Workover & Completion Well Control PDF

Well Control for Workover
and Completion
1
Outline
» 1. Review: Pressure and Basic Calculations

2. Review: Well Control fundamentals
3. Review: Well Control Equipment
4. Review: Well Control Techniques
5. Completion and Workover operations
6. Fluid systems used in workover and completion
7. Production equipment and pressure control
8. Conventional, Wireline, Coiled Tubing, and
Hydraulic Workover
9. Well control situations during workovers
We assume that you’ve already had a basic or advanced ‘Well Control’ course. We
will review most of the concepts from that course. If you haven’t had the well-
control course, you’ll be able to understand almost all the concepts and
fundamentals of well control, we just won’t go into great detail on the calculations
and work sheets used in those courses.
2
Pressure Basics
Pressure is a force that is exerted on an

area.
– In US
force = pounds; area = square inch
Unit is pounds per square inch (psi)
– In Metric units
Force per area = kiloPascal (kPa)
1 psi = 6.894 kPa
Pressure is
3
Hydrostatic Pressure
Hydrostatic pressure is the force

exerted by a column of fluid
– Force caused by weight (density) of the
fluid
– Weight is in 1 direction; pressure is in all
directions
A column of air 1” x 1” that is 60 miles

high = 1 atmosphere = ~14.7 psi =
100 kPa
Air is also a fluid. A column of air that measures 1” by 1” and is 60 miles high
weighs 14.7 pounds or 100 kPa. Another way of saying this is that the column
exerts a pressure of 14.7 pounds per square inch.
4
Hydrostatic Pressure
Hydrostatic pressure is the force exerted

by a column of fluid
– Force caused by weight (density) of the fluid
– For liquids, in US oilfield
Density unit is ‘Pounds per Gallon’
Gallon’ (PPG or ppg)
Water weighs 8.33 pounds per gallon
– In Metric units
Density unit is kg per cubic meter (kg/m3)
1 PPG = 119.8 kg/m3
In most cases in the oilfield, we’re talking about the hydrostatic pressure of liquids.
The most common oilfield unit of density is ‘Pounds per Gallon’, derived from the
old usage for mixing drilling mud. The equivalent metric unit is kilograms per cubic
meter.
5
Pressure Calculations
Static Pressure
Hydrostatic pressure at any point in the fluid column
P = TVD x MW x K where
P = pressure, psi (kPa)

TVD = true vertical depth, ft (m)
MW = mud weight or fluid density (PPG) (kg/m3)
K = .052 (.0098)
We can calculate the hydrostatic pressure exerted by the weight of the fluid column,
considered at any point in the fluid column. An example is presented on the next
slide.
6
Example Static Pressure
Assume:
TVD = 8,202 ft (2500 m)
MW = 11.1 ppg (1330 kg/m3)
P = 8202 x 11.1 x 0.052 = 4,734 psi
= 2500 x 1330 x 0.0098 = 32,585 kPa
7
Hydrostatic pressure expressed
as Equivalent Mud Weight
EMW = BHP ÷ TVD ÷ K

where
EMW is expressed as (ppg or kg/m)
BHP = bottom hole pressure, psi (kPa)
K = .052 (.0098)
It is also common to express the weight of the fluid column as an ‘equivalent mud
weight’ rather than as psi. We say ‘equivalent’ mud weight because the fluid
column may not be composed of mud, but of water, oil, gas or other fluids, but the
pressure is stated as if the column were mud. Example on next slide.
8

Assume:
BHP = 4734 psi
TVD = 8,202 ft (2500 m)
K = 0.052 (.0098)
= 4734 psi ÷ 8202 ft ÷ 0.052 = 11.1 ppg

or
32,585 kPa ÷ 2500 m ÷ 0.0098 = 1,330 kg/m3
9

Assume:
BHP = 4734 psi
TVD = 8,202 ft (2500 m)
K = 0.052 (.0098)
How about the ‘atmosphere’ example?

EMW = 14.7 psi ÷ (60 x 5280) ÷ 0.052
Atmospheric pressure = about 0.0009 PPG
Here’s
10
Hydrostatic pressure expressed as
Hydrostatic Gradient
Average Gradient (G) as psi per foot of depth

(kPa/m)
G = BHP ÷ TVD
or
G = MW x K
Where
BHP = bottom hole pressure, psi (kPa)
MW = mud weight or fluid density, PPG (kg/m3)
K = .052 (.0098)
Another way to express pressure is as an ‘Average Gradient’. The units we use are
‘psi per foot of depth’ or kPa per meter.
This is a simple calculation that assumes that the entire hydrostatic column is
composed of a homogeneous fluid, and that’s not always the case. On the other
hand, ‘Average Gradient’ is a convenient way to allow interpolating pressure
between depths.
11
as Hydrostatic Gradient
Assume:
kg/m3)
BHP = 4734 psi, TVD = 8,202 ft (2500 m), MW = 11.1 ppg (1330 kg/m
K = 0.052 (.0098)
G = BHP ÷ TVD
= 4734 psi ÷ 8202 ft = .577 psi/ft
= 32,585 kPa ÷ 2500 m = 13.03 kPa/m
G = MW x K
= 11.1 ppg x 0.052 = .577 psi/ft
= 1330 kg/m3 x 0.0098 = 13.034 kPa/m
12
The well as a ‘U-Tube’
Think of the well as a U-Tube

One leg is work string
Other leg is annulus
– If both legs are filled with fluid
of the same weight,
Fluid level is same on both sides
Hydrostatic pressure same on both
sides
No flow from one leg to the other
The primary concept of well control is that we can describe the pressure behavior of
the well as a ‘U-Tube’, with the work string as one leg and the annulus as the other.
If both legs are filled with fluid of the same density, the Fluid level is same on both
sides, Hydrostatic pressure is the same on both sides, and there is No potential for
flow from one leg to the other.
13
The well as a ‘U-Tube’
Fluid tries to reach a balance

11 ppg fluid in work string
10 ppg fluid in annulus
10,000 feet well
11 ppg x 10000 x .052 = 5720 psi
10 ppg x 10000 x .052 = 5200psi
Heavier fluid creates pressure differential

Heavier side causes flow to annulus until
balance
Heavier side shorter than lighter side at
balance (takes more light fluid to balance)
In a U-tube and in the well, the fluid columns try to achieve balance. Suppose we
fill the annulus with a heavier fluid, say 11 pounds per gallon. The annulus is filled
with fluid that weighs only 10 pounds per gallon. We can calculate the pressure at
the bottom of each fluid column using the equation from a previous slide. The result
shows that, before balance, the work string side exerts 5720 psi at the bottom,
compared to only 5200 psi on the annulus side. We would say that there is a 520
psi pressure differential from the work string to the annulus. If we put the system in
motion, flow would immediately occur from the work string side to the annulus side,
until balance is reached.
A key point to remember is that when balance is achieved, the height of the heavy
side is less than the height of the lighter side. One way to look at it is that it takes
more of the lighter fluid to balance the heavier fluid. Imagine a balance-beam scale.
It would take a huge pile of feathers on one side to balance a small piece of lead on
the other.
14
Types of Pressure
Hydrostatic pressure
<- Pressure exerted by the fluid
column in the wellbore
Formation pressure
<- Hydrostatic pressure exerted
by fluids in the formation
1. Formation pressure is the force exerted by fluids in the formation. Some

engineers also refer to this as Pore pressure or reservoir pressure. Formation
pressure varies with depth and other geologic conditions.
2. Hydrostatic pressure is exerted by the fluid column in the wellbore. 3. Standpipe
pressure is measured at the top of the drill stem. 4.Choke Pressure is Annulus
pressure at the surface in a U-tube well scenario.
15
Types of Formation Pressure
Normal
– Equal to a column of water
– 0.468 psi/ft, 9.0 PPG, or 1.08
SG
Subnormal
– Less than the pressure
exerted by a full column of
water
Abnormal
– Overpressure, geopressure
– Greater than normal pressure
– Up to EMW of 19.9 PPG
Formation pressure varies with the depth of the hole and other geologic conditions.
Formation Pressure can be determined by shut-in drill pipe pressure (SIDPP), or
measured using an MWD recorder or a wireline pressure bomb.
16
Operating Pressures
– Standpipe or tubing pressure

required to move fluid down the
tubing/drill stem
– Annular pressure loss (APL)
Pressure required to move fluid up
the annulus
– Choke pressure
Annulus pressure at the surface in
a U-
U-tube scenario
– Pump circulating pressure
required to circulate fluid through
the entire hole
Includes standpipe, APL, and choke
pressures
slide
17
Circulating Pressure Losses
Friction is resistance to
movement
It takes force to get a stationary
object to move
– Suppose it takes 50 psi to move
fluid up the annulus
When pump is running, it adds 50psi
to the hydrostatic column at bottom
When pump is shut off, BHP is
reduced 50 psi
Annulus pressure loss is the pressure required to move fluid up the annulus. It
typically ranges from 40 to as much as 200 psi. The important thing to remember is
that when the pump is running, the APL is added to BHP. When the pump is shut
off, the 50 psi is no longer available and BHP is reduced by 50 psi. This can be the
difference that allows the well to become ‘underbalanced’ and for a ‘kick’ to occur
(formation fluids enter the wellbore).
18
Example
This is an example of the pressures and pressure losses in an active pumping well.
In a static well, the BHP is 5200 psi (see next slide for calculation).
19
Pressure Calculations
Static Pressure
Hydrostatic pressure at any point in the fluid column
P = TVD x MW x K where
P = pressure, psi (kPa)
K = .052 (.0098)
P = 10,000 ft x 10.0 ppg x .052 = 5,200 psi
We can calculate the hydrostatic pressure exerted by the weight of the fluid column,
considered at any point in the fluid column. Using the example of the previous
slide, the static bottom hole pressure is 5200 psi.
20
Example
1. Circulating pressure losses can exceed 2,400 psi
When the pump is shut off, the surface pressure at the pump is 0 psi and the
surface pressure at the return line is also 0. When the pump is on and the well is
circulating, the surface pressure at the pump is 2,400 psi, but the pressure at the
return line is still zero (unless the well is being controlled with choke back-pressure).
The 2,400 psi of pumping pressure has been expended in moving fluid through the
system: 650 psi friction loss in the work string, 1700 psi through the bit nozzles, and
50 psi to move fluid up the annulus. As the mud spills out of the return line, the
pressure is zero.
If the well were being controlled with the choke, we would add choke back-pressure
to the pumping losses (and the pump pressure would be higher by that same
amount).
We calculated the static BHP as 5200 psi. When the well is pumping, the BHP is
5250 psi (adding the APL).
21
Example
1. Circulating pressure losses can exceed 2,400 psi
2. When the pump stops, annulus BHP is reduced 50 psi
Remember, when the pump stops, BHP is reduced by 50 psi (the annulus pressure
loss).
22
Differential Pressure
A key ‘Differential Pressure’ is the

difference between formation pressure
and bottom-hole hydrostatic pressure in
the well
– Balanced: BHP = formation pressure

– Overbalanced: BHP > formation pressure
– Underbalanced: BHP < formation pressure
‘Differential’ pressure is a comparison of two pressures. The most important

differential pressure is the comparison of formation pressure and bottom-hole
hydrostatic pressure in the wellbore.
23
Outline
1. Pressure and Basic Calculations
» 2. Review: Well Control fundamentals
Hydraulic Workover
24
Kick Fundamentals
A ‘Kick’ is an unwanted flow of formation

fluids into the wellbore
– Water, gas, or oil
– Occurs when well is ‘underbalanced’
BHP is lower than formation pressure
– Inflow will continue until pressure is equalized
– Inflow further reduces BHP
Formation fluids are usually lighter than well fluids
Allowing more inflow, and so on
The most important principle in well control is the definition of a ‘KICK’. A ‘Kick’ is an
unwanted flow of formation fluids into the wellbore. The formation fluids may be
Water, gas, or oil; and it Occurs when well is ‘underbalanced’, that is, BHP is lower
than formation pressure. The TWO most important aspects to remember are that
flow from the formation into the wellbore, unless counter-acted, will continue until
the two pressures are equalized, and that formation fluids are usually lighter than
fluids in the wellbore, and with the introduction of lighter fluids BHP is reduced
further, which allows more inflow, which reduces BHP further, etc etc - it’s a vicious
cycle.
25
Cause of Kicks
Well Control: maintaining

sufficient hydrostatic pressure in
the wellbore to prevent inflow
The cause of a ‘Kick’ is

insufficient hydrostatic pressure
in the wellbore
– Failure to control inflow can lead
to a blowout
26
Reasons for Insufficient
Insufficient fluid weight (density)

Wrong weight mud for conditions
Diluted mud
Changed over to completion fluids
Failure to keep the hole full

As the work string is pulled, the
volume of metal removed must be
replaced with correct fluid
Let’s summarize the ways that hydrostatic pressure can be reduced and a ‘kick’
encountered.
27
Swabbing and Surging

Moving the string too fast or too tight clearance
Swabbing = pulling up
Surging = tripping in
Vacuum or pressure causes balance upset
Lost Circulation ->

If the weight of the fluid column is too great,
formation strength can be overcome
Fluid leaks into weak formation, hydrostatic level
lowered, 2nd formation kicks
28
Abnormal formation pressure

Caused by faulted structures, salt domes, geo-
geo-
pressured shales, underground blowouts
Obstruction in the wellbore

Such as sand bridging or plug, can trap pressure
below the obstruction
29
Equipment failure
Rig and well equipment designed to control
pressures can fail due to corrosion or fatigue
Human Error
Poor judgment, lack of attention, poor training
cause mistakes in well operation
30
Kick Warning Signs
Pit Gain
– Pit-
Pit-level device registers
increase in flow from the
well
The Number One warning sign of formation inflow is called ‘Pit Gain’. Under normal
circumstances, the amount of fluid circulated into the well will equal the volume
coming out. Any increase is almost always due to formation fluid inflow. Any
difference in mud volume is measured by level, volume, or rate measuring devices
in the mud tanks.
31
Kick Warning Signs
Flow Check
– Stop circulating, check for
continued outflow from
well
A surefire way to check for inflow is with a flow check. Simply shut in the mud
pump – if there is flow still coming from the return line, you are experiencing a kick.
32
Kick Warning Signs
Well not taking proper

amount of fill-up during
trip stands
– Stand removal requires
correct volume to replace
metal
– Less ‘fill’
fill’ volume than
normal may indicate inflow
When a stand of pipe is pulled from the well, the fluid level in the well goes down to
reflect the amount of fluid displaced by the pipe. For purposes of well control, it is
important to refill the well when pipe is pulled. The amount refilled should
correspond to the volume displaced by the pipe. If the well takes less to fill up, it
may be an indication that formation fluid is entering the wellbore.
33
Kick Warning Signs
Sudden increase in drilling rate

ROP may increase or decrease as over-
over-
pressured zone is penetrated
Increased Pump speed, but decreased

Pump pressure
Reduced annulus pressure causes imbalance,
pump speeds up
Pump pressure decreases because less weight
to lift in annulus
34
Kick Warning Signs
Change in gas type or gas increase

Requires mud gas detector
Trip gas, gas-
gas-cut mud
Salinity change or water-cut mud

Water inflow from over-
over-pressured zone
Change in flow properties of fluid

Monitor characteristics of mud or completion
fluid
35
Gas behavior in Kicks
For a Gas kick

– Gas is lower density, migrates
up annulus
– Higher it migrates, more it
expands
– More it expands, higher
pressure on annulus
– If not adjusted, increasing gas
pressure can
Exceed casing max rating
Cause ‘Underground Blowout’
Blowout’
If the kick fluids are composed of liquids such as salt water or oil, the kick can be
controlled fairly easily. The real problems in well control arise when the fluids are
gas. As gas migrates up the annulus, it expands as depth (and confining pressure)
becomes less. As the gas expands, it exerts a greater pressure. If not controlled,
the increasing pressure can rupture casing or cause ‘underground blowouts’. We’ll
talk about underground blowouts in a few slides.
36
Gas dissolved at BHP is an

even greater concern
H2S dissolves in water-
water-based mud
Methane dissolves in oil-
oil-based mud
Behaves as liquid, not noticed

until expansion/pressure
increase occurs rapidly at
~3,000 feet
No pit gain etc. until gas is high in
the annulus
Much less time to recognize and
react
An even greater danger is gas DISSOLVED in the drilling fluids. Dissolved gases
don’t show the warning signs of a ‘kick’ until they are near the surface, when they
come out of solution and begin to expand like conventional gas kicks. There is
much less time to recognize and react to a ‘dissolved-gas’ kick.
37
How large an annulus pressure increase due

to gas inflow?
Greater the ‘underbalance’

underbalance’ = higher annulus pressure
Larger kick volume = higher annulus pressure
Lower density of kick = higher annulus pressure
Deeper Well depth = higher annulus pressure
Smaller diameter annulus = higher annulus pressure
These factors affect the amount of annulus pressure increase during gas kicks.
38
If not adjusted and controlled,

rapidly increasing gas pressure
in the annulus can
‘Unload’
Unload’ the hole and cause
surface blowout
Exceed casing max burst rating
Cause ‘Underground Blowout’
Blowout’
39
Underground
Blowout
Increasing gas pressure in
annulus exceeds fracture
pressure of another formation
Usually shallowest, uncased zone
Fracture pressure increases with depth
Causes ‘short circuit’ of gas from

deep zone into shallower zone
Ruins productive zone
Overpressures shallow zone
Can blowout to surface (craters, etc)
In a nutshell, an underground blowout is a pressure increase in the annulus that

causes a fracture in another formation, and allows the gas to flow into the
shallower formation. Is that a problem? Yes indeed, because at the very least you
are draining off the gas in the production zone. Remember that without intervention
the flow will continue indefinitely, until the pressures are equalized. Worst case,
however, is that gas flow to a shallow zone can cause migration to the surface, and
this can lead to uncontrollable fires and even craters under the rig.
40
Underground Blowout
Shallow underground
blowout offshore
Gas migrates to surface
Capsize rig or drillship due to
reduced density of frothy water
Fire risk, can be uncontrolled
Underground Blowouts
very difficult to control
– May require relief well
Offshore, the situation becomes even more critical. Not only is there the risk of fire,
but the reduction in water density due to gas frothing can capsize a drill ship or
platform.
41
Barriers to Kicks
1. The circulating mud system

Mud density must be maintained to ‘overbalance’
overbalance’ the formation
pressure
In the event of a kick, the mud density must be adjusted to meet
the requirements for increased BHP
2. Equipment to shut-in the well

Kelly cock, Annular preventer, BOP stack, choke, etc.
3. ‘Well Control’ techniques to circulate out the kick,

prevent further inflow, and resume safe operation
It’s important to consider the ‘barriers’ that protect us from ‘kicks’. The primary
barrier in any well operation is the ‘overbalance’ provided by drilling or other
workover fluids. The fluid system density can also be changed to prevent or stop
formation fluid inflow. If the primary barrier fails, there is a wide range of equipment
commonly used on rig sites to shut in the well and control inflow. Furthermore, a
series of well control ‘procedures’ have been tested and developed over the years
that allow us to circulate out the kick, prevent additional inflow, and resume normal
operations.
42
Outline
1. Review: Pressure and Basic Calculations

» 3. Review: Well Control Equipment
Hydraulic Workover
In this section, we will review well control equipment.
43
Barriers to Kicks

pressure
2. » Equipment to shut-in the well

Annular preventer, BOP stack, Safety valves, choke
3. ‘Well Control’ techniques to circulate out the kick,

prevent further inflow, and resume safe operation
Well-control equipment is the second barrier we utilize to prevent and control the
inflow of formation fluids.
44
BOP Stack Assemblies
BOP stacks may be

configured in many
different ways
– Typical:
Annular preventer
Pipe rams
Blind rams
API RP53: Blowout

Prevention Equipment
Systems
Blowout Preventers, also called BOPs, are the first thing we think of as well-control
equipment. There are 3 basic types of BOPs: Annular Preventers, Pipe rams, and
Blind rams.
45
BOP stack components
Annular Preventer
– Top of stack
– Can close around casing,

drill pipe, tool joints,
collars, the Kelly,
wireline, and open hole
46
Pipe Ram
– Sized to close around
pipe of a specific
diameter
– Usually several sizes of
pipe and pipe rams
– Will not close on tool
joint
47
Variable-bore pipe Ram

– Sized to close around a
range of pipe diameters
– Primary barrier, or backup

to pipe rams
48
Blind rams
– Features large elements that
close on open hole ->
‘Shear’
Shear’ rams
– Have special blades that can cut
through any size well tubulars in
an emergency
‘Blind-
Blind-Shear’
Shear’ rams ->
– Special blind ram that
incorporates a shear
– Cuts, also seals open hole
49
BOP Operating Units
Hydraulically
operated closing
systems
– 3,000 psi closing
pressure
– Air-
Air-pressurized
cylinders contain
hydraulic fluid
– Control panel ->
on module or rig
floor
The operating module provides the hydraulic pressure to close and open the
blowout preventers. The system consists of several bottles or cylinders (called
‘accumulators’) that contain hydraulic fluid under up to 3000 psi pressure.
Triggered by operating controls on the module or on a remote control panel on the
rig floor, the pressurized fluid provides the force to operate the annular and ram
preventers. As the cylinders are depressurized, an air pump automatically starts to
re-pressurize them.
50
BOP Testing
After assembly, BOPs must be tested

– Usually low pressure (200-300 psi) water test,
followed by high pressure test
– Tests use pipe blanks, cup testers, plugs
– BOPs also tested during well operation
Offshore testing prescribed by regulation

MMS regulations, Part D.250
51
Kelly Cock safety valve
Full-opening safety
valve
– Made up to top of
work string
– Isolates tubing
52
Choke Manifolds
Choke is essential to controlling annulus pressures

– Adjustable choke, Manual or remotely operated
– Remote operation uses panel on rig floor
53
Downhole safety valves
Downhole safety valves

are made up on tubing
– prevent backflow up
tubing from downhole
– Spring-
Spring-type, simple
flapper, and pump-
pump-down
– Also known as ‘bit float’

float’,
‘string float’
float’, and ‘I-bop’
bop’
inside blowout preventer
54
Outline

» 4. Review: Well Control Techniques
Hydraulic Workover
55
Barriers to Kicks

pressure
2. Equipment to shut-in the well

Annular preventer, BOP stack, Safety valves, choke
3. » ‘Well Control’ techniques to circulate out

the kick, prevent further inflow, and resume
safe operation
The third set of barriers to kicks are well-control techniques that circulate out the
kick, prevent further inflow, and resume safe operation.
56
Shut in the well
Once a kick is detected (or suspected),

Shut In the well
If casing set and cemented, shut in is safe step
– Purposes
Stop the inflow from the formation
Protect the crew and rig
Measure key pressures
– SITP and Annulus (casing) pressures
Diagnose and organize the Kill procedure
The first and primary reaction to a kick is to shut in the well. Shutting in can help to
stop the inflow from the formation if the pressures can find equilibrium. Most
important, shutting in serves to protect the crew and rig from the effects of a
possible blowout.
57
Typical shut-in procedures
Fluid being circulated, tubing on bottom

1. Stop pump; check for flow
2. Open the choke
3. Close the annular BOP
4. Close the choke while watching casing
pressure
5. Record tubing and casing pressure
6. Pick up to ensure tool joint is not in BOP
These are the steps in a typical shut-in procedure, when pipe is on bottom and well
is circulating. Note that this procedure uses a ‘soft’ shut-in, in that the choke is
open when the BOP is closed. A ‘hard’ shut-in happens when the choke is closed –
it is a little quicker but increases the risk of fracturing an intermediate formation.
58
Review: Well Control
Techniques
Purposes of shut In
» Measure key pressures
Diagnose and organize the Kill procedure
The second reason to shut in is to allow accurate measurement of key pressures in

the tubing and casing. These pressure measurements allow diagnosis of the kick
and planning to remedy it.
59
Measure Key pressures
Shut-in Tubing Pressure (SITP)

Pumps shut in when kick detected, tubing should
be full of clean fluid
If on bottom, SITP indicates formation pressure
Formation pressure = BHP + SITP
Example: mud weight is 11 ppg, depth 7,040 feet, SITP = 350psi

Hydrostatic = 11 x 7040 x .052 = 4027 psi
Formation pressure = 4027 + 350 = 4377 psi
After the well is shut in, measure the shut-in tubing pressure, also called SIDPP for
‘shut-in drill-pipe pressure’. Whatever you call it, the pressure should stabilize
within 5 minutes or so. SITP is the key to determining the formation pressure that
has caused the ‘overbalance;’ and inflow. If the tubing is on bottom, calculate BHP
from the mud weight, and add the SITP you recorded.
60
Shut-in Tubing Pressure (SITP)

Also use SITP to calculate Kill weight of new mud
Mud increase = SITP ÷ TVD ÷ .052
Example: mud weight is 11 ppg, depth 7040 feet,

SITP = 350psi
Mud increase = 350 ÷ 7040 ÷ .052 = 0.96 ppg

Kill Mud = 11 ppg + 0.96 ppg = 12 ppg
SITP also allows a calculation for a new mud weight to counteract the formation
pressure and bring the situation back into balance.
61
Low or No SITP
– Reasons
Gauges shut off
Float or safety valve in tubing
Gauge scale too high
Well has no or little pressure
Open choke and see if annulus flows

If not, try to circulate small amount
If there is no SITP shown on the standpipe gauge, try these actions to diagnose the
problem.
62
Shut-in Casing Pressure (SICP)

SICP reflects annulus, which contains the kick
fluids
SICP can indicate the density of the kick (gas, oil,

or water) but requires accurate measurement of
kick volume (pit level increase, etc.)
– Best practice is to assume kick is gas
Rising SICP may indicate gas percolating up

annulus
– or low-
low-permeability formation
SICP, or annulus pressure, should also be measured, and there are several
methods to try to calculate the ‘kick density’, that is whether oil, gas, or water.
Almost all company procedures require that you treat EVERY kick as gas, however,
and take the appropriate actions instead of trying to calculate a density.
63
Techniques
Purposes of shut In
Measure key pressures
» Diagnose and organize the Kill procedure
The third step for shut-in is to allow you to diagnose and organize the procedures to
bring the well back into balance with formation pressure.
64
Techniques
Three methods of circulating out the kick, but

all have similarities
Constant bottom-
bottom-hole pressure (BHP) must be
maintained
Constant BHP is maintained by circulating at a
constant pump rate, and
Adjust the choke to maintain constant BHP
Possible to shut in at any time without jeopardizing the
well
Let’s review the basics of well-control techniques and procedures. Conventional

well-control practice recognizes three basic methods of circulating out a kick and
bringing the well back into balance with formation pressure. The methods are
called the ‘Driller’s’ method. The ‘Wait and Weight’ method, and the ‘Concurrent’
method. Rather than spend our time graphing and calculating each method, our
review will concentrate more on the characteristics of the methods, and how they
are similar (and different). I’ll also try to point out the advantages and
disadvantages to each one.
65
Techniques
Three ‘Control’ methods have similarities

Shut in, record SITP and SICP
SITP added to KRP* to determine ICP, the Initial
Circulating Pressure
Constant BHP maintained by circulating at constant
pump speed and by adjusting the choke
* predetermined ‘kill rate’

rate’ pressure of pump, at
reduced pumping rate
66
Techniques
Main difference between the 3 methods:

– How and When ‘kill-weight mud’ is pumped
Driller’
Driller’s method: kick circulated out with same mud
that was in the well when kick occurred, then KWM is
circulated
Wait & Weight method: kick is circulated out at the
same time KWM is pumped in
Concurrent method: increase mud weight in steps,
recalculate circulating pressures each step, until final
KWM is achieved
The basic objective of all control methods is to bring the well back into balance with
formation pressure. To achieve that balance, a new mud weight is necessary to
provide the additional BHP to counteract the new formation pressure that caused
the kick. The new mud of increased density is called ‘Kill-Weight Mud’.
67
Techniques
Driller’s method
– Hold casing pressure
constant as pump is
brought up to ‘kill rate’
rate’, to
determine ICP
– Pump at kill rate, holding
FTP constant using choke
adjustment
– Calculate KWM, tubing
capacity, strokes to bit
Here are the basics of the Driller’s method. A worksheet is used to calculate the
key parameters of the circulating program.
68
Techniques
Driller’s method
– Advantages
Simple, few calculations
Circulation starts immediately
– Disadvantages
Highest surface pressures if gas kick
– KWM not used to circulate kick; all control pressure is
choke pressure
– Highest risk of ‘Underground Blowout’
Blowout’
Longest time to kill (2 complete circulations)
69
Techniques
‘Wait & Weight’ method
– Prepare Kill-
Kill-weight mud
– Circulate KWM as kick
circulated out
– Constant pump rate,
rate, but
pump pressure decreases as
heavier mud replaces lighter
– Casing pressure increases as
kick circulated, but BHP kept
constant using choke
Graph of DPP versus time,
DPP corrected with choke
The ‘Wait and Weight’ method uses a combination approach – the mud weight is
increased to kill weight and pumping begins. As the new mud displaces the older,
lighter mud in tubing, the BHP increases gradually and proportionally.
70
Techniques
‘Wait & Weight’ method

– Advantages
Potential for lower surface pressures if gas kick
Shorter time until kick is circulated out
– Disadvantages
‘Wait’
Wait’ for full load of KWM to be mixed
More complex procedure to design and operate
The name of the method comes from having to ‘Wait’ to mix an entire new batch of
kill-weight mud (‘Weight’) before pumping starts.
71
Techniques
‘Concurrent’ method
– Combination of ‘Driller’
Driller’s and ‘Wait’
Wait’
Mud weighted up in series of steps,
rather than KWM all at once (as in
‘Wait’
Wait’ method)
– Constant pump rate,
rate, but pump
pressure decreases as heavier
mud replaces lighter
Graph of DPP versus time is
complicated by periodic increases in
mud weight
– Casing pressure increases as kick
circulated, but BHP kept constant
using choke
Projected DPP corrected with choke
The concurrent method is a combination of the Driller’s and ‘Wait/Weight’ methods.
72
Techniques
‘Concurrent’ method
– Advantages
Starts sooner than ‘Wait’
Wait’ method
Potential for less surface pressure than ‘Driller’
Driller’s but
not as good as ‘Wait’
Wait’
– Disadvantages
Even more complicated to design and operate than
‘Wait’
Wait’ method
Mud weighting in steps must not compromise mud
quality
73
Techniques
Additional control methods

– Volumetric (gas kick only)
Controls BHP and surface pressures when no pipe is
in the hole or when well cannot be circulated
– As SICP rises, mud is bled off (or pumped into) the annulus
using a calculated psi/bbl relationship
– Reverse Circulation
Circulates down annulus, up tubing
Better control of surface pressures in drill pipe
Circulating up through bit jets is slow, maybe slower
than gas percolation in annulus
There are several modifications and additions to the 3 control methods. The most
common are these two.
74
Techniques
Special Considerations
– Pipe off bottom (or out of hole)
Run pipe in, by stripping or snubbing (next slide)
– Off-bottom Kill
KWM calculated using TVD to bottom of tubing,
not bottom of hole (results in heavier mud)
More risk of lost circulation, underground blowout
If a kick occurs when the pipe is off-bottom, most procedures specify that pipe be
run into the hole to bottom. For a kick that occurs when the pipe is not on bottom,
the procedures are the same except that the density of the kill mud is calculated to
the bottom of tubing, not to total well depth. Off-bottom kills are more risky than
having the pipe on the bottom, because there is more hole exposed to potential
inflow and the risk of fracturing an intermediate formation is greater.
75
Stripping and Snubbing
Stripping: running pipe into

the well under pressure
Annular preventer or rams are
primary barrier
Snubbing: pipe is ‘light’,

must be mechanically forced
into well
Upward-
Upward-acting BHP greater than
weight of pipe
Snubbing is slow
If a kick occurs when the pipe is off-bottom, most procedures specify that pipe be
run into the hole to bottom. If there is not enough pipe in the hole to ‘pull’ it down
against pressure by using the weight of the pipe, then a ‘Pipe Light’ scenario
occurs. In a ‘pipe light’ situation, BHP is sufficient to force or float the pipe out of
the well. In this situation, it becomes necessary to ‘Snub’ the pipe, mechanically
force the pipe downward into the hole against a greater, upward-acting pressure.
76
Outline

2. Review: Well Control Fundamentals
» 5. Completion and Workover operations
Hydraulic Workover
The following section is a summary of workover and completion operations, and the
well-control aspects associated with each.
77
Completion and Workover
Completion
Preparing a well to produce oil and gas
Establishes one or more flow paths for the efficient
production of reservoir fluids
Workover
After completion, any operation to restore or
increase production, or to abandon temporarily or
permanently
Completion is performed once, before the well is put into service. After the well is
initially completed, workovers may be necessary to repair the well, restore or
increase productivity, or abandon the well.
78
Types of Completions
Conventional
– Casing set and
cemented through pay
zone
– Perforated casing
– Packer on tubing, set
above pay zone
– 75% of onshore wells
A so-called conventional completion is used in 75% or more of onshore wells.
79
Packer
– Mechanical device with
sealing element
– Seals OD of tubing to ID
of casing
– Creates ‘tubing-
tubing-casing’
casing’
annulus, usually filled
with corrosion-
corrosion-inhibiting
fluid
‘annulus’
annulus’ or ‘packer’
packer’ fluid
80
Dual completion
– Separate flow paths for
2 pay zones in one well
– Casing set and
cemented through 2 pay
zones, perforated
– 2 tubing strings
– Dual-
Dual-string and single
packers, set above pay
zones
As we’ll see in detail in the following section, a ‘Blast joint’ is specially reinforced
pipe, to resist the abrasion effects of sand produced from the shallower production
zone.
81
‘Annular’ Dual completion

– Separate flow paths for 2 pay
zones in one well
– Casing set and cemented
through 2 pay zones,
perforated
– Only 1 tubing string
– 1 packer, set between zones
– Upper zone production is up
annulus, lower through tubing
82
Tubingless completions
– Open hole (‘
(‘barefoot’
barefoot’) ->
– Cased hole perforated (below)
– No tubing or packer,
production flow is up casing
– Casing as small as 3.5”
3.5”
– Sometimes ‘packerless’
packerless’
Has tubing, but no packer
83
Pumping wells
‘Sucker rod’
rod’ pump completion
– Conventional completion with

tubing anchor
Minimizes tubing movement
– Pump may be run on tubing or

on ‘rods’
rods’ set inside tubing
– Completion similar for

downhole electric or hydraulic
pumps
84
Gas Lift completion

– Conventional, oil flow through
tubing set on packer
– Gas-
Gas-lift valves run on tubing
– Gas injected down the
annulus, through the gas-
gas-lift
valves, and into tubing
– Reduced density causes oil to
flow to surface
85
HPHT ‘Treater’ string

For high-
high-corrosion environments
(or sometimes diluent injection for
heavy oil)
– Separate tubing string run
inside tubing for treatment
injection
Intermittent or continuous
May be ‘kill’
kill’ string for hi pressure
– In extreme cases, may be dual

completion with one string for
treating only
86
Workover objectives
Control water, gas, or sand production
Repair mechanical problems
Stimulate the reservoir and increase production
Re-
Re-complete into additional or new reservoir
Plug and Abandon (‘(‘P&A’
P&A’) the well
Completion is performed once, before the well is put into service. After the well is
initially completed, workovers may be necessary to repair the well, restore or
increase productivity, or abandon the well.
87
Workover
Controlling water production
– Static: separate oil and water zones
– Depleted, low rate production:

water can be sucked into oil-
oil-wet
zone
– Depleted, higher rate: water flows

in preference to oil as area near
wellbore becomes water-
water-wet
During the life of an oil well, the interface between oil and water zones may change
(or the well may have been improperly completed from the beginning). A common
scenario is ‘up-coning’ of the oil-water interface due to changes in reservoir
pressure or increased production rates. Once water has ‘wetted’ the pores near the
wellbore, water will be produced in preference to oil. The oil is still there - It just
can’t flow into the wellbore. Workover solutions usually involve treatment chemicals
to restore oil permeability, squeeze-cementing the lower perforations, or re-
completing the well higher in the zone.
88
Workover
Controlling gas production
– Static: separate gas, oil, and

water zones
– Depleted: gas sucked down into

perforations
Producing gas in an oil well uses up
reservoir energy that allows oil to
flow to well and be produced, lifted
Similarly, the interface between gas and oil zones may change with time and
production. A common scenario is gas short-circuiting to the oil perforations.
Workover usually involves squeeze-cementing the upper perforations or re-
completing the well lower in the oil zone.
89
Workover
Controlling sand production

– Production of sand a major
problem in some areas, some
reservoirs
– Cleanout involves washing in
with hi-
hi-gel fluid
– Recompletion techniques to
prevent sand inflow
Simple perforation allows sand
into wellbore
Gravel-
Gravel-packing most common
90
Basic Workover operations

Perforating
Remedial cementing and squeeze-
squeeze-cementing
Drill stem testing
Acidizing and fracturing
Cleanout and sand control
Plugging back, deepening, or side-
side-tracking
Plugging
91
Workover
Perforating
– Completion or workover
– Primary tool for water
control
– Jet-
Jet-charge guns run on
wireline, coiled tubing, or
tubing
– ‘Underbalance’
Underbalance’ BHP during
perforating
92
Workover
Squeeze cementing
– Excludes water or gas zones from the well
– Allows a new zone to be completed
– Repairs damaged or corroded casing
– Correct problems with the primary cement
job
– Squeezed through perforations to emplace
behind casing
93
Workover
Squeeze cementing
– Usually special squeeze-
squeeze-
tool run on work string
– Has packer(s) to isolate
zone in casing
– Tool positioned above or
astride zone to be
cemented
– Cement pumped, then
excess reversed out
94
Workover
Types of ‘Squeeze jobs’

– Standard packer squeeze ->
– Bradenhead squeeze
No packer or squeeze-
squeeze-tool,
cement set in casing
– Bullhead squeeze
Uses packer, all fluids into zone
– Set-
Set-through squeeze
Cement washed out of casing
– Circulation squeeze
Packer set between 2 sets of
perfs, circulation established first
95
Workover
Drill-stem testing
– Setting a temporary completion to determine the productivity of a zone
– Zone isolated with packer and downhole valve
– Flow to surface, then valve closed and pressure build-
build-up recorded
96
Workover
Acidizing
– Clean up mud invasion and/or dissolve minerals to
improve zone permeability near the wellbore
– Inject acid below fracture pressure (matrix Acidizing),

or above (Acid-
(Acid-fracturing)
– Acids: hydrochloric (HCl), hydrofluoric (HF), acetic and

formic acids (H or CH3 COOH)
97
Workover
Fracturing
– Pumping fluid into a zone
until the fracture pressure is
exceeded; zone ‘breaks
down’
down’ and fracture created
– Fracture then filled with
plastic beads or sand to
‘prop’
prop’ open
– Fractures are vertical and
extend from the wellbore as
‘wings’
wings’
– Radical increase in drainage
and permeability near well
98
Workover
Sand control
– Production of sand a major
problem in some areas,
some reservoirs
– Cleanout involves washing
in with hi-
hi-gel fluid
– Recompletion techniques
to prevent sand inflow
Simple perforation allows
sand into wellbore
Gravel-
Gravel-packing most
common
99
Sand control
Some completions use screen or slotted liner only
Screen liner with gravel pack
Perfs washed to remove sand; sized gravel or beads
pumped to bottom; screen or slotted liner washed in
100
Workover
Plugback
– Moving the producing interval from a deeper to a
shallower one
– Wellbore below the new zone is plugged and
abandoned
Old perforations squeezed off
Cement plug and/or permanent packer to ‘plug-
plug-back’
back’ depth
(new well TD)
Deepening
– Upper perfs squeezed off, new zone drilled out
– Liner hung and cemented off old casing
– New, deeper zone perforated and put on production
101
Workover
Sidetracking
– Another way to abandon or
bypass the lower part of a well
Damaged casing, permanent
junk, or skin-
skin-damaged zone
– Cut casing window, then a
whipstock packer used to
direct drilling off-
off-axis
– Plugback old well; liner hung
and cemented off old casing
– New zone perforated and put
on production
What’s wrong with this picture?
102
Workover
Plugging
– Well abandoned for mechanical or
economic reasons
– All States have plugging regs and
requirements
– Perforations squeezed
– Plugs set to prevent:
Migration from one zone to another
in the wellbore
Contamination of freshwater
Blowouts after casing deteriorates
103
Outline

» 6. Fluid systems used in workover and
completion
8. Conventional, wireline, Coiled Tubing, and Hydraulic
Workover
The fluids used in workover and completion include water- and oil-based muds, as
well as a variety of brines, foams, and treating chemicals.
104
Fluid systems
Workover fluids
For perforating, cementing, fracturing etc
Gases, brines, muds, acids, gels, foams, etc.
Packer fluids
Annulus fluids that are non-
non-corrosive, may feature
other properties; must be stable for life of well
Completion fluids
Designed to prevent damage to formation
permeability during completion
105
Fluid systems
Fluid characteristics
Dense enough to control well pressures, but not so
heavy to fracture formation
Cost effective; many fluids available for different
purposes
Non-
Non-corrosive, non-
non-reactive, stable
Free of solids
Not hazardous to personnel if handled correctly
106
Fluid functions
Circulate materials
IN: cement, pills, gravel and sand, frac materials
Out: used cement, cuttings, debris and sand, etc.
Suspension of materials when circulation stops

High gel strength resists settling of solids, BUT
High gel strength develops high swab pressures
– Most materials reverse-
reverse-circulated out
Pressure control
Well must be killed for workover or completion
107
Fluid functions (cont’d)
Heat removal and Lubrication

For bits, mills, and downhole motors
Special Tool functions

Underbalance; hydraulic energy; special logging fluids
Avoiding Formation damage

Solids free, non-
non-reactive, non-
non-wetting, clay compatible
108
Types of Fluids
Oil Fluid systems

– Lease crude
Plentiful and economic to use
Non-
Non-reactive, no clay swelling, non-
non-wetting
May have solids (wax, paraffin, or sand)
May be corrosive (if H2S or CO2 present)
About 7 ppg: perfect for depleted wells, too light for
others?
– Diesel and kerosene
Inexpensive; cleaner and lighter; but fire hazard
The most common workover fluid in oil wells is lease crude.
109
Types of Fluids
Oil-Emulsion fluids
– Oil-in-water emulsion commonly uses diesel
Emulsifying agents make stable
Heavier than diesel, but still non-
non-reactive and
formation-
formation-friendly
– ‘Inverse’ emulsion is water droplets in oil
More physically stable, but breaks down over 200°
200° F
Gases as completion fluids

– Natural gas or nitrogen
110
Types of Fluids
Water-based fluids
– Brines
Sodium, calcium, and
potassium chloride salts
Calcium and zinc bromide
add weight to solutions for
pressure control
Salt saturation can cause
crystals to form
– Muds
Inexpensive but solids a problem
Brines make an excellent completion and workover fluid, and they are very
inexpensive and easy to produce and handle. Bromide salts allow the brine to be
‘weighted’ for pressure control and killing the well initially.
111
Types of Fluids
Water-based fluids
– Acids
Water-
Water-diluted acids (5% - 25%) for permeability
enhancement near wellbore
– Hydrochloric (HCl) dissolves limestone (and carbonate
cements in sandstones)
– Hydrofluoric (HF), called ‘mud acid’
acid’, dissolves mud-
mud-solids
invasion of pores
– Acetic and formic acids (H or CH3 COOH) dissolve asphalts,
paraffin, and other oil solids blocking pores
Gelled acids for acid-

acid-fracturing
– Gelling agent improves viscosity for better frac hydraulics
112
Types of Fluids
Water-based fluids
– Foams
Requires ‘foaming agent’
agent’
Foam is an emulsion; fluids
uniformly distributed, do not
separate easily
Has structure and strength:
– bubbles of gas surrounded by
liquid film
– water around gas forms 12-
12-sided
structure (deforms but does not
shear when pumped)
113
Foam fluid systems
Light weight (2-5 ppg)

– Underbalanced so no
formation damage
Foam has exceptional
solids-lifting capacity
Foam ‘structure’
structure’ is reason
– Best lifting: 50% - 90%
gas
– High lifting cap. means low
annulus velocity
Compared to water and mud, foam has a much higher capacity to lift cuttings, sand,
and debris. This enhanced capacity is probably due to the unique structure of the
water molecules in foams, which deforms during flow but does not shear. A greater
capacity to lift solids means that a lower pumping rate and lower annular velocity is
necessary to lift cuttings. Typical pumping rates in foam systems are as low as 20
gallons per minute of water and 266 cubic feet of gas per minute to achieve normal
120 feet per minute annular velocity, 10-times better hydraulic performance than a
typical mud system.
114
Types of Fluids
Plugs and Pills

– Dense fluid/solid mixtures, used to
Seal (temporarily) casing leaks
Correct injection profile
Stop lost circulation
Divert acid, stop water flows
Block flow inside tubing or casing
Stabilize unconsolidated zones
Seal fractures and thief zones during cementing
Kill underground blowouts
Plugs and pills are dense fluid/solid mixtures. They are ‘spotted’ into tubing, casing,
or open-hole and act like temporary plugs to control flow or pressure.
115
Types of Fluids
Plugs and Pills

– ‘Soft’ Plugs (pumpable)
Neat cement mixture
Oil-
Oil-based mud with cement thickener
Diesel-
Diesel-cement mixture
Diesel-
Diesel-bentonite mixture
Bentonite-
Bentonite-cement mixture
Polymer/plastics/silica mixtures
May also include lost-
lost-circulation or weighting materials
and viscosifiers to make denser
116
Types of Fluids
‘Soft’
Soft’ Plugs (pumpable): Examples of polymer gel plugs
117
Types of Fluids
Plugs and Pills

– ‘Hard’ Plugs (‘setting’ plugs)
Usually 1 to 5 barrels volume
Accelerant speeds up setting time
Time-
Time-delayed, self-
self-complexing (polymer) plug
Sometime a ‘breaker’
breaker’ enzyme added to polymers for
predictable breakdown time (1-(1-10 days)
Example: macaroni string run in tubing, ‘packed off’
off’
with flash-
flash-set, weighted polymer plug; when the
macaroni string is pulled, the polymer plug ‘heals’
heals’ and
blocks flow until breakdown
118
Types of Fluids
Packer fluids
Provides formation pressure control
Prevents casing collapse, tubing burst
Prevents corrosion, stable for life of well
Compatible with seal elements
– Typical fluids
Brines with commercial additives (75%)
Diesel or crude oil
119
Outline

»7. Production equipment and pressure control
8. Conventional, wireline, coiled tubing, and
Hydraulic workover
120
Production
pressure control
Pressure control tools and

devices
– Surface
Trees, pumps, lines, controls
– Subsurface
downhole safety valves, mandrels,
packers, nipples, subs, and guides
– Some equipment installed and
left; others used only
temporarily during workover
This is a particularly complicated assembly used for workover operations, but it

basically uses ‘one of everything’.
121
Production pressure
control equipment
Christmas Tree
First device
encountered
during workover
Assembly of
valves, spools, and
flanges that
control pressure
and the flow of
fluids from the well
122
Wellhead
Christmas tree
– Control assembly set
above the ‘wellhead’
Wellhead consists of:

– ‘casinghead’ body, which
encloses the casing
hanger assembly
– ‘tubinghead’ body, which
supports the tubing
hanger
123
Wellhead
Casing hanger
Slips-
Slips-and-
and-seal assembly
from which the casing
string is suspended
Tubing hanger
Suspends the tubing
string, seals off the
upper casing annulus,
and allows flow to the
tree
Valves
Allow access to casing
and tubing annuli
124
Component
parts of
a wellhead
125
Component Heads and
Hangers
Casing Tubing
126
Wellhead
Casing hanger
Slips-
Slips-and-
and-seal
assembly from which
the casing string is
suspended
Tubing hanger
Suspends the tubing
string, seals off the
upper casing
annulus, and allows
flow to the tree
127
Christmas Tree
Master valve
Primary shut-
shut-off valve
Wing valve
Flow control valve
Choke
Adjusts the amount of
flow from the well
Crown or swab valve
Allows access for
wireline etc.
128
Removing the Tree
In many workover operations,

the tree must be removed for rig
access
– Tree is pressure-
pressure-control barrier
Typical Steps
– Check for tubing-
tubing-casing annulus
isolation
– Pump kill fluid to bottom of tubing
– Set wireline plug in tubing
– Remove the tree and install BOP
stack
129
Casing
A well’s construction
program usually consists of
several sizes and lengths of
steel casing
– Casing is run from the surface
(and cemented)
– Liners are ‘hung’

hung’ in casing and
do not extend to the surface
130
Liners
Liners are suspended in casing

using a ‘liner hanger’
– Mechanical or hydraulic slips
– Usually cemented in place
– Run for various reasons:
Simply shorter, it’
it’s cheaper than
a full casing string
Isolate unexpected problems
encountered during drilling, such
as lost circulation zone or high
pressure formation
131
Tubing and packer
Tubing
– Conducts flow from pay zone to surface
– May be pulled for workover, replaced
with ‘work string’
string’
Packer
– Mechanical device with sealing element
– Seals OD of tubing to ID of casing
– Creates tubing-
tubing-casing annulus, usually
filled with corrosion-
corrosion-inhibiting fluid
‘annulus’
annulus’ or ‘packer’
packer’ fluid
132
Removal of Packers
Retrievable Packers
– For workover, packer is removed
using
Hydraulic: hydraulic pressure to
seat/unseat
Mechanical: rotation and/or pull
Wireline and slickline: set and
retrieved using remote methods
Permanent Packers
– Must be milled out
133
Seal Nipples
Run on bottom of tubing

string to latch into packer
– Positive seal to prevent fluid
leaks at packer/tubing union
134
Bridge Plug
Set in tubing or casing to

isolate a zone, prevent fluid
movement
– May be permanent or
retrievable
– May be run on tubing or
wireline
– Set and retrieved similar to
packers
135
Miscellaneous tools
Blast Joint ->

In multiple
completions,
protects the
tubing that is
opposite the
upper completion
Safety Joint
Quick-
Quick-release tool
Back off or shear,
releases stuck
tools
136
Miscellaneous
tools
Sliding Sleeve ->
– Wireline-
Wireline-actuated port that
allows circulating from
tubing into casing
– For treatment, well kill, etc.
Mandrels
– Usually for gas lift, allows
injection from casing into
tubing
– Usually several at bottom
in gas-
gas-lift well
137
Miscellaneous tools
Landing and Seating nipples

– Small sub run in tubing in which flow-
flow-
control and pressure-
pressure-control devices
can be installed by wireline
– Devices:
Blanking plug for well shut-
shut-in or pressure
test
Equalizing check valves
Safety valves
Chokes (to reduce surface flow)
Instrument hangers
– Landing nipples have latching device
138
Miscellaneous
tools
Sliding Sleeve ->
– Wireline-
Wireline-actuated port that
allows circulating from
tubing into casing
– For treatment, well kill, etc.
Mandrels
– Usually for gas lift, allows
injection from casing into
tubing
– Usually several at bottom
in gas-
gas-lift well
139
Miscellaneous tools
Cement retainers and

squeeze tools
– Used for squeeze cementing
or to isolate casing
– Set on tubing or wireline
– Incorporate a packer plus
up/down flow valve and ports
– Squeeze tool is retrievable,
retainer must be milled out
Cement retainer ->
140
Miscellaneous tools
Circulating Wash tool

– Straddle-
Straddle-packers allow zone isolation,
testing, or acidizing
– Circulating ports can open between
tubing and casing
Can reverse sand or debris from well
141
Miscellaneous tools
Packer mills
– For removal of ‘permanent’
permanent’
packers and cement retainers
– Cuts only the packer slips
– A ‘picker’
picker’ latches into the
packer body for retrieval
Junk and Boot baskets ->

– Collects debris from milling
operations
– Junk basket run separately
on tubing; boot basket run
above mill
142
Outline
» 8. Conventional, Wireline, Coiled Tubing, and
Hydraulic Workover
143
Conventional workover rig
Self-propelled
(highway or barge)
Capabilities:
– Pressure control
– Tripping
– Rotate
– Circulate
144
Hoisting system
– Derrick
– Drawworks
– Crown block
– Traveling block
– Wire rope
– Hook and elevators
145
Rotating systems
– Rotation necessary to
Drill cement
Place packers or plugs
Mill
Fish
Set downhole tools
Conventional Rotary table
146
Rotating systems (cont’d)

Top drive
– Many newer workover rigs
feature top-
top-drive technology
– Advantages
No KB rotating on floor
Break out work string in 2-
2- or 3-
3-
joint stands
– Faster, safer, better pressure
control
Rapid response to kicks
– Stab in and spin up
147
Rotating systems (cont’d)
Power swivel
– Light duty workover
operations
– May use rig’
rig’s hydraulic
system or portable power
unit
Skid or trailer mounted
148
Circulating system
– Pumps
– Lines
– Standpipe
– Rotary hose
– Swivel
– Kelley
– Shale shaker
– Tanks and/or pits
– manifolds
149
Conventional rig pressure
control
BOP stacks may be

configured in many
different ways
– Typical:
Annular preventer
Pipe rams
Blind rams
API RP53: Blowout

Prevention Equipment
Systems
150
Annular Preventer
– Top of stack
– Can close around casing,

drill pipe, tool joints,
collars, the Kelly,
wireline, and open hole
151
Pipe Ram
– Sized to close around
pipe of a specific
diameter
– Usually several sizes
pipe/pipe rams
– Will not close on tool
joint
152
Variable-bore pipe Ram

– Sized to close around a
range of diameters of pipe
– Primary barrier, or backup

to pipe rams
153
Blind rams
– Features large elements that
close on open hole ->
‘Shear’
Shear’ rams
– Have special blades that can cut
through any size well tubulars in
an emergency
‘Blind-
Blind-Shear’
Shear’ rams ->
– Special blind ram that
incorporates a shear
Cuts, and seals open hole
154
BOP Operating Units
Hydraulically
operated closing
systems
– 3,000 psi closing
pressure
– Air-
Air-pressurized
cylinders contain
hydraulic fluid
– Control panel ->
on module or rig
floor
The operating module provides the hydraulic pressure to close and open the
blowout preventers. The system consists of several bottles or cylinders (called
‘accumulators’) that contain hydraulic fluid under up to 3000 psi pressure.
Triggered by operating controls on the module or on a remote control panel on the
rig floor, the pressurized fluid provides the force to operate the annular and ram
preventers. As the cylinders are depressurized, an air pump automatically starts to
re-pressurize them.
155
BOP Testing
After assembly, BOPs must be tested

– Usually low pressure (200-300 psi) water test,
followed by high pressure test
– Tests use pipe blanks, cup testers, plugs
– BOPs also tested during well operation
Offshore testing prescribed by regulation

MMS regulations, Part D.250
156
Kelly Cock safety valve
Full-opening safety
valve
– Made up to top of
work string
– Isolates tubing
157
Choke Manifolds
Choke is essential to controlling annulus pressures

– Adjustable choke, Manual or remotely operated
– Remote operation uses panel on rig floor
158
Wireline workover
Electric or ‘slick’ line

Capabilities:
– No tripping (wire only)
– No rotate or circulate
Advantages
– Faster, cheaper, self-
self-
contained
159
Wireline workover
Wireline workovers
– Setting and retrieving equipment
gas lift valves, chokes, plugs, packers, etc.
– Fishing and jarring
– Logging and sampling
– Perforating
– Spot treating or spot cementing
Wireline ‘basket’
basket’ dumps chemicals or cement
at selected interval
– Bailing and paraffin cutting
Sand bailer at right ->
160
Wireline workover
Wireline pressure control

– Lubricator assembly
Stuffing box seals wireline against
well pressure
Riser joints sufficient length for
workover tools
Valves and unions
– Lubricator assembly also may be
used with wireline BOP
161
Wireline workover
Wireline pressure control

– Lubricators have limited
pressure control rating
Wireline BOPs
– Hydraulic or screw-
screw-type
Rams close on wireline
– Allow workover under
pressure
162
Coiled Tubing workover
Coiled Tubing unit

– Continuous length of ½”
to 3½”
3½” OD tubing on
reel
– Tubing injector moves
the pipe in or out of the
well
163
Capabilities:
– Tripping (no connections)
– Circulate
– No rotate BUT downhole
rotating tools are available
Advantages
self-
contained
164
Advantages (cont’d)
– Because it is not jointed,
coiled tubing can be run at
much faster speeds into or
out of a well
– Fluid can be circulated

through the tubing while it
is being inserted into or
withdrawn from a well;
allows for work on a
pressurized well without the
need to kill the well
165
Disadvantages of coiled
tubing
– Only light drilling
– Tubing sizes limited
– Tubing collapse and
yield strength low
– In gas and H2S
environments, potential
for gas-
gas-filled tubing on
reel
166
Coiled tubing workovers

– Sand washing, cleanouts, and
jetting
– Acidizing and chemical
treatment using packers
Advantage: can be done
‘underbalanced’
underbalanced’
– Cementing
– Light drilling and milling
Using downhole motor
– Fracturing ->
167
CT pressure control
– Injector head
pulls/pushes tubing,
not reel
– Stripper assembly
Seal elements surround
the tubing, hydraulic
force provides seal
– BOP stack
Blind, cutter, slip, and
pipe rams
168
CT BOP – typical 15K ‘Quad
stack’
Injector Head
Stripper 2 9/16” 10m
CB34 Union 3 1/16” 10m

Side Door Stripper 3 1/6” 10 m
Flange 3 1/16” 15 m BX 153
Quad BOPs 3 1/16” 15m
Flange 3 1/6” 15m BX 154
Drill Spool 3 1/6” 15m flanges top/bottom

2 1/6” 15m flanges top/bottom
Single BOP 3 1/6” 15m
169
Hydraulic Workover Unit
Aka ‘Snubbing Unit’

Capabilities:
– Tripping
– Circulate
– Rotate
Advantages
self-contained
– allows for work on a
pressurized well without the
need to kill the well
170
Advantages (cont’d)
– Heavier pipe than CT
unit
– Rotary table for drilling
Disadvantages
– Slower trips, because
all pipe must be
snubbed into well
– Procedures generally
more complicated
171
HWO workovers
– Fishing and milling
– Drilling cement and bridge plugs
– Acidizing, jetting, and chemical
treating
– Squeeze cementing, plugback, and
P&A
– Sand washing and consolidation
treatments
– Perforating (underbalanced)
172
HWO pressure control

– Stripper assembly
Sealing elements for
well pressure less than
3000 psi
Hydraulically or
mechanically applied
– Blowout preventer
stack
173
Typical HWO BOP stack

– HWO stack may be
installed on wellhead,
Christmas tree, or on top
of another BOP stack
– Two Stripper rams plus

pipe (safety), blind/shear,
and slip-
slip-type rams
– Equalizing loop
Adjusts pressure between
stripper rams
174
Outline

Hydraulic Workover
» 9. Well control situations during workovers
175
Well control during
workovers
Work string off-bottom
Quicker reaction means less difficult situation
1. Open the annulus and stab/close the

workstring safety valve, then close BOPs
2. Strip pipe to bottom
Control kick using original fluid, or
3. If stripping not possible, control the kick using
heavier weight fluid
Calculate kill weight using tubing length, not TVD
A Full opening workstring safety valve and inside BOP/Gray valve

must be available on rig floor at all times during workover operations.
176
Well control during
workovers
Stripping in using an annular preventer
1. Adjust closing pressure to a minimum, so

that element weeps fluid slightly
2. Run pipe in no faster than 1 ft/sec
3. Maintain constant SICP with choke
If gas is migrating up the hole, bleed pressure using the
volumetric method of Section 4
4. Every stand should displace fluid; if not,
circulation has been lost
177
Well control during
workovers
Stripping in using RAM preventers
1. Measure carefully between the pipe rams, and adjust
closing pressures to 500 psi or less
2. With upper ram closed, lower the pipe until the tool
joint is 2 feet above the upper ram
3. Close the lower ram; bleed off the pressure between
the upper and lower rams
4. Lower the pipe until the tool joint is between the 2
rams; stop lowering and close the upper ram
5. Pressure up the space between the rams to well
pressure, and open the bottom ram.
6. Repeat steps 2- 2-5.
RAM preventers can be used for pipe stripping if annulus pressure is too high to
allow using an annular preventer, if rubbers on the tubing cannot be removed, or if
an annular preventer is inoperable or not available.
As in the method using an annular preventer, Maintain a constant SICP with choke.
If gas is migrating up the hole, bleed pressure using the volumetric method of Section 4. Every
stand should displace fluid; if not, circulation has been lost.
178
Well control during
workovers
Work string out of the well
1. Shut in well. Record SICP every 15 minutes.

2. Make preparations for stripping or snubbing
pipe in hole (see previous procedures).
3. If SICP is rising, bleed fluid from the annulus
using the volumetric method of Section 4.
179
Well control during
workovers
Hole in work string during kick circulation
FTP decreases but no decrease in FCP
Closing choke causes higher FCP but little
increase in FTP; higher FCP may cause other
problems
Hole exposes the tubing to pressure in
annulus
1. Is hole above or below kick fluids?
180
Well control during
workovers
(cont’d)
1. Is hole above or below kick fluids?
If above kick, it may be difficult (or impossible) to
maintain constant BHP
Hole exposes the tubing to pressure in annulus
– If SITP is much higher than expected (or
SITP=SICP) and does not decrease when a
small amount bled from tubing = hole is likely
ABOVE the kick fluids
181
Well control during
workovers
2. If the hole is below the kick fluids,

continue circulating out the kick but
reduce the kill rate
Slower kill rate reduces chance that hole will be
washed out larger
Probably able to continue to circulate well
without excessive back pressure
182
Well control during
workovers
3. If the hole is above the kick fluids, shut

in the well
– If SICP increases (gas kick), bleed pressure
from annulus using volumetric method
Bleed tubing/observe SITP periodically until
tubing pressure indicates gas kick has risen
above hole
Continue circulating out the kick, but at reduced
kill rate
183
Well control during
workovers
3. If the hole is above the kick fluids, shut

in the well
– If SICP maintains (probably not gas kick),
consider alternative control methods, e.g.
Bullheading tubing and annulus simultaneously
Circulation of gunk plug/heavy mud down tubing
184
Well control during
workovers
Plugged work string during kick circulation

When barite or other materials are used to formulate
‘kill-
kill-weight’
weight’ mud, clumps of solid material may plug a
workover tool or the work string itself
Pump pressure suddenly increases but annulus
pressure remains constant
Important that choke operator doesn’
doesn’t open the
choke to reduce FTP normally; lower annulus
pressure will allow additional inflow
1. Increase, then decrease the pump rate

Surging may clear blockage
185
Well control during
workovers
Plugged work string during kick circulation
(cont’d)
2. Surging doesn’t clear the blockage, but tubing is
only partially plugged
A. Stop the pump and close the choke; record SITP
and SICP
B. Open the choke, start the pump, and bring the rate
up to the original ‘kill rate’
rate’ while keeping annulus
pressure constant
C. When the pump is up to ‘kill rate’
rate’, note FTP; this is
the new circulating pressure.
D. If this pressure is too high for the pumps to handle,
use a slower pump rate and repeat the steps.
186
Well control during
workovers
Plugged work string during kick
circulation (cont’d)
3. Pump Surging doesn’t clear the blockage,

and tubing is completely plugged
A. Use a string shot or charge near the plug to jar it
loose
B. Perforate the work string above the plugged tool or
area
187
Well control during
workovers
Hole in casing or Lost Circulation during

well control
Kicks and well-
well-control procedures cause additional
pressure in the well; care must be taken to avoid
fracturing intermediate formations or damaging
casing
Most control procedures are designed to circulate
heavy fluid to kill the kick; holes in casing or lost
circulation make it difficult or impossible to circulate
the required fluid
If returns are reduced or fail to flow to the surface,
it’
it’s safe to assume that circulation is lost
188
Well control during
workovers
well control (cont’d)
Reasons for lost circulation:
Bad cement job at shoe
– can cause broaching to surface
Induced fractures
– may heal when pressure relieved
Vuggy or naturally fractured formations
– additional pressure during well control can
induce communication with an existing fracture
network
189
Well control during
workovers

1. Well control with partial lost returns
A. If mixing can keep up with losses, continue
the procedure
• Pressure on the ‘lost’
lost’ zone will be reduced when the
‘kick’
kick’ fluids are circulated above the zone, so problem
may solve itself
190
Well control during
workovers

B. If losses worsen, shut in the well.
• After 30 minutes to 4 hours of ‘rest’
rest’, fractures may heal
or be sealed with mud as pressures equalize
• Keep SITP constant by relieving choke pressure
• If choke pressure increases by more than 100 psi, go to
Step C
191
Well control during
workovers

C. Try a reduced circulating rate and a new
‘Initial Circulating Pressure’ (ICP)
• Remember, ICP is the ‘kill-
kill-rate pressure’
pressure’ (KRP, pre-
pre-
determined for different pump rates) plus SIDPP (the
amount of underbalance in the well)
• Open the choke, start the pump at the slower rate, then
close the choke until annulus pressure is the same as
when shut in
• Shift to the new, reduced-
reduced-rate ‘ICP’
ICP’ on the workstring
192
Well control during
workovers
Hole in casing or Lost Circulation during well

control (cont’d)
D. Mix a slug of appropriate ‘lost circulation material’
material’
and circulate at the new ‘ICP’
ICP ’
E. If returns do not improve, abandon the current well-

well-
control procedure and try to ‘bullhead’
bullhead’ the kick
• A slug of heavy mud should work if the ‘loss’
loss’ zone is
above the zone that is kicking
• After the kick is killed, solve the Lost Circulation problem
193
Well control during
workovers
Hole in casing or Lost Circulation during well
control (cont’d)
2. Well control with total or severe lost returns
F. If losses can not be stopped, use a barite or ‘gunk’
gunk’
plug in the wellbore to seal off the kick zone
• The ‘Kick’
Kick’ zone is most likely located below the ‘loss’
loss’ zone
• Mix a plug of 18 to 22 ppg barite or ‘gunk’
gunk’ (bentonite and
diesel), sized for 500 feet of tubing
• Spot the plug, then pull up above the plug, hold back-
back-pressure
on the annulus, and circulate
• Isolate the kick zone, then solve the Lost Circulation problem
194
Well control during
workovers
Multiple pay zones in a kicking wellbore

In multiple-
multiple-completion wells, two or more perforated intervals
may be present in the same wellbore
In a well-
well-control situation during a workover, kill-
kill-weight fluids
will also affect intervals that are not involved in the kick
– Causing formation damage or even a fracture and underground
blowout or lost circulation
Solution: Chemically or mechanically isolate the

uninvolved interval
• Isolate using bridge plug (if lower than kicking zone)
• Plug off using CaCO3 or commercial polymers
• Plug materials later removed using acid or chemical wash,
zone restored to production
195
Outline

3. Review: Surface Control Equipment
Hydraulic Workover
196
Well Control for Workover
and Completion
The End
Thank you for your attention
197

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Well Control for Workover

» 1. Review: Pressure and Basic Calculations

Pressure is a force that is exerted on an

1 psi = 6.894 kPa

Hydrostatic pressure is the force

A column of air 1” x 1” that is 60 miles

Hydrostatic pressure is the force exerted

P = pressure, psi (kPa)

P = 8202 x 11.1 x 0.052 = 4,734 psi

= 2500 x 1330 x 0.0098 = 32,585 kPa

EMW = BHP ÷ TVD ÷ K

EMW = BHP ÷ TVD ÷ K

= 4734 psi ÷ 8202 ft ÷ 0.052 = 11.1 ppg

EMW = BHP ÷ TVD ÷ K

How about the ‘atmosphere’ example?

Average Gradient (G) as psi per foot of depth

Think of the well as a U-Tube

Fluid tries to reach a balance

Heavier fluid creates pressure differential

1. Formation pressure is the force exerted by fluids in the formation. Some

– Standpipe or tubing pressure

P = 10,000 ft x 10.0 ppg x .052 = 5,200 psi

A key ‘Differential Pressure’ is the

– Balanced: BHP = formation pressure

‘Differential’ pressure is a comparison of two pressures. The most important

A ‘Kick’ is an unwanted flow of formation

Well Control: maintaining

The cause of a ‘Kick’ is

Insufficient fluid weight (density)

Failure to keep the hole full

Swabbing and Surging

Lost Circulation ->

Abnormal formation pressure

Obstruction in the wellbore

Well not taking proper

Sudden increase in drilling rate

Increased Pump speed, but decreased

Change in gas type or gas increase

Salinity change or water-cut mud

Change in flow properties of fluid

For a Gas kick

Gas dissolved at BHP is an

Behaves as liquid, not noticed

How large an annulus pressure increase due

Greater the ‘underbalance’

If not adjusted and controlled,

Causes ‘short circuit’ of gas from

In a nutshell, an underground blowout is a pressure increase in the annulus that

1. The circulating mud system

2. Equipment to shut-in the well

3. ‘Well Control’ techniques to circulate out the kick,

1. Review: Pressure and Basic Calculations

In this section, we will review well control equipment.

1. The circulating mud system

2. » Equipment to shut-in the well

3. ‘Well Control’ techniques to circulate out the kick,

BOP stacks may be

API RP53: Blowout

– Can close around casing,

Variable-bore pipe Ram

– Primary barrier, or backup

After assembly, BOPs must be tested

Offshore testing prescribed by regulation