical
barrier with a minimum of 100 ft MD of cement above it.
Non-routine Operations
Operations
During non-routine operations (operations where maintaining 2 barriers is not
possible or practical), proceeding with a single barrier for a finite duration is
permissible if supported by SOP and risk assessment.
If one of the required minimum barriers fails, forward operations

shall be suspended until the minimum number of required barriers
can be re-established.
Prior to commencing operations, a well diagram or table shall be

prepared that defines the barriers to prevent flow along each
potential flow path, for each stage of the well construction process.
 This shall include barriers put
pu t in place for short-term
suspension if the rig is to be moved off location for any reason.
 During operations, if any deviations occur from the original plan
or if the condition of the barrier changes, the well diagram or
table shall be updated to reflect current conditions.

Training & Competency
All rig personnel having well control duties must be competent in

their ability to perform those duties. To ensure competency Chevron
requires:
Well Control Training

All CVX supervisory personnel must maintain a Chevron recognized well control
certification at the level of their job duties.
Well Assessments
All personnel will be regularly assessed to ensure competency is maintained.
Participation in Well Control Drills

Rig personnel must regularly participate in the following Drills:
Drills (D&C GTS: Well Control Requirements) Frequency (per crew)
Hole Monitoring While Drilling, Milling, or Once per week

Circulating
Shut-In Drill Once per week
Well Kill Drill Once per month
Choke Drill Once per month
Diverter Drill Once per month
Stripping Drill Once per quarter
Non-Shearable Drill Prior to event
Drill for Non-Routine Operations Once per operation
Emergency Disconnect Sequence Drill Once per month

Well Control Responsibilities
The following Contractor and Service Company personnel

assignments are for an offshore floating vessel. Similar
assignments and responsibilities should be available and posted
for any rig working for Chevron D&C.
Toolpusher
• Ensures that the crew is organized and prepared for killing the well.
• Liases with the Drill /Well Site Manager (DSM/WSM) throughout the well kill
operation.
• May operate the choke (or his designee).
Driller
• The Driller is responsible for monitoring the well at all times, identifying kick
indicators, and shutting-in the well quickly and safely.
• Once the well is shut-in, calls the Person-in-Charge.
• On floating rigs, calls the Subsea Engineer to the drill floor initially.
• Monitors key parameters (pressures, volumes and time) and designates a
crew member to record same during the kill operation.
• Operates the mud pump during the kill operation.
Assistant Driller / Derrickhand

• Lines up the mud gas separator and vacuum degasser.
• Lines up the mixing pumps and bulk barite system for weighting up the mud
and stands by for specific instructions from TP and Mud Engineer.
• Once pumping starts, keeps constant check on mud weight and pit volumes
and reports these to the Driller.
Floormen
• Follow instructions from Driller
Mud Engineer
• Reports to the pit room to check the AD/ Derrickhand’s preparations and co-
ordinates the building and maintenance of the required mud system.
• Checks and confirms all volumes of mud and chemicals on board. Monitors
mud properties and return flow for any abnormalities.
• Checks and confirms calibration of mud balance.
Barge Supervisor / Captain

• Ensures that the bulk system is charged and ready for use.
Version 1.3 Chevron Well Control Handbook 1 - 10

Well Control Responsibilities - continued

• Stands-by in the control room or bridge in preparation for responding to an
emergency situation.
• Notifies the standby vessel (if available) to move into evacuation position.
• Ensures readiness of the evacuation equipment.
Crane Operator
• Ensures that doors and hatches are closed, where necessary.
• Assists mud mixing operations.
• Supervises Roustabouts
• Report to mud pits / sack room to assist the AD and Derrickhand.
Subsea Engineer
• Reports initially to the drill floor to check functions and operating pressures on
the BOP control panel. He/she must be present at the control panel in case of
equipment problems.
Mud Logging Engineers

• Report to the mud logging unit and continuously monitor the circulating and
drilling systems.
• Review all data and report any abnormalities to the DSM/WSM, Driller, and
Senior Toolpusher.
Cementer
• Ensures that the cement unit is tested and ready for operation.
• Ensures slurry formulation and additives are ready in case a cement plug is
required.
• Operates the cement unit, if required, under the instruction of the Senior
Toolpusher.
Electrician / Mechanic
• Standby for possible instructions.
Control Room Operator

• Ensures that rig stability is maintained and monitors safety systems (Gas
Alarms, etc.) during well control operations.
Radio Operator
• Logs all calls, telexes and faxes and keeps the lines open for the DSM/WSM,
OIM and any other personnel authorized by the OIM to use the
communications system.
• Assists the OIM and DSM/WSM in all matters of communication.

Basic Concepts: Wellbore Pressures

Hydrostatic Pressure
   = 0.052 ×  × 
To calculate the total vertical depth (TVD):
MW
10.8 ppg  =   ( −  ) × cos()
4000’
 = 4000  (10000 − 4000) × cos(40°)
 = 4000  4596 = 8596′
 = 0.052 × 10.8 × 8596 = 4828 
6000’
4596 ‘
4828 psi
Displacement
TVD=8,596’ TMD=10,000’
500 psi
 
    =    
Gas  =           
400’
2 ppg
 = 500  0.052 × 2 × 400  0.052 × 10.8 × (8596 − 400)
 ≅ 500  42  4603 = 5145 
MW
6000’ 10.8 ppg 5145 psi
TMD=10,000’
TVD=8596’

3 KICK INDICATORS
“Always maintain the integrity

of dedicated systems.”
Tenet 6

© 2014 Chevron U.S.A. Inc. All Rights Reserved. Company Confidential. 3 - Kick Indicators
Positive Indicators (Drilling)
DRILLER IS EMPOWERED TO
IMMEDIATELY SHUT THE WELL IN!
Flow With Pumps Off

Since a well is more likely to flow with the pumps off due to the loss of ECD,
stopping the pumps and checking for flow allows for detecting possible
underbalance while drilling.
Flow-Check Procedure
While Drilling:
1. Pick up off bottom
2. Shut the pump(s) off
3. Check for flow for a minimum of 15 minutes (do not break joint if on a
connection)
Chevron requires the Driller to shut-in immediately if there is

flow with pumps off.
Increase in Flow-Out
w/No Change in Flow-In
If the flow show device indicates an increase in flow returns. The Driller should
immediately shut in the well.
Increase in Pit Volume

If the pit volume totalizer (PVT) shows an increase in pit level . The Driller
should immediately shut in the well.

Positive Indicators (Tripping)
DRILLER IS EMPOWERED TO IMMEDIATELY

SHUT THE WELL IN!
Flow w/Pipe Static

Anytime flow is detected with the pipe static, the Driller is to immediately
shut- in the well.
Flow Checks While Tripping:

• Establish well is static prior POOH ( use trip sheets).
• Flow check prior to pulling BHA into the BOP stack.
Trip Log Deviation
A trip tank system providing continuous hole fill-up should be used when
tripping both in and out of the hole. A trip tank, allows comparison of fluid
volumes pumped into or returned from a well with the steel volumes pulled
out or run in. Using incremental and cumulative figures, if less fluid volume
than calculated is needed to fill the hole while tripping out, or more fluid is
displaced out of the hole than calculated while tripping in, a flow check should
be performed.
If the flow check is positive, the well should be immediately shut in. If the flow
check is negative, trip to bottom carefully, circulate bottoms up, and condition
the mud.
Note:
When pulling a wet drill string (from a closed drill pipe float or plugged pipe
for whatever reason), internal string volume lost must be considered in
calculations unless it is recaptured into a measured mud tank.

Flow Check Opportunities
Drilling
• After any drilling break
• Prior to making any connection during
drilling
• Before and after running a survey
• Prior to slip and cut operations
Tripping
• Anytime pipe displacement or hole-fill is
incorrect during a trip
• Prior to pulling or running non-shearables
through the BOP
Subsea
• Anytime a trip is suspended in order to
boost the riser
• Prior to recommencing a trip after boosting
the riser
During wireline operations

While testing the BOPs
After any well control operation
After unseating a packer
After cutting a casing string
Any time Driller is in doubt as to the
occurrence of a kick

Possible Kick Indicators
Real Time Warning Signs that Require Investigation

by Crew Members but Do Not Require Immediate
Well Shut-in.
Reduction in Pump Pressure or Increase

In Stroke Rate
A loss of pump pressure and a corresponding increase in the pump rate may
occur due to the differential pressure between the drill string and annulus
when an influx is in the well. A washout in the drill string can have the same
indicators, but the Driller should always react as if a kick is occurring and
conduct a flow check to verify the well is static.
Drilling Breaks
A sudden change in ROP is known as a drilling break . This may be either an
increase or a decrease in penetration rate and can reflect a sudden change in
down-hole conditions. This sudden change could coincide with changes in
formation type, permeability, fluid content, or pressure.
If the bit penetrates a formation that is underbalanced due to insufficient

mud hydrostatic pressure, penetration rate may increase dramatically.
LWD Resistivity Decrease
LWD (Logging While Drilling) conducts a real time electric-log of formation

resistivity while drilling. The under-compacted shale in an abnormally pressured
zone will have more natural “sea water” in the pore spaces. As a result the
resistivity value decreases and the shale becomes more “conductive”.

Possible Kick Indicators - continued
Increase in Torque & Drag

Increased drag and / or torque are often noted when drilling into over-pressured
formations. This is due to the inability of the under-balancing mud column to hold
back physical encroachment of the formation into the wellbore.
Drag and rotating torque are indirect indicators of overpressure. Increases often
may indicate that a transition zone is being drilled. Up drag an d down drag, as well
as off bottom & while drilling torque values, should be recorded at pre-
determined intervals (often at each pipe connection) and plotted. Plots should be
reviewed for changes in trends that may indicate an impending problem.
Bottoms Up Warning Signs of Increasing Formation

Pressure that Require Investigation by Crew Members
but Do Not Require Immediate Well Shut-in.
Changes in Mud Properties & Increase in

Flow-line Temperature
A change in fluid properties after bottoms-up circulation clearly indicates that
formation fluid has entered the wellbore. Mud chlorides may increase due to an
increase of pore volume when drilling “ under-compacted” shale. Usually the pore
space contains native waters which may add chlorides to the mud sy stem.
In some muds, the viscosity will increase when salt water enters the wellbore and
mixes with the mud. This is called flocculation because the small particles of mud
solids, which are normally dispersed, form small clumps called flocs.
In oil-based muds, water contamination acts as a “solid” and causes viscosity

increases.
Abnormally pressured shale is usually beneath an impermeable formation which

serves an insulating barrier. This causes the pressured shale to be at a hig her
temperature than that of a normally pressured zone and is usually indicated by an
increase in flow-line temperature of the returning mud.

© 2014 Chevron U.S.A. Inc. All Rights Reserved. Company Confidential. 5 – BOP Equipment
Choke Manifold Valve Positions
For Hard Shut-in While Drilling and Tripping

A numbering scheme for all valves and chokes should be
put into place to eliminate confusion when lining up any
manifold for drilling and tripping operations. In addition to
the numbering scheme, a recommended choke manifold
specific diagram showing valve / choke lineup
requirements (normally open (NO), and normally closed
(NC) for hard shut while drilling or tripping. It is
recommended this diagram be posted on the choke
manifold and in the dog house for quick reference by the
rig crews.
Example Manifold & Proper Valve Positions

HC1(NC) 13(NC)
15(NO)
HC2(NC) 12(NO)
5(NC)
To
HCR MGS
4(NC) 8(NO)
6(NO)
9(NC)
1(NC) 1(NO) 3(NC)
7(NC)
2(NC)
MC2(NC) 11(NC)
MC1(NC) 10(NC) 14(NC)
Primary Flow Path

© 2014 Chevron U.S.A. Inc. All Rights Reserved. Company Confidential. 5 – BOP Equipment
Detection Equipment
Pit Volume Totalizer (PVT)

Pit volume measuring systems, complete with audible and visual alarms, should be
installed to detect fluid gains and/or losses. These devices transmit a signal from
sensors located in the drilling fluid pits to instrumentation near the Driller’s station
on the rig floor.
Flow Rate Sensor

A flow rate sensor, complete with audible and visual alarms, should be mounted in
the flow line to provide for early detection of formation fluid entering the well or of
loss of returns
Sample Flow Rate and PVT Indicators Display

6 KICK TOLERANCE
“Always operate within design and

environmental limits.”
Tenet 1

© 2014 Chevron U.S.A. Inc. All Rights Reserved. Company Confidential. 6 - Kick Tolerance
Maximum Anticipated Surface Pressure (MASP)
Used to design the well program:

• Casing design (casing burst/collapse)
• BOP pressure requirements
• Wellhead pressure requirements
Assumptions (typically specific to well, SBU, or field):

• Partial/total evacuation of well “worst case”
• Known pore pressure profile
• Known fracture gradient
Example: Total Evacuation
 =   −   

 = 0.052 × 14.5 × 12400 − 0.1 × 12400 (   )
 = 9350 − 1240 = 8110 
8110 MASP
Gas Gradient = 0.1 psi/ft
Gas Sand @ 12400’ TVD

Pore Pressure = 14.5 ppge = 9350 psi

Operational KT - continued
5. Using the same KHmax calculate kick volume with the top of the gas at the
casing shoe (KVshoe). (Note: Skip this step for Oil or Saltwater Influx)
 =  ×  = 687 × 0.046 = 31.6 
6. Calculate the KVdynamic by using P1V1=P2V2 to convert KVshoe to conditions on
bottom (KVdynamic). (Skip for Oil or Saltwater Influx).
 × 
 =
 + 
0.052 ×  × ℎ ×  3232 × 31.6
 = = = 15.4 
 + 0.052 ×  ×  0 + 6625
7. Compare both KV static and KVdynamic . Use the lesser volume as KV in KT window
(for KI=0). Plot only the KV static value for Oil or Saltwater Influx.
8. Identify KT window for the well.
 = 0.77 
 = 15.4 
 = 20.5 
KT Window for Example Well – Chart Made Using

The Chevron Rig Site Well Control app.
The KT window can be constructed (sufficiently accurate) by drawing a straight

line from KImax and KV (dynamic and static). The Chevron Rig Site Well Control
app calculates the KV for varying KIs from zero KI to KI max.

Design Kick Tolerance
Design KT can be used to check that a planned

hole section TD can be reached with a specified
KT target.
Example:
Plan is to drill 8 ½” hole to 9800’ TVD/MD
with a planned MW of 13.0 ppg at TD. The 9 5/8”,47#
well plan calls for setting 9 ⅝ 47# casing @ 4200 TVD
at 4200 ft TVD/MD. Anticipated shoe LOT
8 ½”X 5” DP
is 14.8 ppge.
ACF- 0.0459 bbl/ft
Management has indicated TD should be

reached with the following KT parameters:
Drill 8 ½” Hole
KV = 5 bbl and KI = 0.5 ppg. to 9800’ TVD
Does the well plan meet management
objectives?
1. Use the formula below to calculate the maximum TVD for a planned hole
section that can be drilled with a given KI and KV target.
 =

 ×  ×  −  × 
=
 +  ×  −  ×  +  ×  ×  × 
0.0459 × 14.8 × 14.8 − 13.0 × 4200

 =
13.0 + 0.5 × 13.0 − 1.98 × 5 + 0.5 × 0.0459 × 14.8 × 4200
 = 9,938 
2. Use the formula below to calculate the Kick Tolerance (KV) for a given KI. (For
Example: What is the KV for a 0.5 ppg KI at planned TD?)
 ×  ×  ×  −  ×  −  × 

 =
 +  ×  −  × 
0.0459 × 14.8 × 4200 × 14.8 − 13.0 × 4200 − 0.5 × 9800

 = = 5.2 
13.0 + 0.5 × 13.0 − 1.98 × 9800

Design Kick Tolerance - continued
3. Use the formula below to calculate the minimum LOT required to meet the TD
objective and have a KT of KI=0.5 ppg and KV=5 bbl.
Where:

 =  ×  = 0.0459 × 4200 = 809676.00

 =  ×  ×  +  ×  ×  × 
b = 0.0459 × 4200 × 13.0 + 0.0459 × 4200 × 9800 × 0.5 = 11470410.00
 =  ×  +  ×  −  × 
c = 5 × 13.0 + 0.5 × 13.0 − 1.98 × 9800 = 7289730.00
 +  + 4 ×  × 
 =
2×
11470410 + 11470410 + 4 × 809676 × 7289730
= = 14.77 
2 × 809676
4. Use the formula below to calculate the maximum MW (pore pressure) required
to drill to TD objective and have a KT specified as KI=0.5 ppg and KV=5.0 bbl.
Where:
 ×  × ( −  ) +  ×  ×  

=
 × 
 ×  ×  ×  ×  −  ×  −  ∗   ×  
=
 × 
9800 × 5.0 × 0.5 − 2.0 + 14.8 × 0.046 × 4200
= = 243.59
9800 × 5.0
9800 × 0.5 × 14.8 × 4200 × 0.046 − 2.0 × 5.0 − 0.046 × 14.8  × 4200
= = 3342.37
9800 × 5.0
  
  = − + +
2 2

243.59 243.59
  = − + + 3342.37 = 13.02 
2 2

7 PROCEDURES
“Always involve the right people in decisions

that affect procedures and equipment.”
Tenet 10

© 2014 Chevron U.S.A. Inc. All Rights Reserved. Company Confidential. 7 - Well Control Procedures
Trapped Pressure Check
Identify After Initial Shut-in
Pressure can be trapped in the well by:

• Shutting in with pumps still running and
poor choke manipulation.
• Attempting to bump the float.
• Migrating gas after initial shut-in.
Consequences of trapped pressure include:

• Improper shut-in pressure recordings.
• Formation breakdown and / or pipe light
conditions.
How to Remove
Bleed very small increments of mud (coffee
cups) from the choke and verify that
pressure has reduced and stabilized.
SIDPP
SICP
Check After Kill To

Confirm Well
Well is Dead
D ead
After the first circulation of the Driller’s

method, the shut in casing pressure and
shut in drill pipe pressure should both be
equal to the initial SIDPP (plus any trapped
pressure). If both are equal but higher than
the SIDPP value then a Trapped Pressure
Check should be conducted. This should
also be done after circulating kill mud
weight around to confirm well is dead.
Always be aware that excessive bleeding

may allow additional influx.

Bump The Float (BTF)
DPP
Procedure CP
1. If not
not pre
previ
viou
ousl
sly
y don
done,
e, mark
mark the
the SICP
SICP
value on the choke panel gauge to
represent the initial stabilized SICP value.
2. Line
Line up to pump
pump OM
OMW
W int
into
o the
the dril
drilll
string.
3. Pump
Pump as slow
slowly
ly as pos
possi
sibl
ble
e int
into
o the
the dril
drilll
string with well and choke closed. (Use
cement pump if available at ¼ bbl per
min.)
Drill string
4. The
The dri
drill
ll pipe
pipe pres
pressu
sure
re will
will incr
increa
ease
se Float
continuously pressuring the string up to
open the float. Watch closely for an
increase in casing pressure as mud in the Kick
Influx
annulus becomes pressured (after the
float has opened).
5. When
When the casi
casing
ng pres
pressu
sure
re incr
increa
ease
se is
noted, stop the pump and record the
new CP and the “trapped” pressure
increase.
6. Read
Read the
the dri
drill
ll pipe
pipe pres
pressu
sure
re and
and sub
subtr
tract
act the
the
trapped pressure slowly from the casing gauge. Record the value
as the SIDPP. Tapped pressure or SF
 =   − (   −  )
7. Bleed
Bleed trap
trapped
ped pressu
pressure
re from
from casing
casing pres
pressur
sure
e if desire
desired.
d.
Consider leaving some residual “trapped” pressure to use as the Safety

Factor for the well kill.
At times, people confuse the increase in casing pressure due to pumping

with gas migrating in the well. Usually gas migration is not an issue since
bumping the float should only take a short amount of time.

Bring Pump Up To Speed (BPUTS) for Surface BOP
900
ICP
800
500
Example:
SICP
SIDPP from BTF = 250 psi
400 Original SICP = 400 psi
Desired Kill Rate = 30 spm
Drill Pipe Casing
30 DPP Value = 900 psi
Safety Margin 100 psi
SPM Choke Position
0024
Pump % Open % Closed
Strokes
Open Close
1. As the pump comes on line the Choke Operator should crack open the choke
as needed to maintain casing pressure at the Original SICP value (plus any
desired Safety Margin). Choke Operator should provide constant feedback to
the Driller as to the progress.
2. Use choke to control CP constant until DP pressure has stabilized @ the kill
pump rate. Read and record this drill pipe pressure as the BPUTS Value.
3. Determine the Initial Circulating Pressure (ICP) and mark this on the Choke
Panel Gauge for reference.
 =    −   

 = 900 − 100 = 800 
 =  − 
 = 800 − 250 = 550 
Note: Bring Pump To Off (BPTO) is done to shut down the mud pump (at any
time) during well control operations. BPTO is done the same way as BPUTS,
but pump rate is slowly reduced to zero while casing pressure held constant.

Establishing Correct ICP
The choke panel

gauge readings for
SICP
400 a shut –in well are
Drill Pipe Casing
shown here. (Float
0
not yet bumped,
SPM and SICP = 400 psi)
Choke Position
00000
Strokes
Open Close
The float is bumped and the SIDPP obtained. Pumps are started and
brought up to the desired rate while choke pressure is held constant.
After which, the resulting pressures are shown below :
(DP pressure = 900 psi and Casing pressure = 500 psi).
What is the correct ICP?
The casing pressure

is 100 psi above ICP
the original shut in 800 900
value of 400 psi.

This means the 500
SICP
well is 100 psi
400
overbalanced. The
Drill Pipe Casing
correct DP pressure 30
needed to balance SPM
Choke Position
the formation
00046
pressure (the ICP)
is 800 psi and Strokes
marked on the Open Close
gauge as such.

Use CP To Guide Adjustments To The DP Pressure
3rd Then Wait and Check for

Desired ICP = 800
900
500
Open Choke to Drop

1st 2 nd
Choke Pressure to 400
Note DP pressure is
Drill Pipe Casing
100 psi too high. 30
SPM Choke Position

0038
Strokes
Open Close
Use the surface casing pressure to help manage DP

pressure when making adjustments with the choke.
For example: If drill pipe pressure (as noted above) is

100 psi too high, open the choke and allow the casing
pressure to reduce by 100 psi. Then wait for the DP
gauge to reflect the change after the lag time
(approximate 2 second per 1000 ft of well measured
depth). Do the opposite if the DP pressure is too low.
Learning how to “drive” the choke controls helps

prevent the “windshield wiper” effect on the DP
pressure gauge.

Bullheading (BH): General Procedure
Procedure & Considerations
1. Calculate the required density and volume to bullhead. For

density use TVD of top perfs; for volume use TVD of bottom perfs.
2. Calculate the surface pressure limitations and create a schedule of
surface pressure limitations vs. volume bullheaded (pumped).
3. Pressure test all equipment.
4. Bring the pumps up to speed to overcome the well pressure and
establish injectivity. Pump the kill fluid down either the annulus
and / or tubing / drill string. Monitor pump pressure and volume
pumped during the operation. (If gas is already present at the
surface, the Lube and Bleed Technique can be used to eliminate
the gas or to lower surface pressure before starting the
bullheading operation).
5. Regulate pump speed so that the surface pressure limits are not
exceeded. For BH to be successful, pump fast enough to exceed
the rate at which gas may be migrating. As the produced fluids are
forced back into the formation, the added hydrostatic pressure
should lower the surface pressure.
6. When sufficient volume has been pumped, stop the pump (unless
an over-displacement was approved), shut in the well, and
monitor the shut-in pressure. Determine if well is still under-
balanced or if trapped pressure exists. If pressure is observed,
then the gas may have migrated up-hole faster than the fluid was
being pumped down hole, or the fluid density in the hole is not
sufficient to kill the well.

Bullheading (WO/CO)
Static Shut In
Tubing Pressure
Workover (WO) Procedure : Example 2500 psi
WH rated
Calculations:
WP limit = 4000 psi
1. Average Weight of Fluid in Tubing (W TF)
  −  3 1/2” N80
  = 9.3# Tubing
0.052 ×  
0.0087 bbl/ft
0.45 × 9800 − 2500 Burst = 8640 psi
 = = 3.75 
0.052 × 9800
2. Kill Fluid Weight (KFW) 9 5/8” N80
 47# Casing
 =   + 0.0732 bbl/ft
0.052 ×   Burst = 6870 psi
2500
 = 3.75 + = 8.7 
0.052 × 9800
Packer - 9300 ft
EOT - 9500 ft
(Continued on next page) Top Perfs
9,800 ft
Bottom Perfs
10,000 ft
Formation
Pressure Grad = 0.450 psi/ft
Frac Grad = 0.650 psi/ft
The controlling formula for calculating maximum bullheading

pumping pressure vs. the volume bullheaded is shown below:
0 psi
 :
 =   +  − 
0 psi
   
 =  −  + 
Note: For critical situations, the friction pressure can be calculated
and added to MSP limits. See Appendix for applicable formula.

Bullheading (WO/CO) - continued
3. Bullhead Volumes to EOT, to Top Perfs, and to Bottom Perfs (measured depths).
(Capacity factor of tubing = CF Tubing )
  =  × 
   = 0.0087 × 9500 = 83 
   =    +   × (   −  )
   = 83 + 0.0732 × 9800 − 9500 = 83 + 22 = 105 
    =    +   × (  −   )
    = 83 + 0.0732 × 10000 − 9500 = 83 + 37 = 120 
4. Determine Maximum Surface Pressure (MSP) limits: Initial, KFW @ EOT, KFW @
Top Perfs, and KFW @ Bottom Perfs.
 =  −  @  
 = 0.65 × 9800 − 0.052 × 3.75 × 9800 = 4460 
@ =  − @ −  
@ =
= 0.65 × 9800 − 0.052 × 8.7 × 9500 − 0.052 × 3.75 × 9800 − 9500
= 2014 
@ =  − @  
@ = 0.65 × 9800 − 0.052 × 8.7 × 9800 = 1936 
@  =  − @  
@  = 0.65 × 10000 − 0.52 × 8.7 × 10000 = 1976 psi
5. Create pump pressure vs. volume pumped schedule.
Surface to EOT:
 − @
∆    = ×  
 
4460 − 2014
∆  5   = × 5 = 147.3 ≅ 150   5 
83
EOT to Top Perf:

@ − @  
∆    = ×  
    
2014 − 1936
∆  5  = × 5 ≅ 18   5 
0.0732 × (9800 − 9500)

© 2014 Chevron U.S.A. Inc. All Rights Reserved. Company Confidential. 8 - Complications
Pump Failure & Changing Pumps
ICP
800 900
500
SICP
400
Drill Pipe Casing

30
SPM
Choke Position
0038

Strokes
Open Close
Indicators of a failing mud pump are rotary hose

oscillations and erratic and dropping standpipe pressure.
During choke work, the indication would be a rapid drop

in both the drill pipe and casing pressure gauges.
Immediately stop the pump (holding CP constant if

possible) and shut-in the well. Switch over to the
auxiliary pump or cement unit and BPUTS holding casing
pressure (or KLP if subsea) constant.

Plugged Nozzle(s)
New ICP = 900 psi

ICP
800
500
Drill Pipe Casing

30
SPM
Choke Position
0248

Strokes
Open Close
A sudden increase in drill pipe pressure with little to no choke

pressure change is the primary indicator of a plugged bit
nozzle. The temptation is to open the choke to reduce the DP
pressure but this would probably allow additional influx. The
best procedure is to stop the pump, shut-in the well, re-
establish correct shut-in pressures, and then BPUTS holding
casing pressure constant (or KLP when using Subsea BOP) and
obtain a “new” ICP. Pump rate may need to be reduced
depending on degree of plugging.
An alert choke operator may accomplish the same thing by

holding the choke pressure constant momentarily until the
standpipe pressure stabilizes at a new and higher value (may
want to reduce circulating rate). This new higher value is the
correct ICP and the remaining circulating pressure schedule
should be adjusted accordingly.

Choke Washout
ICP
1
Decreasing Choke Pressure
2
DrillDrop
Lagging Pipe in Drill Pipe Pressure Casing
30
SPM
Choke Position
0038

Strokes
Open Close
A choke is unlikely to suddenly “cut out”. So, there is usually not a dramatic
indication that this problem is occurring. Abrasive sands and high pressure gas
exiting the choke can wear the tungsten parts inside and the resulting wear acts
the same as if the choke operator was opening the choke.
This pressure drop is relatively slow and

worsens with time. The person operating
the choke can mistakenly continue to close
Abrasive the choke to compensate for the loss of drill
Influx pipe pressure.
Exiting Choke
If this continues, it may become impossible

to maintain a suitable circulating pressure
even with the choke indicated to be fully
closed.
Whenever detected, the well should be shut

in and the back-up choke put into use (check
CP value for gauge consistency when
BPUTS).

© 2014 Chevron U.S.A. Inc. All Rights Reserved. Company Confidential. 9 - Subsea
Well Shut-In
Shut annular,
While Drilling 1st PU, and tag TJ.
1. Stop rotation
2. Space out: Pick up string to shut-in

position Choke
Kill Line
UA
3. Stop the pumps Line
4. Shut-in the Annular BOP and open
the choke line valves on BOP stack LA
1. Notify Toolpusher and OIM 2nd Close hang-off

SR ram and hang off DS.
(OIM to notify DSM)
2. Monitor the riser for flow CSR

and be prepared to divert if
necessary (riser flow may be UPR
either gas in the riser or a
leaking annular) MPR
5. Record and monitor the shut-in drill LPR

pipe and choke pressure (note
density of fluid in choke and kill
lines). Record the gain in pit volume
and time of day.
6. Confirm the space-out and close the designated hang-off rams with
reduced closing pressure. Reduce the annular pressure as per
manufacturer’s guidelines, slack off and land drill string on the rams using
the drill string compensator (DSC).
7. Increase the manifold pressure back to 1500 psi. Engage ram locks.
8. Bleed off pressure between pipe rams and annular (if possible) and open
annular.
9. Adjust the DSC to support the drill string weight to the BOP plus 20,000
lbs. Position the DSC at mid-stroke.

Bump The Float (BTF)
Prior to any well circulation, consider flushing the C&K Lines to

break gels and reduce CL/KL friction pressures.
1. If not previously done, mark the SICP SIDPP

value on the choke panel gauge to
represent the initial SICP value. SICP CP
KLP
2. Line up to pump active mud into drill
string.
3. Pump as slow as possible into string

w/well and choke closed. (Use cement
pump if available at ¼ bbl per min.)
4. The drill pipe pressure will be increasing

continuously pressuring the string up to
open float. Watch closely for an increase
in casing pressure as mud in the annulus
becomes pressured.
Kick
5. When the casing pressure increase is Influx
noted, stop the pump and record the
new CP and the pressure increase.
6. Read the drill pipe pressure and subtract
the casing pressure increase to BTF and
record this value as the correct SIDPP.
 =  − ( −  )
7. Bleed trapped pressure off casing

pressure if necessary.
Consider leaving some residual “trapped” casing pressure as the Safety

Factor to be used for the well kill.
At times, people confuse the increase due to pumping with gas migrating
in the well. Usually gas migration is not at a rate to become an issue with
the procedure as it should only take a few minutes.

Measuring CLF & KLF Values
Procedure: Open Hole Method

KLFP/CLFP
1. Manifold rig pumps to allow circulation
down the choke line and into the
wellbore.
2. Pump down the CL at predetermined
reduced circulating rate(s) while taking
returns through the riser. Record the
CL/KL pressure noted for each pump
rate.
It is important to keep choke and kill lines
free from gelled or settled mud solids. To do
so, flush these lines once a tour. The CL/KL
friction pressure values may be efficiently
recorded at this time. CLFP & KLFP should
also be taken whenever mud properties
change.
Deep Water Example: Cased Hole Method Actual CLFP & KLFP Values
Date: 1/7/99 3” ID Choke and Kill Lines

Depth: 9,441 ft Water Depth: 5,491 ft MW: 10.5 ppg
Pump Output: 0.1394 bbl/stk Viscosity: 45 sec/qt YP: 20 (15@120⁰
1) Pressure thru bit and up 2) Pressure thru bit and up CL

riser (closed annular)
Kill Monitor
7 spm 60 psi 7 spm 170 psi 70 psi
3) Without shutting down, 4) Calculate the CLFPs

open KL and record
pressures Up Choke Line Down CL Both C & K
(measured)
20 spm 240 psi 20 spm 180 psi 160 psi 120 psi

Bring Pump Up To Speed (Using KLP)

Prior to any well circulation, consider flushing the C&K Lines to
break gels and reduce CL/KL friction pressures.
ICP 900
800
500
SICP
400
380
Drill Pipe Casing
30 KLP
SIKLP
SPM 400
Choke Position
0024
Strokes
Open Close
Example:
SIDPP from BTF = 250 psi SICP = 400 psi
SIKLP=400 psi Desired Kill Rate = 30 spm
BPUTS DPP Value = 900 psi CLFP =120 psi
Safety Margin 100 psi
1. As the pump comes on line the Choke Operator should crack open the choke
as needed to maintain KLP constant at the SIKLP value (plus any desired Safety
Margin). If the CLFP is greater than the SICP, the CLFP cannot be totally
compensated for and will show on the KLP monitor and DP gauge. If
uncompensated CLFP is excessive, the kill rate should be reduced. Choke
Operator should provide constant feedback to the Driller as to the progress.
2. Use choke to control KLP constant until DP pressure has stabilized @ the kill
pump rate. Read and record this drill pipe pressure as the BPUTS Value.
3. Determine the Initial Circulating Pressure (ICP) and mark this on the Choke
Panel Gauge for reference.
 =    −   

SM=KLP-SIKLP
 = 900 − 100 = 800 
 =  − 
 = 800 − 250 = 550 

Wait & Weight Method Pressure Profiles (SS)
W & W Method
Gas @ Surface
PcMax →
DP psi
e Casing psi
r
KL psi
u
s
ICP
s Shoe psi
e
r
P FCP
SICP X
SIDPP X
To Bit To Shoe BOPS Bottoms Up Total Circ
Pump Strokes
Advantages of the Driller’s Method Advantages of

of the
the W &W Method
• Circulation can be started right • Pressures exerted in the wellbore

away if necessary will generally be lower than if the
• Allows removing the influx from Driller’s Method was used. This
the well even if weighting difference is most significant if the
materials or means of increasing influx is gas, and for large kicks.
the mud weight are insufficient • The maximum pressure exerted on
• Minimizes the effect/chance for the shoe (or weak point in the open
gas migration hole) will normally be lower thus
• First circulation simple to reducing the risk of losses.
execute without calculations (Assuming:
Voldrillstring<AnnularVol beneath shoe)
• The well and well control
equipment will be under pressure
for less time.

Gas Entering the Choke Line
DP DP
CP CP
KLP KLP
Kill L gas
Line Choke
Line
Gas Just Gas Entering

Reaching SS BOP The Choke Line
KLP + HP KL to TVD = BHP = CP + HP CL to TVD + ∆P CLFP
When a gas influx begins entering the reduced ID of the CL , the result is an
increased rate of loss of hydrostatic from the choke gauge side of the
annulus and some of the original CLFP, thus an increase in CL pressure gauge.
The KLP monitor gauge is experiencing an increase in the HP on the KLP

gauge side of the annulus and begins to decrease slightly. Choke operator
may need to adjust (close) the choke slightly to increase the KLP to maintain
the ICP and BHP constant.
This is an early indicator that soon the gas will be at the choke and the choke
operator should be vigilant and prepared to “stop the drop” by proper choke
manipulation.

“Stopping the Drop” as Gas Reaches Surface
DP psi
2nd CP
KLP
Monitor DP and 1st
KLP. After the
appropriate lag, Steadily close
pressures should choke to stabilize
quickly stabilize the KLP.
and the choke
adjusted to set
proper DP
pressure.
Gas @ Surface
Opposite
technique helps and
when mud hits Exiting the
the choke after Choke
the gas exits.
The maximum casing pressure (Pcmax) on the casing gauge occurs when the gas
influx arrives at the surface choke. Thereafter, the casing pressure will begin to
drop as gas exits the system. The choke should be used at this point to control
the rate at which the casing pressure is decreasing. A gentle rate of pressure
decrease is preferred to a rapid one.
As a result of their different properties, the size of the choke opening that will
maintain the required backpressure on the well is different for liquid (mud, brine,
etc.) and gas. Consequently, the choke needs to be manipulated to increase or
decrease the size of the choke opening whenever there is a change in fluid type
going through the choke. Failure to do this in a timely manner may result in going
underbalanced or fracturing the weak point in the well.
What to do
When you observe the casing pressure and the kill line pressure decreasing
rapidly (not due to choke manipulation), steadily close the choke until you
stabilize the kill line pressure. If you over-correct, the kill line pressure will
increase rapidly requiring that the choke be opened to stabilize it. Confirm that
the KLP gauge has stabilized for 5 seconds or so, before checking the DPP gauge
to figure out your overbalance/underbalance condition and then adjust choke
accordingly.

Stack Gas Clearing

OMW Base Oil (BO)
KMW Gas KMW to surface, riser filled
w/KMW and well dead. Possible
gas beneath any closed BOP.
Kill Choke 1. Isolate wellbore by closing the lower pipe

Line UA Line rams. Line up and circulate BO down KL
and up upper most CL outlet while
holding “backpressure” on BOP cavity.
LA
2. After BO returns are verified, shut down
pump while holding CLP constant and
SR
close choke to trap pressure on the BOP
cavity.
CSR
3. After conditions are static, open choke
UPR and bleed off backpressure and allow
residual gas to expand and enter CL. (If
LPR available, monitor BOP HPHT gauge below
lower most closed rams for leakage).
4. Circulate an additional total circulation of

BO across BOP. Vary rates to “flush” as
much as possible any remaining gas.
5. Line up and circulate KMW across BOP

cavity and flush and fill all KL and CL
outlets w/KMW.
Kill Choke
Line UA Line 6. Open the isolating lower BOP and check
well is dead.
7. Open BOPs and circulate BU from BOP

LA while monitoring riser.
SR 8. Circulate and condition mud.
Note:
CSR
The negative pressure differential must not
UPR exceed the rating of the WH, BOP, choke,
and KL seals and gaskets.
LPR
This is a generic and simplified description of
a complex procedure. Each SUBSEA Rig
should have a Standardized Procedure in
place for safely removing residual “stack
gas”.

Gas in Riser and Unloading
RKB Late Detection

In severe instances, gas in the riser can
cause riser collapse and / or serious
“unloading” events. Every effort should
ℎ = ℎℎ   be made to prevent these occurrences.
Some causes of this “late detection”
include:
• Influx occurs on connection due to

ℎ = ℎℎ   loss of ECD (and not detected)
• Gas in solution and bubble point
depth in riser section
• Failure to remove gas trapped
beneath BOP after kick
Example:
Riser length (TVD)=5000’
Riser ACF (19 x 5”)=0.326 bbl/ft
BOP ACF (18¾ x 5”)=0.317 bbl/ft
What is the “Unload Capacity (UC)” if gas from an 8 ft

cavity beneath the closed BOP enters the riser and
circulated to the surface?
Unload Condition
When height of gas is equal to the height of mud column above it.
ℎ = ℎ 
Unload Capacity (UC) in bbl of drilling fluid:
ℎ
 
 = 2 ×  × × ℎ ×  − ℎ

0.317
 = 2 × 0.326 × × 8 × 5000 − 8 = 128 
0.326

Dynamic Volumetric / Lubrication

0
-10 +10 Present SICP
400 psi
-20 +20
-30 +30
MGS SIKLP
400 psi CLFP
∆V Trip Tank 80 psi
64 bbl @ 20 spm
The Dynamic Volumetric/Lubrication

method uses the principles of the
volumetric and lube and bleed
procedures to remove gas from Est. Gas Vol
45 bbl ACF
beneath a subsea BOP. Circulation 0.0707 bbl/ft
is maintained across the wellhead
while the pit gain/loss and surface MW
Choke and Kill line pressures are 12.6 ppg
controlled using the choke to allow
the gas to exit the well while
controlling BHP.
Two schedules are used during the process. A volumetric schedule is used to
account for gains in the surface pit volume due to expanding gas exiting the
annulus beneath the BOP and travelling up the choke line. A lube and bleed
schedule is used to account for mud that displaces the gas from the annulus
section beneath the BOP. Typically, the expectation is that the surface pit volumes
would initially gain volume as circulation is initiated and then begin losing mud
volume as gas is removed by the mud gas separator.
Preparation
Check that the Trip Tank has a suitable volume of Lube mud and able to measure
small mud volume changes (+/- 1 bbl). The volume to be lubricated should be
greater than the estimated volume of gas (be prepared to add mud “on the fly” if
necessary). Line up to circulate from the trip tank, down the KL, an d up the CL.
Also route the returns through the mud gas separator.
Ensure that the kill line is full of mud. If there is any doubt, then the well should be
isolated and the kill line circulated with mud. This is required in order to ensure
that the pressure at the stack is accurately monitored.

Emergency Disconnects
Emergency Disconnect
An emergency disconnect is inevitable when operating in deep water. It is
important that the sequence takes place without jeopardizing the safety of the
crew and without damaging the riser, BOP equipment, and the environment.
Some of the more common reasons for an emergency disconnect are:

• Loss of power
• Single point failure (moored vessels)
• Dynamic positioning failure (DP vessels)
• Operator error
• Rapid and severe weather change
Emergency Disconnect Sequence (typical)

1. Hang off the DP
2. Shear the DP
3. PU DP out of BOP ram area
4. Close the B/S rams
5. Disconnect The LMRP
6. Move the rig away from wellhead
Telescopic Joint Stroke-Out vs. Vessel Offset

Time to Disconnect (min)
Water Depth 3000’ 4000’ 5000’ 6000’
Distance to Travel 425’ 490’ 550’ 600’
Time to disconnect(1) 5.6 6.4 7.2 7.9
Distance to travel:
Horizontal distance that gives 30 ft stroke-out of telescopic joint. Differing space-
outs of the telescopic joint will alter the above times.
(1) Drift-off at ¾ knots average speed.
(2) Drift-off at 2 knots average speed.
(3) Drift-off in 3 knots current.
Example Taken from a Deep Water Drillship

Dead-Man, and Auto-Shear Systems
Dead-Man System (DMS)

The purpose of the DMS is to shut-in and secure the well in event of a parted riser
caused by a drift-off or drive-off of a DP vessel. The DMS should respond
automatically and not require manual initiation, “dead -man”. The system should
auto sense the drift-off / drive-off condition and initiate the DMS. Battery power
will provide electrical power and signal and the subsea accumulators will provide
hydraulic fluid power.
DMS to initiate if the following conditions exists:

• Simultaneous loss of hydraulic supply and signal transmission capacity in both
subsea control pods.
• Subsea accumulators are charged
• DMS selector switch at panel is in “ARM” position
The DMS is considered a “rapid discharge” system.
Auto-Shear System
The auto-shear is designed to automatically shut-in the wellbore in the event of a
disconnect of the LMRP. This is considered a “rapid discharge” system . Should be
tested on the test stump.
Note: When the auto-shear is armed, a disconnect of the LMRP closes the shear
rams.

Remote Operating Vehicle (ROV) Intervention
ROV Intervention
The ROV is the eyes and arms below

water. The ROV can perform tasks with
cameras and manipulators in support of
the drilling operations. Critical functions
on the BOP stack are equipped with a
hydraulic over-ride intervention system.
The over-rides are operated through
hydraulic stabs which have fluid supplied
from mini accumulators and pump
located on the ROV. In an emergency,
seawater may be substituted and
pumped straight to the functions.
The ROV intervention system is installed

to work as a back-up to the Multiplex
control unit. A panel should be located
on the Lower Marine Riser Package
(LMRP) and tied into the hydraulic
connector and release of the ring gasket.
A lower panel should be located on the

BOP stack for operating:
• Each shear rams
• One pipe ram
• Ram locks
• Release of the hydraulic connector
• Release of the wellhead ring gasket
All critical functions shall meet closing

time requirements indicated in API STD
53.

© 2014 Chevron U.S.A. Inc. All Rights Reserved. Company Confidential. 10 – Completion & Workover
Kick Awareness and CO/WO Operations
Rig Operation Kick Awareness
• Fluid loss to the formation is common in WO/CO

operations
• Loss varies with permeability, fluid viscosity, and
degree of overbalance
• Wide range of viscosifiers, and solids are used to
Tripping w/Fluid
control loss rates
Loss • If loss rates remain consistent while tripping, then
monitoring the proper fill on the way out is more
straight forward and less of a risk
• Loss rates can vary with pipe movement and with
the simple passing of time
Practices for displacing to lower density fluid

Wellbore Fluid
Displacement fluids and pressure effects across well
Displacements barriers
Risks and mitigations

Negative Testing Pressure differentials, formation fluids influx
Perforating and • Handling influx volumes and types

Drill Stem Testing • Underbalanced perforating
(DST) • Reversing
Slick line
• Alloys available for H2S & CO2
• OD of wire is easy to seal around /packing
element in stuffing box
Wireline Braided line
Operations • Multi-strand, stronger than slick line
• OD of wire require a grease seal arrangement
e-line
• Multi-strand with internal wires sheathed with
insulating material

Kick Awareness and CO/WO Operations - continued
Rig Operation Kick Awareness

Lubricators
• Sufficient length to cover tool string
• 5000 psi, 10000 psi, & 15,000psi units
BOPs, Slick line Valve/Ram and Seal
• Manual or hydraulic
Wireline • Cannot manually open a hydraulic slick line valve
• Can manually close a hydraulic valve if fitting on
Operations valve is removed
(continued) • Seal can contain pressure without wire
Braided Line BOP
• Grease must be injected between upper and
lower rams to effect a seal on well pressure
• Should wire break, a ball check or pump out plug
will stop flow from the top of lubricator
• Rat hole below packer may contain formation

fluids
• When packer is unseated or the seal nipples
pulled above the packer bore, trapped gas
Unseating Packers escapes into the annulus and starts migrating up
the wellbore
• Usually no immediate indicator that the trapped
gas is there thus the crew may be unaware of the
possible danger
• Circulating to remove fill from the active wellbore

occurs with frequency in CO/WO operations
Cleaning Out Fill • Fill can seal off the producing zone from the hole
above the fill, possibly at considerable distance off
bottom

Planning Checklist for Workover
Pre-Workover Well Diagnostics

Information Comments
Ensure that the tree has been serviced and

any repairs have been made. Verify BPV
Tree schematic thread profile.
Ensure that hot bolting, packing pins, etc.
meet specifications.
Review well files and all wireline tickets.

Well files / Wireline
including office file and field files. The wireline
tickets
company also maintains records.
If the SCSV is isolated for testing, verify ability

to lock with a fusible plug (threaded cap) that
Surface controlled is designed to melt (compliance with
safety valve (SCSV) regulatory requirements).
Repair or remove SCSV as needed and install
a standard manual valve.
Verify ability to fully open without any control

line leak. An operable SCSSV can be used as
Surface controlled a temporary barrier when nippling down the
sub-surface safety tree and nippling up the BOPE.
valve (SCSSV)
Wireline ops can be performed through a
flapper type SCSSV using a hang-off tool.
The valve can be locked open.
Critical for pressure equipment needed for

wireline operations. Actual pressure
measurements can be taken to determine
MASP (e.g., SBHP gauge).
Maximum allowable
A flanged connection at the top of the tree
surface pressure
(MASP)
recommended for pressure in excess of 3500
psi.
The number of rams and use of hydraulically
assisted pack off is dictated by MASP.
Consult with the slickline operator.

Thermal Expansion of Clear Brines
Brine weight (ppg) Weight loss (ppg/°F)

8.4 – 9.0 0.0017
9.1 – 11.0 0.0025
11.1 – 14.5 0.0033
14.6 – 17.0 0.0040
17.1 – 19.2 0.0048
Density of brines decrease with increasing temperature
Example:
Calcium chloride brine
Average wellbore temperature (AWBT) = 150 F °
Fluid Density (FD) to balance zone pressure = 11.2 ppg (Calculated from
reservoir pressure)
Surface mixing temperature = 80 F °
What fluid density should be mixed?
°
FD @ 80 = FD @ AWBT+ (AWBT – Surf Temp) x Weight loss (ppg/ F) °
° °
= FD @ 150 + (150 – 80 ) x 0.0033°
°
= 11.2 + 70 x 0.0033
= 11.2 + 0.23 = 11.5 ppg
Crystallization of Clear Brines

 Crystallization occurs at lower temperatures when salt crystals
settle out from brine solution.
 Crystallization lowers the density of a brine and may develop flow

restrictions.
 To avoid crystallization and allow weight up of brine (consult brine

supplier), use proper brine formulation.

Reversing
Reverse Circulation
Reverse circulation is a method of pumping down
the shut-in annulus and receiving returns through
the tubing back through a choke.
Common Reasons:
• Bullheading not an option
o Plugged perfs
o Low permeability zone
o Questionable tubing and casing
conditions
• Drill Stem Test (DST)
Maintaining constant BHP may not be a concern

while reversing out an influx. In case it is required
to hold constant BHP, annulus should be full of a
known fluid and the casing pressure should be
maintained constant while circulating. To hold
constant BHP also requires lining up the tubing to
the choke manifold.
Advantages to Reversing
• Faster influx removal
• Casing is protected from harmful fluids
• Less contaminated fluid at the surface
• Casing may be exposed to less pressure
compared to Driller’s Method

Reversing, Example
Where the annulus contains clean completion fluid (with a known

overbalance) and does not threaten severe formation damage if some fluid
invades the pay zone, the following procedure should provide adequate BHP
control while reverse circulating to kill the tubing.
Static Shut In
Tubing Pressure
Procedure: Example 2300 psi
It is decided to reverse kill a well that contains oil

and gas in the tubing and clean completion fluid in
the annulus above the packer. Reversing is SICP= 0 psi
From Mud
preferred over bullheading, because it is believed
Pump
to be faster and easier and it is desired to minimize
fluid loss to the formation.
2 7/8” 6.5# Tubing
Pertinent well conditions (straight hole): 0.00579 bbl/ft
Pore Pressure: 4300 psi (12.2 ppg) @ 6800 ft Burst = 8640 psi
Frac Gradient: 0.78 psi/ft 7” 29# Casing

SITP 2300 psi 6.184” ID
0.03715 bbl/ft
SICP 0 Burst = 6870 psi
Completion fluid: 12.6 ppg CaBr 2 (~150 psi
overbalance (OB) @ 6800 ft) Circulation Point Packer – 6,720 ft
Packer fluid: 12.6 ppg CaBr 2 EOT – 6,780 ft
Selected pump speed 2 BPM Top Perfs
6,800 ft
Bottom Perfs
7,140 ft
Kill proceeds as follows:
1. Establish circulating point from annulus to tubing @ 6700 ft (open
sliding sleeve, punch tubing just above the packer, or release packer).
(SITP goes up about 150 psi to 2450 psi).
2. Bring pump up to speed by doing one of the following:
a. Use choke to reduce TP by the Tubing Friction pressure @ 2
bbl/min (critical wells)
b. Hold casing pressure constant at Initial SICP. (non critical wells)
3. Establish desired safety factor (+/- 200 psi) and continue to maintain
casing pressure constant at circulating rate.

© 2014 Chevron U.S.A. Inc. All Rights Reserved. Company Confidential. Appendix
Formulas - continued
19. Volume Gain From Pumping Slug

  
  =  ×

 
20.   =   × 
21. Boyle’s Law -  ×  =  ×  or,

 ×   × 
 = &  =
 
22. Maximum Lube Volume/Pressure Per Lube Cycle
   ×   
  =  +
2 ×    
.

   ×     × 
 +
2 ×       
Where: V gas = Volume of Gas Prior to Lube
LM= Lube Mud
CPInitial =Casing Pressure Prior to Lube

.−×
23.     = .
24.  ℎ =  × ℎ

25. ,,  & Snubbing Force (SF)
  = 0.7854 ×  ×  ℎ
 =   +   +  ℎ
26. Buoyed Weight of Tubulars (closed ended & no fluid in pipe): Wb (lb/ft)
 × 
 =  
24.5
Version 1.3 Chevron Well Control Handbook A - 6

27. After filling the pipe, Effective String Weight will be: (closed ended, different
fluid in pipe and annulus) Wb (lb/ft)
 ×   × 
 =  + 
24.5 24.5
28. The Balance Point in unfilled pipe occurs when the length of pipe run into the
well is: L (ft)

=
 × 
  24.5
29. The Balance Point while filling pipe occurs when the length of pipe run into
the well is: L (ft)

=
 ×   × 
  24.5 + 24.5
30. Maximum Down Force on Jacks
   = 0.7 ×       
31. Effective Area of Snubbing Jacks (2 or 4) (in2 )
  =    × 0.7854 ×     
32. Hydraulic Pressure to Snub (psi):
   
    = =
  
33. Approximate barite requirement for weight-up (100 lb sacks)
15×
 =  ×
35
34. Mud weight from ⁰API
1178.7
 =
⁰ + 131.5
35. Cutting back MW or Weighting up
  
    =   ×
   
36. Final Density of a mix of fluids
 ×  +  × 
 =
 + 

37. Temperature correction for Brines

 =   +     × ℎ  ℉
Brine Weight (ppg) Weight Loss (ppg /F⁰)

8.4 - 9.0 0.0017
9.1 - 11.0 0.0025
11.1 – 14.5 0.0033
14.6 – 17.0 0.0040
17.1 – 19.2 0.0048
Four Choke Panel Marks
1. Initial SICP (ISICP)

2. Choke Opening Position
3. ICP
4. Choke Sweet Spot

Mud Gas Separator (MGS) Sizing: SPE No. 20430
Gas Vent Line

Mud / Gas Mixture
Mud Gas Cut Mud Inlet
Impingement
Gas Plate
Baffles
Siphon
Breaker
Mud Mud Leg

Return Line
ID
To understand the operating principle of the MGS only requires following the flow
path of the fluids. Mud and gas mix enters the vessel via the mud inlet line where it
flows and impacts an impingement plate. The impingement plate reduces wear
inside the vessel and also causes some gas to “breakout” due to the impact. The
plate also routes the flow downward onto an arrangement of several
s everal baffles.
The increased turbulence caused by the baffles further causes gas mud separation.
Gas, due to it’s density, flows upward and exits the gas vent line and the mud flows
to the bottom and exits via the mud return line that discharges the active mud into
the pit system. Where it is usually further processed by a vacuum degasser.
The operating pressure within the separator is equal to the friction pressure of the
gas exiting the vent line. Fluid level is maintained by the hydrostatic of the mud
mud
leg. If the vent line friction pressure exceeds the mud leg hydrostatic, gas will blow
through to the mud pit system.
There are many important variables that go into the design of a mud gas separator.
Most separators being manufactured today are designed to work effectively,
however it is still a good idea to check on capacity limits.
Version 1.3 Chevron Well Control Handbook A -18

Mud Gas Separat

Separator
or (MGS)
(MGS) - continued
Separators include horizontal and vertical models but most separators used in the
drilling industry are vertical, and that is what’s described here.
The important issue when sizing a MGS is to ensure there is minimal chance for gas
“blow through” to the mud pit system. The two cases where this may occur is:
1. The mud return line friction pressure and
an d hydrostatic “mud leg” should be
greater than the gas vent line friction pressure when
when the MGS is operating
fully.
2. Insuff
Insuffici
icient
ent vess
vessel
el ID could
could reduc
reduce
e the rete
retenti
ntion
on time
time in the sepa
separato
ratorr thus
reducing the gas separation from the mud. The exiting mud would then
contain an undesirable gas volume as it discharges to the mud pi ts.
Working through an example will illustrate these issues and allow for a better
understanding.
Example Data:
Well kick occurred and the shut-in conditions indicate that the 15 bbl kick
could yield 66 bbl of gas with a Pcmax value of 970 psi when circulated
circulat ed to the
surface using the Driller’s Method. This would require the MGS be capable of
handling 2.65 mscf/day peak flow rate. The OMW is 12.0 ppg and the
planned Circulating Rate (CR) is 3 bbl/min.
Sizing Procedure
1. Estima
Estimate
te the vent
vent line fricti
friction
on press
pressure
ure when
when the
the MGS
MGS is expos
exposed
ed to the
the peak
peak
gas flow rate Q max (mscf per day). Assuming an empirical friction factor for that
of a smooth, straight, steel pipe and a gas density of 0.01 ppg permits using
the following formula:
Where:
Le= Total vent line length plus equivalent lengths for bend, etc. (For this
example: vent line consists of 200 ft of 7” ID pipe with 2 sharp right bends)
Ds=Vent line ID (7” for this example)
Q max= mscf per day of gas flow
5.0× ×  
   =
 

5.0 × (200 + 70 + 70) × 2.65
   = = 0.71
0.71 

7.0
(Note: Effective vent line lengths will be greatly effected by the installat ion of
flame arresters or auto-igniters.)

Mud Gas Separa

Sep arator
tor (MGS) - contin
continued
ued
2. Check
Check that
that the mud leg
leg hydros
hydrostati
taticc is grea
greater
ter than
than the
the vent
vent line
line frict
friction
ion
pressure. The worst case of HP in the mud leg would be if full of oil. (For
this example an oil of 0.26 psi/ft gradient is used).
   0.71

  
 
ℎℎ = = = 2.7 

 0.26
3. Check
Check for suffi
sufficie
cient
nt separa
separator
tor ID for
for the planne
planned
d kill
kill circul
circulati
ation
on rate.
rate. (Here
(Here
the CR=3 bpm.
  
" = 15.72 × √ = 15.72 × 1.73 = 27"
Equivalent Equivalent
Source Sketch Length Source Sketch Length
Bend Bend
Acute Obtuse
3 15
Round Sharp
Bend
Acute Contraction
150 1
Sharp Gradual
Bend
Right Contraction
1 10
Round Abrupt
Bend
Right Expansion
70 1
Sharp Gradual
Bend
Obtuse Expansion
1 20
Round Abrupt
Table of Bend/Corner Equivalent Lengths

Steam Operations
Steam Behavior: Temperature and Pressure Relationships
Water boils at 212⁰F when at atmospheric pressure (14.7 psi

absolute). The boiling water is changed from a liquid state to
gaseous steam vapor. But if water is under a pressure greater than
atmospheric, the boiling (vapor) temperature is greatly increased.
But if the pressure is rapidly reduced, the water state explosively
flashes to a vaporous (steam) state .
14.7 psi
80 °F
Valve
16501650
gal of
1 Gallon
Of Water
gallons
steam of
steam!
250 psi
400 °F
1 Gallon
Of Water
If the containing valve is quickly

Water will not boil at 212 deg. F
opened, one gallon of water will
when contained with 250 psi
explode to 1650 gal of steam.

Steam Operations - continued

Basic Concepts at Issue
High bottom-hole temperature at shallow depths
 Rapid transport of fluids from shallow depths
 Potential for exposure to hot fluids at surface (hot mud/steam)
Water-based muds or brines may be exposed to high temperatures

 May flash at wellbore temperature-pressure conditions
 Potential BLEVE (Boiling Liquid Expanding Vapor Explosion)
A BLEVE can occur with no notice and very rapidly
explosively unload the well and blow-out to the surface.
Circulating Stop Circulating

80⁰F
150⁰F
Potential
BLEVE
400+⁰F
200⁰F
410⁰F 410⁰F
HP=250 psi @ 500’
FP=220 psi @ 500’
Once circulation is stopped, the mud will begin to heat up to

400+⁰F. Bottom hole Temperature and hydrostatic pressure
remains constant. If left unchecked, could rapidly result in a
BLEVE event!

Steam Operations - continued
Preventing a BLEVE
In Steam Flood Operations, it is important to determine (during planning
operations) whether or not conditions for a BLEVE do or could exist.
1. Collect information about proposed or potential wellbore (formation)
temperatures.
2. Use a “Steam Table” to determine whether or not proposed or
acceptable fluid densities will provide enough hydrostatic pressure to
prevent boiling at any point in the wellbore.
3. If conditions for a BLEVE exist, plan the operation to ensure
temperature control as well as pressure control. Periodically introduce
cooler fluids from the surface.
Shut-in Considerations
– Is there time to stab a fully opened safety valve?
– Is there a float valve and circulating sub installed in the DP / tubing?
– Have “pipe light” issues/risks been considered/mitigated?
– Is there a shear/blind ram in the BOP?
– Is it possible to divert flow to the disposal pit, possibly by use of a pre-
installed rotating head?
Killing Wells in Steam Flood Operations

If possible to control the well with fluid hydrostatic alone:
– Kill the well normally using the Driller’s Method, but monitor return
fluid temperature to identify unexpectedly high wellbore temperature.
If BLEVE conditions may exist:
– Pump kill weight fluid, but consider/monitor the wellbore temperature
to prevent additional steam evolution (boiling).
– Local SOPs may specify fluid and pumping options (mud circulation vs.
cooling vs. bullheading).

Broken U-Tube
Possible Plan of Action (POA) - continued

o Pump barite pill, gunk squeeze, dewatering pill or cement
plug...to bridge and isolate the producing zone from the
loss zone
• Non conventional kill methods:
o Bullhead kill fluid to the loss and/or producing zones
o Bottom Kill … pump weighted slug below the loss zone to
overbalance the producing zone
o Sandwich Kill …. bullhead kill fluid from both above and
below the loss zone
o Dynamic Kill … pump kill fluids in stages at high rates
increasing fluid weight until well is killed … use modeling
software to design the kill process

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Well Control

Chevron Well Control Handbook

“Always comply with all applicable rules and

Version 1.3 Chevron Well Control Handbook 1- 1

Well Control Goals

• Maintain primary hydrostatic control of the well at all

• Efficiently use secondary well control options

• Restore primary control of the well, using acceptable

• Land drilling rigs

• Offshore jack-ups and platform rigs (surface BOP)

• Offshore semis and drillships (subsea BOP)

Version 1.3 Chevron Well Control Handbook 1- 2

Version 1.3 Chevron Well Control Handbook 1- 3

D&C GTS Well Control Requirements (excerpts)

10. Well control

Version 1.3 Chevron Well Control Handbook 1- 6

Barriers (D&C Global Technical Standard: Well Barrier Design)

The three classifications of barriers are:

Hydrostatic Barrier Examples:

A static test is the primary means of Hydrostatic

Cement Barrier Verification

• Verification of placement (inside the wellbore or casing annulus) is also

Version 1.3 Chevron Well Control Handbook 1- 7

Barrier integrity shall be verified upon installation and at periodic intervals, as

APPLICATION OF THE BARRIER STANDARD

Long-term Suspension & Abandonment

If one of the required minimum barriers fails, forward operations

Prior to commencing operations, a well diagram or table shall be

Version 1.3 Chevron Well Control Handbook 1- 8

Training & Competency

All rig personnel having well control duties must be competent in

Well Control Training

Participation in Well Control Drills

Drills (D&C GTS: Well Control Requirements) Frequency (per crew)

Hole Monitoring While Drilling, Milling, or Once per week

Shut-In Drill Once per week

Well Kill Drill Once per month

Choke Drill Once per month

Diverter Drill Once per month

Stripping Drill Once per quarter

Non-Shearable Drill Prior to event

Drill for Non-Routine Operations Once per operation

Emergency Disconnect Sequence Drill Once per month

Version 1.3 Chevron Well Control Handbook 1- 9

Well Control Responsibilities

The following Contractor and Service Company personnel

Assistant Driller / Derrickhand

Barge Supervisor / Captain

Version 1.3 Chevron Well Control Handbook 1 - 10

Well Control Responsibilities - continued

Mud Logging Engineers

Control Room Operator

Version 1.3 Chevron Well Control Handbook 1 - 11

Basic Concepts: Wellbore Pressures

 = 0.052 × 10.8 × 8596 = 4828 

Version 1.3 Chevron Well Control Handbook 1 - 12

“Always maintain the integrity

Version 1.3 Chevron Well Control Handbook 3- 1

Positive Indicators (Drilling)

Flow With Pumps Off

Chevron requires the Driller to shut-in immediately if there is

Increase in Pit Volume

Version 1.3 Chevron Well Control Handbook 3- 2