section 7b

well control
section 7b Scomi Oiltools

introduction 2
kick detection 3
determining the drilling fluid density requirement 3
well control calculations 4
controlling the well 5
wait and weight method 6
drillers method 7
concurrent method 7
volumetric method 7
barite plugs 7
Section

7b pressure control - well control

pressure control - well control

introduction
The primary control of formation pressure is provided by the hydrostatic head of the drilling fluid.
Secondary control is provided with the use of a mechanical barrier - the Blow Out Preventors (BOP).

When a well influx (a kick) occurs, the formation fluid flows into the well bore and primary control from
the drilling fluid is lost. The BOP is closed to provide well control while actions are taken to regain the
primary control by increasing the density of the drilling fluid. If the flow becomes large and unmanageable
e.g. failure of the BOP or undetected flow, a blow out can occur with disastrous results.

Well control signifies that the well has become active or a kick has been taken and a series of steps are
required to circulate out the kick and take remedial action to re-establish hydrostatic control of the
formation pressures.

The following steps are required, the well control strategy:

1. Detection of a kick.
2. Ascertaining the drilling fluid density requirement to re-establish control.
3. Raising the density of the drilling fluid to the required value.
4. Circulating out the kick.

Well influxes typically occur during the following drilling operations:

1. Drilling: If abnormally pressured formations are encountered while drilling, an influx will occur, if
the hydrostatic head provided by the drilling fluid is less than the formation pressure. Kicks may
also occur during lost circulation events due to a drop in the fluid height in the annulus causing a
reduction in the hydrostatic head.

2. Tripping out: One of the most common causes of well control events is not keeping the hole
full while tripping the drillpipe out. As the pipe is pulled from the well, the volume of the steel
removed must be replaced with drilling fluid, or the fluid level in the annulus will drop and
the hydrostatic head will become less than the formation pressure. Hole fill up must be closely
monitored to ensure that the correct volume of fluid is being used to keep the hole full at all times.

While pulling out of hole it is possible that formation fluids may be swabbed into the hole, as the
drillpipe pulls fluid off bottom, reducing the hydrostatic pressure in the wellbore. This can occur
due to balling of the bit, or balling of drill collars which reduce the annular clearance such that the
drillpipe acts like a piston as it is pulled up the wellbore. High fluid viscosity or reactive (swelling)
formations can also cause swabbing during drill pipe removal from the wellbore.

Swabbing is indicated if the volume of mud required to fill up the hole is less than the volume of steel
removed. Trip speeds should be controlled and if required maintain the drilling fluid below the bit by
pumping through the drill pipe or slowly pumping out through a Top Drive System (TDS).

3. Tripping in: The speed of running the drillstring into the hole can result in pressure surges ahead
of the string which can break down the formation causing downhole losses with subsequent loss
of hydrostatic head and formation influx. Tripping speed needs to be controlled to preserve fluid
column integrity.

Fluid returns from the well while running in are closely monitored to ensure the correct volume of
fluid is being returned. Too little flow indicates losses may be occurring while too much flow is an
indication that the there has been an influx.


Industry studies have shown that the majority of well control activities occur during tripping in
development wells, and in the early morning hours between 0300 to 0500. The major cause being
crew inattentiveness from a decreased level of alertness or overconfidence.

kick detection
Wells become active when the hydrostatic head of the drilling fluid becomes less than the formation
pressure and formation fluids enter the wellbore and are detected by the following indicators:

1. Drilling Break: A sudden increase in ROP may be due to abnormal pressure or a change in litho-
logy. It is advisable to perform a flow check and observe the well before drilling ahead.

2. Flow increase: When the formation fluids flows into the wellbore there is an increase in the mud
volume resulting in an increase in the return flow at surface. Return flow rates are constantly monitored
to detect these changes.

3. Pit Gain: An influx will also increase the volume in the pits which should be closely monitored.
Accurate measurements will determine the influx volume if detected quickly.

A trip tank is used to monitor the volume of fluid used to fill the hole while tripping out and volume
of fluid displaced while tripping in. These are small tanks, with volume measurements, allowing
detection of small changes in volume.

4. Reduction In Pump Pressure: As an influx rises in the annulus the pump pressure available to
lift the drilling fluid up the annulus is increased. This will show as a reduction in pump pressure. Note
that this can also be an indication of lost circulation.

5. Gas Level in the Drilling Fluid: As has been noted in the pore pressure prediction section, increases
in gas levels in the drilling fluid occur due to increased gas content of the rock being drilled or
due to an influx. Increasing trends both in background gas and connection gas levels are closely
observed. Frequently they are an excellent indicator of drilling close to balance with little margin
between the hydrostatic and formation pressures.

determining the drilling fluid density requirement

After a kick has been detected it is important that the well be shut in immediately, firstly to ensure
integrity and well control and also to be able to correctly determine the drilling fluid density required
to control formation pressure and regain primary well control.

When the BOP is closed on the wellbore, the pressure on the drill-pipe and the casing at surface will
increase. The drill-pipe surface pressure reading is used to determine the actual downhole formation
pressure and, therefore, drilling fluid density requirements.

At this point the fluid in the drill string is uncontaminated mud and the influx fluid is in the annulus.

The pressure exerted by the formation on the drill pipe is the difference between the formation
pressure and the drilling fluid hydrostatic head. This excess pressure shows up as Shut in Drill Pipe
Pressure – SIDPP. The formation pressure is the sum of the hydrostatic pressure from the mud plus
the SIDPP. This is calculated as an Equivalent Mud Weight (EMW), which is the required mud weight to
safely control the formation pressures and drill ahead.

The drilling fluid in the annulus is contaminated with the formation fluid. The pressure on the annulus
side consists of three elements:

ƒ The drilling fluid gradient


Section

7b pressure control - well control

ƒ The formation fluid gradient (depend on influx type and height)

ƒ A U tube effect from the drill string pressure differential.

This pressure is the Shut In Casing Pressure (SICP) which is higher than the SIDPP due to the loss of
hydrostatic head from the kick fluid.

The height of the influx can be determined from the influx volume recorded at surface, and the
pressure gradient of the influx calculated. This gradient will indicate the influx type, water, oil or gas.

Quick kick detection and closing of the BOP will lead to the most accurate determination of SIDPP
and SICP. The more accurate this data, the easier it is to regain well control.

well control calculations

Oilfield units S.I units
Hydrostatic pressure (psi) Hydrostatic pressure (kPa)
= depth (ft) * mud weight (lb/gal) * 0.052 = depth (m) * mud weight (SG) * 9.81

Drilling fluid gradient (psi/ft) Drilling fluid gradient (kPa/m)

= hydrostatic pressure (psi) / depth (ft) = hydrostatic pressure (kPa) / depth (m)

Formation pressure (psi) Formation pressure (kPa)

= hydrostatic pressure (psi) + SIDPP (psi) = hydrostatic pressure (kPa) + SIDPP (kPa)

Equivalent mud weight (lb/gal) Equivalent mud weight (SG)

= formation pressure / (depth (ft) * 0.052 = formation pressure / (depth (m) * 9.81

Influx height (ft) Influx height (m)

= kick volume (bbl) / annulus vol (bbl/ft) = kick volume (m3) / annulus vol (m3/m)

Influx (psi/ft) Influx (kPa/m)

= Drilling fluid gradient – [(SIDPP (psi) – = Drilling fluid gradient – [(SIDPP (kPa) –
SICP (psi) / Influx Height (ft)] SICP (kPa) / Influx Height (m)]

well control calculation - example

An exploratory well took a kick while drilling a 6” (152 mm) hole at 8000 ft (2438 m) with 10.2 lb/gal
(1222.23 kg/m3) drilling fluid. SIDPP was 600 psi (4138 kPa) and the SICP was 800 psi (5516 kPa). Pit
increase was 10 bbl (1.6 m3). Company policy is to drill with a safety margin of 150 psi (1034 kPa).
Oilfield units S.I units
Drilling Fluid Hydrostatic Drilling Fluid Hydrostatic
= 0.052 x 10.2 x 8000 = 4243.4 psi = 9.81 x 1.22 x 2438 = 29178 kPa

Drilling Fluid Gradient Drilling Fluid Gradient

= 4243.2 / 8000 = 0.5304 psi/ft = 29178 / 2438 = 12 kPa/m

Formation Pressure Formation Pressure

= 4243.2 + 600 = 4843.2 psi = 29178 + 4138 = 33316 kPa

EMW EMW
= 4843.2 / (0.052 X 8000) = 11.64 lb/gal = 33316 / (9.81 x 2438) = 1.40 SG

EMW + 150 psi EMW + 1034 kPa

= 11.64 + [150 / (0.052 x 8000)] = 1.40 + [1034 / (9.81 x 2438)]
= 12.0 lb/gal to drill with safety margin = 1.44 SG to drill with safety margin


Identifyng the influx fluid

< 0.14 psi/ft (3.17 kPa/m) = Gas

0.14 – 0.442 psi/ft (3.17 – 9.99 kPa/m) = Mixture of gas, water or oil
0.442 – 0.52 psi/ft (9.99 – 11.76 kPa/m) = Saltwater

Annular volume with 4 3/4” (122 mm) DC = 0.091 bbl/ft (9.96 L/m)

Oilfield units S.I units

Influx height Influx height
= 10 / 0.0191 = 524 feet = 1590L / 9.96 L/m = 159.6 m

Influx Fluid Gradient Influx Fluid Gradient

= 0.5304 - [(800 – 600 / 524] = 12 – [(5516 – 4138.2) / 159.7]
= 0.148 psi/ft indicating gas = 3.37 kPa

controlling the well

Circulating out the kick and raising the fluid density to the desired value are actions requiring a thorough
understanding of the engineering involved. These processes together are the key parts of all well control
procedures

During the process of circulating the kick to surface, the influx fluid will undergo temperature and
pressure changes. While temperature variations have a limited effect on the influx fluid, pressure changes
can have dramatic effect if the influx is gas. As the fluid moves up the wellbore the hydrostatic pressure
decreases and the gas volume will increase.

Circulating out a water or oil kick can be a straightforward process depending on the type of well control
procedure followed as there is little change in pressures or temperatures as the fluid is circulated out.

Gases follow Boyles and Charles law:

P1V1 = P2V2

where P1 & P2 = initial and final pressures

V1 & V2 = initial and final volumes

Pressure & Volumes are inversely proportional - as the pressure decreases the volume increases and
vice versa e.g.

If P2 = 0.5 P V2 = 2V1

In this case, the gas volume has doubled as the pressure decreased. If the well was not closed in with
the BOP, this would result in large volumes of mud being ejected from the wellbore, due to the expansion
of gas volume reducing the hydrostatic, and allowing more gas to flow into the wellbore.

With the BOP closed and the gas circulated up the annulus without being allowed to expand,
the surface pressures will increase beyond the casing shoe pressure limit, the burst pressures
of the casing, and possibly the pressure limits of the BOP. This will cause failure in the ability
of the wellbore design to handle the high pressures that will develop. For this reason, proper well
control procedures have to be followed for safe removal of the gas influx from the wellbore.


Section

7b pressure control - well control

Kill mud, depending on the well control procedure being followed, is pumped to bit in a carefully
controlled operation, using a predetermined Slow Pump Rate. When the mud has reached the bit the
SIDPP should equal zero. As the heavy mud circulates up the annulus the choke is regulated to maintain
the required pressure by bleeding off volume at higher or lower rates as the influx fluids expand on their
way to surface.

A kill sheet is used to show the pressures required at all stages of the operation.

The Slow Pump Rate is recorded every tour due to the change in drilling fluid density, fluid flow
properties, and well depth. The initial circulating pressure, ICP, is the sum of SPR and SIDPP.

There are three main methods of well control involving circulating out of kick and pumping
the required density of drilling fluid to regain primary control. All of the methods are based on
maintaining a Constant Bottom Hole Pressure. The fourth method is basically when the bit is not at
bottom that is the well activity during tripping operation or when the string is out of hole.

A) Wait and weight method

B) Drillers method
C) Concurrent method
D) Volumetric method

wait and weight method

This is also known as Engineer’s method of well control. The well is closed in and monitored while
the drilling fluid is weighted to the required density. No operation is carried out until the required
volume and density of fluid is available. The weighted fluid is then pumped and the well killed in one
circulation. This method is preferred in most cases. The kill mud is pumped to the bit holding an ICP
as calculated above. Once the kill mud is at the bit the mud is circulated at a constant Final Circulating
Pressure (FOP) and the kick circulated out as per the pressure schedule in the kill sheet.

FOP = Slow Pump Rate Pressure * Kill Mud Weight / Original Mud Weight

When the weighted mud reaches surface the adjustable choke pressure should = FOP and on stopping
the pumps SIDPP = SICP = 0

Advantages:
a) Maximum pressure exerted on weakest point, i.e. the casing shoe, is the lowest of the
methods with less chance of lost circulation.
b) Requires only one circulation and least time to regain primary control.
c) Well is exposed to lower pressures.

Disadvantages:
a) if the well is not clean, i.e. loaded with cuttings pack off and stuck pipe can occur.
b) Gas migration up the annulus during waiting period may cause problems.


drillers method
With this method the kick is circulated out before heavy mud is circulated. A constant bottomhole pressure
is maintained using the adjustable choke throughout the circulation until. The well is shut in with back
pressure equal to the SIDPP recorded earlier to avoid any more influx. During this time the drilling fluid
is being weighted. Once the heavy fluid is ready it is pumped in the well maintaining a constant casing
pressure. May be used in HPHT wells.

Advantages:
a) Less chance of pack off.
b) Gas migration not an issue.
c) Maintain well control while waiting on materials or weather.

Disadvantages:
a) Requires multiple circulations.
b) Exposes casing shoe to relatively higher pressures.

concurrent method
In this method the drilling fluid is weighted while circulating out the kick. It is not a preferred method for
well control.

volumetric method
This procedure is followed when a kick is taken while tripping in or out of the well and also if the well
flows when the string is out of the hole. The main objectives are to get the bit to the bottom while
ensuring that the back pressure or SICP is sufficient to avoid further influx without breaking down
of the formation. Pressure is maintained by bleeding off volume through the choke as an equal volume
of drilling fluid is pumped down the drillpipe to keep the hole full. Simultaneously the string is stripped
in the well through the closed BOP. Once the bit is on bottom standard well control techniques are
followed to regain primary control.

barite plugs
During well control operations the increase in mud weight and hydrostatic pressure may be sufficient
to exceed the fracture gradient and cause loss of circulation. In this case the influx will flow into the loss
zone in a situation known as an ‘underground blow-out’. The placing of a heavy barite plug is usually
done in order to stabilise the borehole for running casing. It is not recommended to drill ahead after
inducing loss of circulation, unless the losses can be cured.

Barite plugs seal the wellbore in the following ways:-

ƒ
They are designed with low viscosities and zero fluid loss so that the barite may dehydrate and settle to
form a solid plug in the hole.
ƒ
The high density increases the hydrostatic head and may prevent additional influx of formation fluid.
ƒ
The high fluid loss and lack of inhibition may also cause the hole to collapse and bridge itself.

Barite plugs in water based mud

Barite slurries are usually mixed and pumped with the cementing unit. The pills are mixed in freshwater
and thinners such as SAPP and or lignosulphonate (HYDRO-SPERSE) are added to keep the slurry thin
and promote settling. It is extremely important to pilot test first as high concentrations of these products,
SAPP 0.2 – 1.0 lb/bbl (0.57 – 2.85 kg/m3) and/or HYDRO-SPERSE up to 10 lb/bbl (28.53 kg/m3) may be
required to allow the barite to settle. At these very high densities barite can support itself.


Section

7b pressure control - well control

Weight/Volume Relationships
(Barite Specific Gravity = 4.2)
Slurry Slurry Volume/
Density Water Barite 100 lb (45.4 kg) sack Sack of Barite
kg/m3 lb/gal L/m3 gal/bbl sacks/m3 sacks/bbl m3/sack bbl/sack ft3/sack
2157 18 640 26.9 33 5.30 0.0300 0.189 1.060
2277 19 602 25.3 37 5.94 0.0267 0.168 0.945
2397 20 564 23.7 40 6.43 0.0247 0.156 0.873
2516 21 529 22.2 44 6.95 0.0228 0.144 0.807
2636 22 490 20.6 47 7.50 0.0212 0.133 0.748
Table 1. Barite slurry (water base)

Mixing
1. Choose a slurry weight and barite/water requirements between 18 and 22 lb/gal (2.16 & 2.64 SG) from
Table 1.
2. Determine how many feet/metres of barite plug in the open hole are desired.
3. Calculate the bbl (m3) of slurry and sacks of barite required, and add an extra 10 bbl (1.6 m3).
4. Mix the slurry and pump it into drill pipe.
5. Displace the slurry so that the height of the barite plug in the drill pipe is 2 bbl (0.3) m3 higher than the
top of the barite plug in the annulus.
6. Break connections and pull up immediately above the plug. If possible circulate on top of the plug,
if possible circulate for several hours.

Barite settling can be very slow with unpredictable results. In many cases numerous pills may be set before
well control is regained.

Example
Open hole = 8.5 inches (216 mm)
Height of barite plug desired = 500 ft (152.4 m)
Weight of slurry = 18 lb/gal (2.16 SG )

1. Volume of barite slurry =

Oilfield units
S.I units

8.52 215.92
1029 x 500 ft = 35 bbl 1.273 x 106 x 152.4 m = 5.59 m
3

2. Total volume required =

Oilfield units S.I units
35 + 10 = 45 bbl 5.57 + 1.59 = 7.16 m3


3. Materials to mix 45 bbl (7.16 m3 ) slurry:
Oilfield units S.I units
Water Water
= 26.9 x 45 = 1121 gal = 29 bbl = 640 l/m3 x 7.16 m3 = 4579.2 l = 4.6 m3

SAPP SAPP
= 0.5 x 29 = 14.5 lb = 1.423 kg/m3 x 4.58 m3 = 6.53 kg

Caustic Soda Caustic Soda

= as needed = as needed

HYDRO-SPERSE HYDRO-SPERSE
= as determined from pilot test = as determined from pilot test

DRILL-BAR DRILL–BAR
= 5.3 x 45 = 239 x 100 lb/sx = 33 sxs/m3 x 7.16 m3 = 239 x 45.4 kg/sxs
= 23,900 lbs = 10828 kg

Total slurry volume Total slurry volume

= 239 x 0.189 = 45 bbl = 239 sxs x 0.0300 m3 = 7.16 m3

Barite plugs in non aqueous fluids

The mixing procedure for an NAF Barite plug is to “water wet” the barite in order to provide viscosity
and barite suspension, then to oil wet the Barite just prior to pumping, allowing the barite to settle out
and form a solid plug.

Barite is added to a mix containing primarily base fluid with a small quantity of water and water
wetting surfactant, HYDRO-KLEEN or equivalent, as quickly as possible. This mix will become very
thick. Before the mix becomes un-pumpable a small amount of oil wetting agent, CONFI-WET, should
be added to thin the mix back so that more barite can be added, it is important not to over-thin the mix
at this point. More barite should be added until the mix becomes very thick again and more oil wetting
agent added, this process continuing until the desired weight is achieved.

Just before pumping, a drum of oil wetting agent should be added, this will thin the mix dramatically
and allow the barite to settle rapidly. The exact amount of oil wetting agent required should be
determined by pilot testing, the amount of base fluid used in the mix, from table 2 below, should then
be reduced by this amount.

Plug density Base Oil Barite Water Surfactant

(kg/m3) (lb/gal3) 3 3
(L/m ) (gal/bbl) (kg/m ) (lb/bbl) (L/m3) (L/bbl) (L/m3) (L/bbl)
2157 18 593 24.9 1682 588 6.29 1 0.629 0.1
2277 19 557 23.4 1828 639 6.29 1 0.629 0.1
2397 20 521 21.9 1959 685 6.29 1 0.629 0.1
2516 21 486 20.4 2131 745 6.29 1 0.629 0.1
2636 22 452 19.0 2274 795 6.29 1 0.629 0.1
2756 23 417 17.5 2422 847 6.29 1 0.629 0.1
2876 24 381 16.0 2571 899 6.29 1 0.629 0.1
Table 2 – Product requirements for various density barite plugs (less oil wetting agent)


Mixing and Pumping Procedure
The mixing pit and mix lines must be free of mud before mixing this plug, contamination with mud will
result in the plug not thinning properly at the end of the mixing process.

1. Fill slug pit, mix tank or batch tank with the required volume of base fluid.
2. Add 1% of the final pill volume of water.
3. Add 0.5% of the final pill volume of HYDRO-KLEEN or similar water wetting agent.
4. Add barite at the maximum possible rate with maximum agitation, including gun lines if possible.
5. Just before the mix becomes so thick it is un-pumpable, add sufficient oil wetting agent CONFI-WET
to thin the mix but not enough to cause the barite to settle.
6. Repeat steps 4 & 5 until the required density is achieved.
7. Just before pumping, sufficient oil wetting agent should be added to thin the mud dramatically, 1 x 55
US gallon (1 x 208 l/drm) is usually sufficient in a 50 bbl (7.95 m3) plug.

Spacers
A base fluid spacer can be pumped ahead and/or behind the plug but is not absolutely necessary, as
mixing of the plug and oil based mud will not result in a particularly high viscosity mixture.