INTRODUCTION

THE INFORMATION CONTAINED IN THIS DOCUMENT IS PROVIDED TO ACT AS

GUIDELINES AND SHOULD BE USED IN CONJUNCTION WITH THE KICK
PROCEDURES.

THESE PROCEDURES BASICALLY APPLY TO THE HP SECTION OF AN HP WELL;

NAMELY THE SECTION OF THE WELL FOLLOWING THE SETTING OF THE DEEP
INTERMEDIATE CASING.

The need to maintain good communications cannot be over emphasised. For situations not
covered by these procedures a plan/flowchart should be drawn up.

Uncommon types of operation should be approached in small steps so that there is always a
way back if a decision turns out to be incorrect. This can be summarised as:

STOP - OBSERVE - CONFIRM.

1.1 Definition of a HTHP Well

High pressure/high bottom hole temperature (HPHT) wells are defined by the Health
and Safety Executive (HSE) in Continental Shelf Operations Notices (CSON’s) 11 and
59 as being:-

“Exploration and appraisal wells where the undisturbed bottom hole temperature at
prospective reservoir depth or total depth is greater than 300 deg. F and, either the
maximum anticipated pore pressure of any porous formation to be drilled through
exceeds a hydrostatic gradient of 0.8psi/ft or pressure control equipment with a rated
working pressure in excess of 10,000 psig is required.”

To clarify, in accordance with the HSE definition, a well is HPHT if:-

>300 deg.F + 0.8 psi/ft

or,
>300 deg.F + 10.000 psi

As such, a 15k well with a BHST of 280 deg.F would not be classified as HPHT by the
HSE.

1.2 Kick Tolerances

 Ideally, during the design of the well, the base line is to satisfy the following minimum
kick tolerance criteria for a hole of 8-3/8 inches and smaller:

- 40 bbl for drilling

- 20 bbl for tripping

However, in exceptional cases a revised low level minimum kick tolerance criterion of
25 bbl for drilling may have to be adopted.

1.3 Future Updates

The nature of HPHT operations means that different aspects of pressure control are
continually being recognised. For example:-

(1) Thermal effects on mud density.

(2) Standard use of extended leak-off tests and the results thereof.

(3) Mud density variations

(4) Surge/swab pressures.

(5) Tripping volumetrics.

Such aspects have not been included in this version of the procedures.

Sections dealing with HPHT wells utilizing both top drives or a kelly have been
included.

2. RIG EQUIPMENT REQUIREMENTS

PON 13 (formerly CSON 59 - Applications for consent to drill or re-enter high pressure
high bottom hole temperature exploration and appraisal wells), includes policies relating
to information about equipment requited for HPHT wells listed under the following
headings:

1. Surface gas handling system.

2. Pressure control system.
3. Well effluent property monitoring.
4. High pressure well killing facilities.
5. Hydrate suppressant injection facilities.
6. Mud volume and rate monitoring.
 The equipment listed in Sections 2.1 to 2.6 does not address every equipment aspect of
PON 13. This is because some items of equipment referred to in the notice, (eg.- subsea
temperature monitoring devices), are no longer appropriate. However, each Drilling
Programme specifically addresses each item of PON 13 with respect to the particular rig
tasked with drilling that well. This equipment usually forms part of the rig’s magnetic
single shot kit are in the equipment checklist in Section 3.1.

2.1 Drillstring Equipment

Circulating Subs.
(1) When running a core barrel, mud motor, or turbine, a circulating sub should
always be included in the bottom hole assembly.

(2) The circulating sub should be dimensionally checked and also drifted with the
tools that are expected to pass through is, eg:- setting ball, survey barrel, survey
barrel spear socket, etc.

Remark: It is important to ensure that the circulating sub sleeve doesn’t cause
the survey barrel spear socket to unlatch from the barrel when being
pulled back through the circulating sub. A method of getting round
this particular problem is to place the Totco ring in a Stabiliser
directly below the circulating sub so that the top of the barrel sits
above the sub. However, should it not be possible to retrieve the
barrel for whatever reason, the fact that the circulating sub is
straddled renders it inoperable.

(3) The circulating sub should be fitted with seals rated for high temperature.

(4) The HDIS should be drifted with the ball that will be used to shift the sleeve of the
circulating sub.

2.2 High Temperature Rated Elastomers

The temperature limitations of BOP rams and annular preventers are detailed in the
document included as Appendix 10.1.

Elastomers rated to high temperatures are required for the following; (in some cases
‘standard’ elastomers may be sufficiently rated):-

(1) Fixed and shear ram preventer packings and seals.

(2) Fail safe valve packings and seals.

(3) The lining of kill and choke line flexible hoses.

 Remark: WEIN 166 (section 8.2) states that lonely Coflon lined Coflexip kill and
choke line flexible hoses are acceptable on HPHT semi’s. This relates to
the unsuitability of Rilsan lined hoses to transport zinc bromide brines
under certain (strain related) conditions, although this recommendation
is outdated (1991) as zinc bromide brines are no longer used by the
MDU. However, in accordance with Coflexip’s own recommendations
only Coflon has a satisfactory rating with respect to product (eg:
methane) compatibility at high temperatures.

(4) Kill and choke line stab connector lip seals.

(5) Packings and seals on choke manifold 15k valves.

(6) Bladders on choke manifold pressure transducers.

2.3 Choke Manifold

(1) Choke manifold valves and chokes intended to be operated under high pressure to
be fitted with hydraulic actuators.

(2) Glycol injection points upstream of the chokes.

(3) A 250 psi pressure relief valve fitted to the buffer chamber on the choke manifold
and venting to the overboard lines. This relief device when activated manually
can be used as the relief device (see 2.4 below) which protects the liquid seal in
the mud-gas separator.

Remark: In certain circumstances, well control may require that displacement of

the kick continues regardless of the capacity of the mud-gas separator
to handle wellbore fluids. Overboard lines are therefore required to
divert flow from the choke manifold and isolate the mud-gas separator.
The pressure rating of the overboard lines should not be less than the
rating of the buffer chamber of the choke manifold to which they are
connected. Overboard lines are also used in the event that the pipe
system downstream of the buffer chamber becomes inadvertently
blocked; for instance plugged with hydrates.

The 250 psi setting is high enough to allow sufficient pressure drop
between the buffer chamber and mud-gas separator to avoid premature
actuation of the valve. Conversely, over-pressurisation in the event of
blockage in the vent line and dip tube.

Furthermore, while controlling a gas kick, a considerable volume of gas

is vented via the choke. The resulting near adiabatic expansion can
yield severe low temperatures downstream of the choke. Consequently
 on some (non-Arctic) rigs, pipework downstream of the high pressure
side of the choke manifold would have to be downgraded by a factor of
2.5, hence necessitating the need for a relief device. (Ref:- SPE Paper
19245/1 by J.M. Prieur of Shell Expro).

2.4 Mud-Gas Separator

In accordance with HSE Safety Notice 11/90, there must be a means by which the mud-
gas separator can be bypassed and isolated when approaching overload conditions or
blockage. (See also 2.3 above).

An aspect of the mud-gas separator capacity is the rate at which gas can be vented when
the seal is operating at its maximum pressure differential when the liquid seal contains
only associated liquids from the hydrocarbon influx. “A gradient of 0.3 psi/ft should be
assumed to determine the maximum pressure differential”. (Ref:- HSE Safety Notice
11/90).

As such, a device is required to protect the liquid seal, (and thereby also prevent
wellbore fluids being transmitted back to the mud system). The pressure setting of this
device shall be based on the height of the liquid seal (ie:- 18 ft.) multiplied by 0.3 psi/ft.,
(ie:_ 5.4 psi). It is acceptable to design for a higher mud seal gradient provided that
fresh mud is continuously circulated either into the tank (in the case of a dip tube seal),
or into the separator itself (in the case of a U-tube seal).

This bypass can be a fully automated device or simply a pressure induced alarm that
triggers a procedure whereby the bypassing and isolation of the mud-gas separator is
performed manually.

2.5 Instrumentation

1. Temperature upstream and downstream of choke.

2. Pressure upstream and downstream of choke.

3. Kill manifold pressure gauge.

4. Poor-boy mud-gas separator temperature.

5. Poor-boy mud-gas separator pressure.

2.6 High Pressure Well Killing Facilities

(1) 15k kill pump, (usually the cement unit).

 The kill pump shall incorporate two triplex pumps, both with 15k fluid ends. At
least one fluid end shall be fitted with liners and pistons rated to 15k, with
additional sets held onboard as back-up. Because of the low volume rates required
when cementing in the HPHT section it may be possible to dress both fluid ends
with 15k liners and pistons. It need only be a consideration to install a remote
control unit for the kill pump on the drillfloor.

The BOP kill line shall be permanently hooked up to the kill pump (cement unit).
At least two valves shall separate the kill line from the cement unit, (in order to
prevent any cement contamination of the kill line). Procedures shall be in place to
flush the surface section of the kill line after every cement job.

(2) Dedicated high pressure (15k) kill manifold and high pressure (15k) kill
(Coflexip) hose.

(3) High pressure kick single assembly to link the kill pump (cement unit) to the
drillstring through the high pressure kill manifold and (Coflexip) hose.

2.7 Miscellaneous Equipment

1. Glycol injection pump.

2. Glycol feed storage tank.

3. Calibrated stripping tank.

4. Sufficient 15k lBOP’s for the drilling stand, kick single assembly, and for stabbing
etc.

3. PREPARATION

The following is a checklist of items to be actioned at some time prior to entering the
high pressure section. The checklist is divided into three sections, namely:-

- Equipment & Materials

- Personnel
- Training

3.1 Equipment & Materials

(1) Fixed ram high temperature elastomers shall be installed in the BOP.

(2) High temperature seals shall be installed in the kill and choke lines.
(3) The BOP and associated well control equipment shall be pressure tested and
accepted by the rig’s certifying authority. The frequency of such certification
shall be in accordance with the rig’s certifying authority’s requirements.

(4) The kill (cement) pump and manifold shall be pressure tested.

(5) The 15k kick single assembly shall be made up to the appropriate size/
weight/grade of drillpipe and pressure tested.

(6) The drilling stand complete with tested kelly cocks and saver-sub to be made up.

(7) The automatic MAASP control system shall be disconnected.

(8) All instruments and recorders shall be checked for calibration and cross checked
for consistency between locations.

(9) Check calibration of returns flow indicator: (indicator to be upstream of outlet to

trip-tank).

(10) Check calibration of all gas detectors.

(11) Check calibration of all H2S detectors.

(12) The hydrate suppressant (glycol) system shall be function tested.

(13) The kill (cement) pump remote control on the rig floor shall be function tested.

(14) Sufficient barite stocks to be onboard, (see section 4.1).

(15) Sufficient cement stocks to be onboard, (see section 4.1).

(16) Sufficient cement additives to be onboard.

(17) Sufficient LCM stocks to be onboard.

(18) Sufficient glycol stocks to be onboard.

(19) Volume of mud equivalent to hole volume to be prepared.

(20) Reserve mud to be prepared.

(21) Weighting-up rate (ie: psi/ft per ‘x’ bbls per hour) to be established.
 (22) Additional 15k IBOP’s to be on board (for drilling stand and kick single
assembly). Provision for the rapid installation of the stab-in IBOP should be
provided.

(23) Additional H2S equipment as required to be onboard.

(24) High temperature magnetic single shot equipment to be onboard.

(25) Service company tools (especially the elastometric content) such as jars,
retrievable packers, and electric wireline logging instruments (including pipe-
conveyed) should all be rated for high temperatures.

(26) Endure that all downhole tools have been checked with respect to casing ID’s
(including allowance for tolerances).

(27) Check that the dart for use with the Hydril drop-in sub will pass through all ID’s
of the drillstring (including the IBOP’s) and BHGA components.

(28) Check that in the event of a power failure, the emergency generator has the
capacity to allow well killing operations to continue.

(29) Check/test procedure/system for isolating mud-gas separator and venting wellbore
fluids overboard.

(30) Check/test pressure relief valve system fitted to choke/kill manifold buffer tank for
venting wellbore fluids overboard.

(31) Check/test system that changes direction of wellbore fluids being vented over-
board.

Note: If prolonged top-drive problems necessitate drilling ahead with the kelly, a
circulating elevator should be acquired for tripping operations.

3.2 Personnel

(1) Two mud engineers should be assigned to the rig for the duration of the high
pressure section.

(2) Mud logging crew should not contain any trainees, additional or otherwise.

(3) Personnel on board should be kept to a minimum.

3.3 Training

(1) All appropriate personnel to be proficient at well control drills (drilling and
tripping) utilising the ‘fast shut-in’ method, strip drills, and H2S drills.
 (2) All personnel to have received onsite H2S/BA refresher training.

(3) A pre-spud (or pre-HPHT section) meeting shall be held and minutes recorded.

4. HPHT DRILLING PROCEDURES

4.1 General

(1) The automatic MAASP control system shall not be used, and should be
disconnected.

(2) The minimum barytes stock shall be 100 MT and the minimum cement stock shall
be 80 MT. If stocks fall below this level operations will stop, therefore it is usual
to maintain stocks far in excess of these minimum levels. Cement additive stocks
shall also be maintained and if applicable shall include the appropriate level of
weighting material (haematite).

(3) The mud mixing (weighting up rate) capability of the rig should be established.
This information will assist in the planning of certain well control operations and
may even impact on the choice of well control method.

(4) Pressures at slow circulating rates shall be established for the kill pump/kick
single/choke line system.

(5) Circulation shall be broken through the kill and choke lines every twelve hours.

4.2 Drilling

Note: Refer also to Section 4.9,’Directional Control and Borehole Surveying’.

(1) When drilling with a top drive, the composition of the drilling stand, (ie:- number
of drillpipe joints and quantity/position of string IBOP’s), varies between
Operators and Drilling Contractors.

Certain minimum requirements shall apply in al situations, and these will

determine the configuration of the drilling stand on any particular rig.
These minimum requirements shall also apply when drilling with a kelly and
therefore may necessitate the use of a ‘mini’ drilling stand below the kelly.

The minimum requirements are as follows:-

(a) It should always be possible to disconnect the top drive yet leave the
drillstring closed-in on one accessible string IBOP.
 Similarly, it should always be possible to disconnect the kelly yet leave the
drillstring closed-in on one accessible string IBOP.

A second IBOP can be installed once the top ;drive/kelly has been removed.

(b) It should always be possible to remove the drilling stand or part thereof yet
leave one accessible string IBOP in place in the drillstring.

(c) It should always be possible to install the kick single assembly on a

drillstring that is closed-in on at least one accessible string IBOP.

(d) It should always be possible to land off.

(e) It should not be possible for the drillstring to heave into ‘bottom’.

(2) No special equipment that restricts the drillstring ID shall be run in the bottom
hole assembly, with the exceptions of the Totco ring, drilling jar, Hydril drop-in
sub, and nozzles in the bit. This is to limit the restrictions in the drillstring that
would increase the chances of blockage occurring in the case that the pumping of
LlCM and/or cement is required to cure severe losses when entering the reservoir.

Note However that:-

(a) The Hydril drop-in sub shall be placed above the heavy-weight drillpipe.

(b) All nozzles shall be the maximum size possible for the particular bit in use.
If the largest nozzles available are less than 18/32”, contact Base. No nozzle
holes shall be blanked off. (The use of nozzles is primarily to protect the
nozzle orifices).

© Teledrift is not classed as having a restrictive bore because of its large flow-
by areas.

Refer also to Section 4.10, “Exemptions from HPHT Procedures”, item

4.10.2, “Use of Thrusters / Motors MWD’s etc. in the HPHT Section”.

(3) The drilling rate should be restricted whereby the ROP does not exceed:

Lag time (hrs) x ROP (ft/hr) = 30 (ft)

Once drilling in a continuous reservoir where no further pressure seals are

anticipated this restriction can be lifted.

Remark: The reasoning behind the 30 ft. value is as follows:

 When first drilling into the high pressure reservoir, it is possible that the formation
pressure is only dynamically overbalanced. A flow check may not show the well
to be flowing. Any influx entering the well during static conditions, (eg: with the
pumps off during a connection), will show however once circulated to surface.

In order to prevent taking more than one influx in the case where the static
overbalance is not present, bottoms-up has to reach surface and be checked for the
presence of influx before stopping the pumps to add another joint of drillpipe, ie:-
before starting to drill a further 30 ft. However, if the pumps have to be stopped,
(to flowcheck for instance), prior to bottoms ups reaching surface, then the
possibility exists to take a second influx. Therefore drilling shall not continue
until bottoms up from the latter moment of stoppage has reached surface. This
ensures that the annulus is influx free and also prevents the possibility of a third
influx if the pumps have to be stopped yet again before the original connection
bottoms up has reached surface.

Once drilling in a continuous reservoir and having established that a static

overbalance exists at top reservoir, (together with the fact that the overbalance
increases proportionally over the length of the reservoir), the reason for the
restriction no longer exists and can therefore be lifted.

The 30 ft. value supersedes the 20 ft. value recommended by SIPM in Report EP
89-1500, section 2.3.14.2, item 1.

(4) Where small kick tolerances are involved, gas coming out of cuttings can have a
significant impact. For example:

- assuming 30% porosity in 1 cu.ft. of cuttings (2.6 ft. of 8.3/8”

hole)
- mud weight of 0.945 psi/ft
- hole depth of 16000 ft
- temperature regime of 40° F at seabed and 350°F at 16000 ft

will give approximately 20 bbls of gas at surface.

(5) Drilling shall not continue if dynamic losses of greater than 10 bbls/hr persist.

4.3 Tripping

(1) Under no circumstances shall any string be pulled out of the hole if the hole is not
in a stable condition, ie:- no losses and/or no flow.
 However, this does not preclude pulling back a short distance, (eg:- to the shoe), in
order to (for instance), set a cement/LCM plug.

(2) Prior to any trip out of the hole a ten stand wet check trip shall be made (pulled
not pumped) in order to check for overbalance prior to finally coming out of the
hole.

It is not allowable to pull less than ten stands even if the bottom of the drillstring
has already reached the casing shoe.

If circulation is necessary to overcome hole problems encountered during this

check trip, then the requirement still remains to check for overbalance by ensuring
that the bottom of the drillstring has been pulled through the whole of the check
trip interval.

Note: On occasion it may be necessary to pull out after performing a leak-off

test having drilled the shoetrack and 15 ft. of new formation. Provided
that during the 15 ft. drilled there is no change in cutting litholigy,
drilling parameters (eg: torque) and gas readings, then it is not
necessary to perform the ten stand check trip.

Refer also to Section 4.10, “Exemptions from HPHT Procedures”, item 4.10.1,
“Omission of Ten Stand Check Trip”.

(3) During the actual trip out of the hole, the drillstring shall be pumped out at least
until the bottom of the drillstring has reached the casing shoe. If a drilling liner
has been installed, then the drillstring shall be pumped out at least until the bottom
of the drillstring has reached the top of the drilling liner. (This is because in
general, annular clearances are smaller).

In circumstances where only a marginal overbalance exists it may be necessary

to pump all of the way out of the hole, ie: to the BOP.

(4) On check trips, no heavy pills (slugs) shall be pumped. No heavy pills should be
pumped on any trip until the bottom of the drillstring has reached the casing shoe.

(5) If a survey is required using a MSS, drop the survey barrel after the flow check
(negative) that follows circulating bottoms up after the check trip. The survey
barrel shall not be recovered until the bottom of the drillstring has reached the
casing shoe.

On round trips it is usual to recover the survey barrel when the BHA is at surface.

(6) On all trips out of the hole, a Hydril drop-in dart shall be pumped down. Where
applicable, the dart will have to be dropped after retrieving the survey barrel at the
shoe. It shall be checked to be in place by hopefully noting a slight pressure
 increase but at least ensuring that sufficient theoretical string contents have been
pumped. Seating can be checked when retrieving the dart at surface.

(7) On all trips in and out of the hole, excessive trip speeds should be avoided in order
to minimise surge and swab pressures to an acceptable level. The reduction in
bottom hole pressure for the drillstring and mud properties in use shall be
calculated.

(8) On all check trips and all trips out of the hole, the Contractor Toolpusher (Night
Toolpusher) and Company Representative shall both be present for at least the first
10 stands pumped/pulled. Furthermore, the contractor Toolpusher (or Night
Toolpusher) shall remain present for tripping out thought the whole open hole
section.

Under no circumstances shall a trip commence prior to the above personnel being
present.

(9) If the hole indicates that swabbing is taking place; but the well is not flowing, then
the drillstring shall be run back to bottom and bottoms up circulated. Note
however that when 75% of the annular contents have been circulated or as soon as
signs of a reduction in mud weight or hydrocarbons are observed, then circulation
shall continue over the choke manifold.

If any doubt exists at any time, bottoms up should be circulated out over the choke
manifold. The riser should then be circulated to clean mud prior to opening the
BOP’s.

(10) All assemblies shall be checked carefully for wellbore contact (wellbore offset
programme), because an undesirable effect of stuck pipe is that swabbing can
occur while jarring.

Notwithstanding the items above, if indications are that the well will swab, the
following options should be considered:-

- Increasing the mud weight.

- Pumping (not pulling) out the ten stands during the ten stand check trip.
- Pumping out all of the way; (see item 3 above).
- Using a heavier mud for tripping purposes.

4.4 Flow Checking During Drilling/Coring and Tripping

The duration of flow checks shall be 15 minutes and shall be taken:-

 (1) Whenever a drilling break is observed, a flow check shall be carried out. If any
doubt exists, circulate bottoms up with additional flowchecks at 50% and 75% of
bottoms up.

(2) When check tripping and/or tripping out of the hole, regular flow checks shall be
conducted as follows:-

(a) On bottom prior to pulling out.

(b) On a check trip after pulling 10 stands. If the bit will be inside the shoe
when 10 stands have been pulled, flow check both at the shoe and after
pulling the 10th stand.

(c) At reaching the casing shoe.

(d) At reaching the top of a drilling liner (if applicable).

(e) At a point halfway between the casing shoe and the BOP stack.

(f) At a point just before the top of the BHA (ie:- HWDP) reaches the BOP
stack. Rotating the drillstring during flowchecks should prevent gels
developing and is a valuable anti-stick precaution.

4.5 Coring

When coring:-

(1) Only perforated core-barrels (ie: fitted with check-valve venting) should be used.

(2) The restricted drilling rate as detailed in Section 4.2.3 shall also apply, but can
also be lifted in accordance with the same procedure.

(3) For all sizes, the length of core-barrel run on any one trip shall not exceed 90 ft.

(4) The tripping and flow checking procedures as detailed in Sections 4.3 and 4.4
respectively shall also apply during coring operations.

(5) The first core taken in the reservoir shall be in rotary mode. Thereafter, motor
coring can be used but only in accordance with Section 4.10.2, “Use of
Thrusters/Motors/MWD’s etc. in the HPHT Section”.

4.6 Running Casing/Liner

(1) The shoe track of the casing set just above the HPHT section and the shoetracks
of all other casings/liners set in the HPHT section shall be magnetised.
 (2) It is important to emphasise that overbalance must always be maintained at all
stages whenever cementing a casing/liner especially under static conditions.

4.7 Pressure Testing of the BOP and Production Casing content

4.7.1 BOP Test Pressures

In order to address some commonly asked questions, the following is a brief

methodology for testing the BOP:-

(1) On the stump, test the BOP to its rated working pressures, typically 15k for the
rams and failsafes, and 10k for the annular preventers.

(2) Whenever running the BOP, test the wellhead connector to its rated working
pressure, usually 15k, and test the kill and choke lines to their rated working
pressure, typically 15k. In cases of a ‘split’ BOP, test the LMRP connection to
10k.

(3) Whenever subsequently testing the BOP, test the rams and kill and choke lines to
1000 psi above the maximum anticipated closed-in surface pressure for the
appropriate hole section. This pressure will be detailed in the drilling programme,
(because in some cases it may not be possible to cater for the full 1000 psi
margin). Test the annular preventers to 70% of their rated working pressure.

As a minimum requirement, subsequent pressure testing of the shear rams shall be

carried out at after setting the casing just above the reservoir.

(4) Because the kick-single is an integral part of the well control equipment (in the
HPHT section), it shall be included in the subsequent (14 day) pressure testing of
the BOP from the start of the HPHT section.

4.7.2 Testing Frequency of the Production Casing

The decision when to perform casing tests shall be advised by the Drilling Manager.
Subsequent testing of the seal assembly will be based on the same frequency as the
casing.

4.7.3 Use of Retrievable Test Packers

Pressure testing of the production casing involves the use of a retrievable packer in order
to isolate/protect:-

(1) The shoetrack

 (2) The cement bond (usually to theoretical top of cement).

(3) A weaker casing in a combination string.

It may be necessary to make a scraper run, (for instance across a production packer
interval). However, casing scrapers shall not be ran in the same string as a retrievable
packer.

Severe loading forces are transmitted to the casing via the packer slips during testing,
and so in order to test the integrity of the slip area in the all important upper section of
the casing, it is necessary to perform the shallow test first so that the deeper test
incorporates coverage of the shallow test slip area.

Taking into account casing specifications of a combination string and also the
temperature considerations, it may be possible to use the same packer components for
both the shallow and deep tests. However, the severity of the shallow test may make it
prudent to pull the packer to surface in order to check its condition prior to running all
the way in hole only to find it is unable to perform the deeper test.

4.8 Casing Wearing

Casing wear should be minimised at the design stage by the use of smooth tooljoint
hardfacing, optimum well path trajectory, and film forming muds.

The burst, collapse, axial and triaxial capacities of worn casing are calculated and
compared to the anticipated loads. If worn casing will only have just sufficient strength
to with stand the design loads, casing wear will have to be monitored during drilling.

It is essential that only smooth hardfacing is used and that it is flush with the body of the
tooljoint. Also of prime importance is the need to minimalise drillstring rotary speed. In
addition, tong marks need to be removed from tooljoints. (Reducing the drillstring
rotary speed can have the added benefit of also reducing the ECD).

As mentioned in Section 4.9, a North Seeking Gyro is run in the casing prior to entering
the reservoir. This is an opportune moment in the operation to consider running a
Multi-Fingered Caliper Tool (MFCT). It is important to run the log immediately after
the casing is cemented, ie: before the drillstring is ran/rotated in the casing. Such a log
then forms the baseline to gauge any casing wear that may subsequently occur. Results
from subsequent MFCT logs can also be used to verify design stage predictions.

When the casing is inspected onboard it is important to have the OD as well as the ID
measured in order to aid wall thickness calculations.

One of, or a combination of the following criteria should be used as guidelines for when
to run a baseline MFCT:-
 (1) If in accordance with the Casing Design Guide casing wear needs to be monitored.

(2) If the angle of the BOP stack is greater than 1 deg.

Results of the casing wear log can be extrapolated and platted against the casing burst
line in order to determine on critical sections where any points of crisis occur.

There is a complicated geometrical interface between casing, wellhead, BOP/wellhead

test tools, and wearbushings, and as a consequence wearbushing ID’s were in some
cases greater than the ID of the uppermost casing. Extended neck wearbushings with a
smaller ID than the uppermost casing have now been developed and test tools have been
re-designed accordingly.

Drillpipe protectors have been fitted retro-actively in response to metal particles in the
returns. In order to establish a consistent approach to monitoring the quantity of metal
returned, the parameter of grams per 1000 revolutions should be used by dividing the
total weight of metal returned by the total number of revolutions of the drillstring and
recorded (say) every two hours. The use of drillpipe protectors can be planned at the
design stage; their use can also reduce torque and drag.

If returned cuttings do contain metal then the wearbushing should be periodically

inspected to check (for instance) that its not the rig’s position over the wellhead that
may be giving rise to metal returns.

‘Cansco’ (or similar) non-rotating drillpipe protectors should be fitted in areas of casing
wear derived from. The non-rotating type drillpipe protector overcomes the ‘grinding
wheel syndrome’ associated with the traditional type of drillpipe protector. The
protectors are usually fitted just above the tooljoint.

Remark: One of the reasons why drillpipe protectors are fitted just above the
tooljoint is so that as the tooljoint just passes below the wearbushing, the
protector, (which will still be in the wearbushing), will centralise the tooljoint,
thereby keeping it off the casing wall.

It is important that a log is kept of where each drillpipe protector is fitted.

4.9 Directional Control and Borehole Surveying in Vertical Holes

In the Well Planning section of the Deviation document it states that no more than 500
ft. of unsurveyed open hole is permitted. This is especially important if above top
reservoir. However, to be flexible, the (ideal) figure of 500 ft. can be extended at the
discretion of the Rig Superintendent; for instance, in order to coincide with a bit trip
after 600 ft. or thereabouts. As per the instruction from UEOW/35 dated 09 Dec ’92;
future HPHT well programmes shall include a North Seeking Gyro in the casing prior to
entering the reservoir.
 Note that it is not within the scope of these procedures to discuss the cost/time
implications of the various methods of borehole surveying.

4.9.1 Teledrift Tools

The use of the Teledrift tool as detailed by flowchart carries two important
qualifications, namely:-

(1) Because Teledrift only measures inclination, the horizontal displacement should be
determined using a single azimuth heading and the Teledrift inclination readings.
This will give the worst case scenatio. The single azimuth heading can be taken
from the last measured value. The tool uncertainty, (11 ft. per 1000 ft. for the
range 0-10 deg.; 13 ft. per 1000 ft. for the range 10-20 deg.), for the particular
depth should then be added to the horizontal displacement. This final
displacement figure becomes the radius of the circle anywhere in which the
position of the bottom of the hole could be located.

Remark: The tool uncertainties quoted above are the current levels of
uncertainty for unknown tool codes for the associated inclinations.

If this estimated ‘circle of uncertainty’ indicates that the target could be missed,
then the situation will have to be assessed in order to decide the most appropriate
safe course of action by which the target can be penetrated; see 4.9.2.

(2) Another important aspect of the Teledrift tool is its limited range to a maximum
inclination of 20 deg. Therefore in cases of higher inclinations an alternative
method of measurement is required; See 4.9.2.

4.9.2 SDC Magnetic Single/Multi Shot

Scientific Drilling Control (SDC) can provide the following magnetic survey probe to
measure inclination and azimuth:-

(1) The magnetic survey probe is ran through a side entry sub using a dedicated
(conductor) wireline unit. Reduced circulation and string reciprocation is still
possible.

(2) The magnetic survey probe diameter is 1.375/1.750 and maximum operating
temperature is 260/600° F respectively.

(3) The probe can be ran in tandem or ran singly in order to provide a surface readout
option. The procedure for running the probe would be as follows:-

(a) Circulate bottoms up then flowcheck.

 (b) Rig up to run probe, installing a kelly cock below the side entry sub.

(c) Run probe, take survey, then retrieve probe (circulating to avoid swabbing).

(d) Rig down.

4.10 Exemptions from HPHT Drilling Procedures

These are particular situations where it is acceptable to deviate from the standard HPHT
procedures and details of these are given below. Other circumstances may arise
necessitating other deviations and theses should be agreed by the Drilling
Manager.

4.10.1 Omission of the Ten Stand Check Trip

It is possible to omit the ten stand check trip, (ref: item 4.3.2) provided that:-

(1) The bottom of the well’s position in the lithology column has been confirmed, (eg:
by core/cuttings samples etc.).

(2) Pore pressure measurements at the top of all exposed reservoirs in the well
indicate that an overbalance exists over the highest pore pressure value with the
riser in place.

(3) The first trip out through the exposed reservoir was preceded by a ten stand check
trip. (This proviso will have been satisfied because the first trip out would have
been to run the formation testing tool, ie:- RFT/FMT).

(4) Offset well data must indicate that stacked reservoirs (varying pore pressure
regimes) are no more than a remote possibility in the lithology column in question.

(5) The drillstring is pumped out of all open hole sections.

4.10.2 Use of Thruster/Motors/MWD’s etc. in the HPHT Section

It is acceptable to use thrusters/motors/MWD’s and turbines etc., or have other similar

string restrictions in the HPHT section but only in accordance with the following
procedures.

(1) Drill to the coring point and take the first core as per standard HPHT procedures
detailed herein. If there is no coring point as such, drill sufficiently into the
reservoir to allow the formation pressure to be measured using electric wireline
logging tools. Continue as per steps 3,4 and 5 below.
 (2) Cut the first core in the reservoir section as per standard HPHT procedures
detailed herein. Sufficient core must be cut to allow the formation pressure to be
measured using electric wireline logging tools.

(3) Establish the formation pressure using electric wireline logging tools and adjust
the mudweight as necessary to give sufficient trip margin.

(4) Offset well data must indicate that stacked reservoirs (varying pore pressure
regimes) are no more than a remote possibility in the lithology column in question.

(5) The well is stable, (ie:- no losses and/or gains).

4.11 Lessons Learnt

The items in this section are included because they are considered to be valuable
learning points.

4.11.1 Drilling Ahead Without a Riser Margin

It is not always possible to achieve and/or maintain the levels of overbalance widely
regarded as being minimal (ie:- 300 psi). In a loss situation it may not be possible to
even cater for a riser margin. Refer to Flowchart 8.10, “Drilling Ahead Without a
Riser Margin - Contingency Plan for Disconnection”.

However, closing the BOP when the riser is attached will entrap the pressure of the
hydrostatic head of mud in the riser provided that the BOP does not subsequently leak.

The decision to drill ahead without a riser margin must be sanctioned by the Head of
Well Operations. Similarly, the Head of Well Operations should be informed whenever
erosion of the overbalance (ie:- change of programmed mudweight) occurs.

4.11.2 Measurement of Mud Weight

There may be instances when narrow well control margins exist, such as minimal
overbalance, and that during such circumstances certain items take on greater
significance. An error of mud weight measurement of 0.005 psi/ft at 18000 ft equates to
90 psi on bottom. As such, when determining mud weights:-

‘Tru-Wate’ mud balances should be used. A ‘master’ balance, accurately calibrated in

town, should be kept onboard for the sole purpose of providing a comparator for the
balances in daily use. The ‘master’ balances could also be used for particularly critical
 mud weight checks. Any calibration adjustments to the balances in daily use should be
logged.

Adopt a standard method of measurement to eliminate any ‘inconsistencies’, human or

otherwise.

4.11.3 MDT Log (Flushing RFT)

Where narrow well control margins exists, the gradient and volume of formation fluids
being flushed into the well bore tae on greater significance. The implications therefore
of excessive continuous flushing should not be under estimated. As such, the decision to
run the MDT tool must be authorised by the SWE (operations).

4.11.4 Heavy Weather

Heavy weather is not within the scope of these procedures. However, mention is made
of a particular philosophy whereby a situation can start to escalate out of hand if one
problem (eg: well control) is exacerbated by a further two, as it should be recognised
that the second problem, namely the weather may be about to happen or is happening
already. Therefore, decisions should always take into consideration potential
interference from adverse weather.

5 HPHT WELL CONTROL PROCEDURES

5.1 General

Certain items in this section have been included because they are considered to be
valuable learning points:-

(1) It should not be assumed that a well control problem will always fall into a
particular text book category. Bullheading or an issue like exceeding MAASP
have traditionally been seen as last resorts, but options such as these should be
taken in context and not dismissed as a matter of course. The key issue is to
recognise then the text book does not apply and act accordingly.

(2) It should also not be assumed that there will always be sufficient warning (such as
background gas) when in a transition zone. Offset wells prove this not always to
be the case.

(3) When background gas reaches an arbitrary pre-agreed level (for instance 5%), all
work permits shall be withdrawn and the standby boat notified accordingly. It is
also usual to notify all on-shift personnel via the P.A. system of the situation.

(4) The ‘fast shut in’ method will be used throughout the high pressure section. As
such, the valve immediately upstream of each choke shall be kept closed during all
operations after cementing the 9.5/8” casing.
 (5) Once a well is closed in following a kick:-

(a) All work permits shall be withdrawn.

(b) The following parties shall be informed:-

- Standby boat
- Drilling Superintendent
- Rig Manager

The OIM will also have responsibilities about whom to inform (eg:-
coastguard) in accordance with his own emergency procedures.

(c) Crews should be mustered and all personnel to be informed of the status.

(6) During well killing operations, in order to prevent valves washing out when
closing them, the choke should be closed first followed by the valve immediately
upstream of the choke. Should this valve fail, the next upstream valve should be
closed. In all cases, the last valve to be closed will be the one furthest upstream,
nearest to the BOP.

Wherever possible, in order to avoid washouts, valves should be equalised rather

than opened/closed under a high differential pressure.

5.2 BOP Ram Configuration.

(1) Temperature limitations of ram and annular preventers.

(2) Hang-off capacities of pipe and variable bore rams.

(3) Configuration of ram type preventers in the BOP primarily with respect to:-

(a) Size, (tubular dependent)

(b) Ram cavity position, (ie:- top, upper/lower middle, bottom).
(c) Bottom hole static temperature (BHST).
(d) Wellhead pressure.
(e) Phase of the operation, (ie: drilling, testing).

Although not specified in the note, the position of the kill and choke lines is
important, resulting in an overall configuration as follows:-

- Upper annular
- Lower annular
- Upper pipe rams
- Upper choke lines
 - Shear rams
- Upper kill line
- Middle pipe rams
- Lower choke line
- Lower pipe rams
- Lower kill line

5.3 Bullheading.

Bullheading has proved to be a viable method of well control because:-

(1) Due to an extended leak-off test having already established that the mud gradient
used was lower than the fracture propagation gradient, it was known that the
operation would not result in static losses.

(2) The open hole section was very short making it almost certain that the influx
would be squeezed back into the same formation from where it had come.

Therefore, bullheading may be the preferred option for one or more of the following
reasons:-

(1) As long as it is known that the ‘bottom won’t drop out of the hole’.

(2) To avoid getting hydrocarbons to surface, especially in cases where doubts exist
about the contents/volumes in the annulus.

(3) If erratic surface pressures are experienced whereby it may not be possible to
proceed with killing the well conventionally.

(4) If it has not been possible to strip-in all the way to bottom.

(5) If rapid pressure increases call for swift action.

(6) If the open hole section is short. However, much depends on the length and
characteristics of the open hole section, if a situation is to be avoided whereby
fluid is being bullheaded higher up the hole above the point where flow may still
be occurring.

If it is decided to control the well by bullheading, it is usual to displace the drillstring

contents first followed by the annular contents. It is a good idea not to fully displace the
drillstring contents so that some positive drillpipe pressure (Pdp) is retained. This will
allow the downhole situation to be monitored while bullheading the annulus, thereby
enabling losses/crossflow to be detected. Furthermore, when bullheading the annulus, it
is advisable to over-displace the contents in order to ensure that any migrated influx is
also returned to the formation.
6. HPHT KILL PROCEDURES

During killing operations when landed off on the upper pipe rams, be aware of the
temperature limitation of variable bore rams. This factor may necessitate having to also
close the middle pipe rams - and utilise the lower choke line.

6.1 Kick with Bit on Bottom - Drilling with a Top Drive

When drilling the high pressure section, a drilling stand fulfilling the minimum
requirements as detailed in Section 4.2, item 1, will be used.

When a kick is first detected, close in the well as soon as possible in the following way:-

(1) Pick up off bottom until the string IBOP is above the rotary table and the upper
pipe rams can be closed below a tool joint. (This position should be determined
before drilling commences and updated as required).

(2) Stop rotating, then stop the pumps.

(3) Close the upper annular preventer.

(4) Open the failsafe valves in the upper chokeline.

(5) Record time and initial closed-in drillpipe and annulus pressures.

(6) Close the upper (remote controlled IBOP).

Remark: This isolates the system downstream of the drillstring against the risk
that the closed-in drillpipe pressure exceeds the setting of the mud
pump relief valve, thereby allowing uncontrolled flow through the
drillstring.

(7) Inform the Company Representative and Contractor Toolpusher onboard.

(8) Install and test the kick single assembly s detained in steps ‘a’ - ‘e’ below.

Remark: Even though the pressure integrity of the top drive system, (ie: the
standpipe pressure while currently drilling just before the kick),
suggests that the influx may be circulated out with the top drive still in
place, it is nevertheless considered necessary to install the kick single
assembly. This is because possibility exists that failure of the pressure
integrity of the drillstring, (eg.: H2S related stress corrosion cracking),
could result in very high annular pressures being communicated to the
top drive system. Installing the kick single after such an event and in
difficult circumstances is deemed highly undesirable.
 (a) Set the string in the slips and close the string IBOP.

(b) Open the upper (remote controlled) IBOP and check the pressure integrity of
the closed string IBOP.

(c) Break the connection above the closed string IBOP.

(d) Make-up the kick single assembly and pressure test the system against the
closed string IBOP to the initial closed-in drillpipe pressure plus 3000 psi.

If the flexible hose to the kick single assembly has been disconnected (eg:-
for racking back purposes), pressure test the connection against the plug
valve to 15k.

(e) Equalise the pressures and open the string IBOP.

(9) Check the space out and close the upper pipe rams (using reduced operating
pressure).

(10) Land the drillstring on the upper pipe rams, (if necessary using reduced operating
pressure on the upper annular preventer), and close the ram-locks.

Note: Remember to increase the operating pressures back to normal again

after landing.

(11) Determine the influx volume and prepare to kill the well in accordance with
Section 6.3, “Circulating Out the Influx”.

Remember that once a well is closed in following a kick:-

(a) All work permits shall be withdrawn.

(b) The following parties shall be informed:-

- Standby boat
- Drilling Superintendent
- Rig Manager

The OIM will also have responsibilities about whom to inform (eg:-
coastguard) in accordance with his own emergency procedures.

(c) Crew should be mustered and all personnel to be informed of the status.

6.2 Kick With Bit On Bottom - Drilling With a Kelly

When a kick is first detected, close in the well as soon as possible in the following way:-
(1) Stop rotating and raise the kelly until the lower kelly cock is above the rotary table
and the upper pipe rams can be closed below a tool joint. (This position should be
determined before drilling commences and updated as required).

(2) Stop the pumps.

(3) Close the upper annular preventer.

(4) Open the failsafe valves in the upper chokeline.

(5) Record time and initial closed-in drillpipe and annulus pressures.

(6) Close the lower kelly cock.

Remark: This isolates the system downstream of the drillstring against the risk
that the closed-in drillpipe pressure exceeds the setting of the mud
pump relief valve, thereby allowing uncontrolled flow through the
drillstring.

(7) Inform the Company Representative and Contractor Toolpusher onboard.

(8) Install and test the kick single assembly as detailed in steps ‘a’ - ‘e’ below:-

(a) Set the string in the slips.

(b) Bleed off the pressure downstream of the closed lower kelly cock and check
the pressure integrity of the closed lower kelly cock.

(c) Break the connection above the closed lower kelly cock.

(d) Make-up the kick single assembly and pressure test the system against the
closed lower kelly cock to the initial closed-in drillpipe pressure plus 3000
psi.

If the flexible hose to the kick single assembly has been disconnected (eg:-
for racking back purposes), pressure test the connection against the plug
valve to 15k.

(e) Equalise the pressures and open the lower kelly cock.

(9) Check the space out and close the upper pipe rams (using reduced operating
pressure).

(10) Land the drillstring on the upper pipe rams, (if necessary using reduced operating
pressure on the upper annular preventer), and close the ram-locks.
 Note: Remember to increase the operating pressures back to normal again
after landing.

(11) Determine the influx volume and prepare to kill the well as per Section 6.3,
“Circulating Out the Influx”.

Remember that once a well is closed in following a kick:-

(a) All work permits shall be withdrawn.

(b) The following parties shall be informed:-

- Standby boat
- Drilling Superintendent
- Rig Manager

The OIM will also have responsibilities about whom to inform (eg:-
coastguard) in accordance with his own emergency procedures.

(c) Crews should be mustered and all personnel to be informed of the status.

6.3 Circulating Out The Influx

To ensure that the limitations of the surface equipment are not exceeded, especially
when any gas reaches surface, the normal killing procedure must be modified as
follows:-

(1) On the well killing graph mark the point at which theoretical top gas reaches the
wellhead. Apply a safety factor to this point by reducing the time (strokes) by
(say) 25%. Stop the pump and closed in at this point then restart the killing
operation at a suitable displacement rate which will ensure that the mud-gas
separator is operated within its capacity.

Remark: For some rigs, the recommended kill rate detailed on the kill curve may
be acceptable to use for the complete circulation in that it is not too slow
and that it also complies with operating within the capacity of the mud-
gas separator. However, for other rigs, although time is not an issue, to
use the recommended kill rate for the complete circulation may be
undesirable, and hence the pre-requisite above, to ensure that at least
the recommended kill rate is not exceeded from when the gas reaches
the wellhead.
At the point when theoretical top of gas (including safety factor) reaches the wellhead,
the injection of glycol should commence. Once it has been determined that the situation
is outwith the range of hydrates forming, then glycol injection can cease. Thereafter, the
situation should be monitored in case as a result of changes in pressure and/or
temperature, injection becomes necessary again.

Remark: The formation of hydrates depends primarily on two parameters,

namely pressure and temperature, for any given gas gravity. (Refer to
Welltest hydrates for more information, or the chart in Fig 11 for
determining the hydrate range).

(2) Details of these limitations are as follows:-

(a) The maximum temperature at the choke manifold should not exceed 230°F.

Remark: The TEMPEST programme estimates the temperature at the seabed

from a temperature at the choke manifold taking into account the
cooling effect of the sea. To reflect the maximum temperature at the
BOP, which for continuous operations is 250°F., a value of 230°F. at the
choke manifold is used.

(b) The pressure in the choke manifold buffer chamber should not be allowed to
exceed 250 psi otherwise a relief valve on the buffer chamber will lift and
vent fluids to the overboard lines. (See section 2.3).

(c) The pressure in the mud-gas separator should not be allowed to exceed circa
5 psi, in order to protect the liquid seal, (and thereby also prevent wellbore
fluids being transmitted back to the mud system). (See section 2.4).

(d) If there are indications of hydrates forming or if the temperature/pressure

range that will support the formation of hydrates is being approached, then
inject glycol.

If any of these limitations are reached, the well should be closed in and corrective
action taken. Having resolved any problems, the killing operation should be
restarted in accordance with standard procedures

(3) Once the influx has been circulated out and kill mud circulated around, close in
and check that the pressures are zero.

(4) Depending on the reason shy the influx entered the wellbore, and increase in mud
weight is likely to be required. The amount of increase will be governed by
several factors including pore pressure, overbalance including riser and trip
margins, maximum allowable mud weight, and ECD.
 Refer also to Section 7.1.1, “Mudweight Reduction in a Loss/Gain Situation”.

(5) Flowcheck the well via the choke line.

(6) Circulate the riser and BOP to the new mud weight in a controlled manner to
address the possibility of trapped gas. (EP 89-1500, section 2.3.4.18 provides a
general approach to coping with trapped gas below closed preventers).

(7) Open up the well, then observe the well dead.

6.4 Kick With Bit Off Bottom - Tripping: Rig With Top Drive

When a kick is first detected, close-in the well as soon as possible in the following way:-

(1) Install the open stab-in IBOP (standby kelly cock).

If unable to do so due to heavy backflow, blear the vicinity of all personnel then
make-up the top drive. Continue as below but adjust for the fact that the stab-in
IBOP is not installed. If unable to even make-up the top drive, lose the shear
rams.

(2) Close the stab-in IBOP.

(3) Close the upper annular preventer.

(4) Open the failsafe valves in the upper chokeline.

(5) Record time and initial closed-in annulus pressure.

(6) Inform the Company OWE and Contractor Toolpusher onboard.

(7) Make-up the top drive and pressure test the system against the closed stab-in IBOP
to the initial closed-in annulus pressure plus 3000 psi.

Remark: It may seem anomalous to install the top drive at this point rather than
the kick single - mush however will depend on the closed-in annulus
pressure. The main difference between the situation off bottom
compared to that on bottom is that the plan is to land-off then strip-in
rather than land-off and circulate out the influx; the latter case
requiring the kick single as explained in section 6.1, item 8, Remark.

(8) Equalise the pressures (using the closed-in annulus pressure as a guide) and open
the stab-in IBOP.
 (9) Check the space out and close the upper pipe rams (using reduced operating
pressure).

(10) Land the drillstring on the upper pipe rams, (if necessary using reduced operating
pressure on the upper annular preventer), and close the ram-locks.

Note: Remember to increase the operating pressures back to normal again

after landing.

(11) If the HDIS dart is in place, record time and ‘initial’ drillpipe pressure by slowly
pumping down the drillstring while observing the closed-in annulus pressure. The
‘initial’ drillpipe pressure should be recorded as the HSID valve opens, ie: just as
the annulus pressure begins to rise.

(12) Determine the influx volume and prepare to strip-in. Note however that the
difference between the buoyant string weight in the hole and the upward force
exerted on it by the closed-in pressure will determine the way in which to kill the
well. Remember that once a well is closed in following a kick:-

(a) All work permits shall be withdrawn.

(b) The following parties shall be informed:-

- Standby boat
- Drilling Superintendent
- Rig Manager

The OIM will also have responsibilities about whom to inform (eg:-
coastguard) in accordance with his own emergency procedures.

(c) Crews should be mustered and all personnel to be informed of the status.

6.5 Kick With Bit Off Bottom - Tripping: Rig With Kelly

When a kick is first detected, close-in well as soon as possible in the following way:-

(1) Install the open stab-in IBOP (standby kelly cock).

If unable to do so due to heavy backflow, attempt to stab the kelly and make the
connection. Continue as below but adjust for the fact that the stab-in IBOP is not
installed. If unable to even make-up the kelly, close the shear rams.

(2) Close the stab-in IBOP.

(3) Close the upper annular preventer.

(4) Open the failsafe valves in the upper chokeline.

(5) Record time and initial closed-in annulus pressure.

(6) Inform the Company OWE and Contractor Toolpusher onboard.

(7) Install and test the kick single assembly as detailed in steps ‘a’ - ‘c’ below:-

(a) Set the string in the slips.

(b) Make-up the kick single assembly and pressure test the system against the
closed lower kelly cock to the initial closed-in annulus pressure plus 3000
psi.

(c) Equalise the pressures (using the closed-in annulus pressure as a guide) and
open the stab-in IBOP.

(8) Check the space out and close the upper pipe rams (using reduced operating
pressure).

(9) Land the drillstring on the upper pipe rams, (if necessary using reduced operating
pressure on the upper annular preventer), and close the ram-locks.

Note: Remember to increase the operating pressures back to normal again

after landing.

(10) If the HDIS dart is in place, record time and ‘initial’ drillpipe pressure by slowly
pumping down the drillstring while observing the closed-in annulus pressure. The
‘initial’ drillpipe pressure should be recorded as the HSID valve opens, ie: just as
the annulus pressure begins to rise.

(11) Determine the influx volume and prepare to strip-in. Note however that the
difference between the buoyant string weight in the hole and the upward force
exerted on it by the closed-in pressure will determine the way in which to kill the
well. Remember that once a well is closed in following a kick:-

(a) All work permits shall be withdrawn.

(b) The following parties shall be informed:-

- Standby boat
- Drilling Superintendent
- Rig Manager

The OIM will also have responsibilities about whom to inform (eg:-
coastguard) in accordance with his own emergency procedures.
 (c) Crews should be mustered and all personnel to be informed of the status.

6.6 Explanatory Notes

Methods by which to proceed to kill well when the bit is off bottom are determined by
whether or not the drillstring can be stripped in. This aspect is expanded in the two
explanatory notes below:-

(1) If the upward force (closed-in pressure multiplied by the cross-sectional area of
the closed-end drillpipe) exceeds the buoyant weight of the drillstring it will not be
possible to strip in. Further action will depend on the gas migration rate.

(2) If the buoyant weight of the drillstring exceeds the upward force (closed-in
pressure multiplied by the cross-sectional area of the closed-end drillpipe) exerted
on it by the closed-in drillpipe pressure, the drillstring should be stripped back to
bottom as per Section 6.8, “Stripping-In Procedures”. Furthermore, it should be
noted that:-

(a) Once the bit is on bottom, install the kick single assembly and land-off as
detailed in steps i. to v. below:-

(i) Set the string in the slips.

(ii) Make up the kick single assembly and pressure test the system against
the closed kelly cock on the bottom of the kick single to the initial
closed-in drillpipe/annulus pressure plus 3000 psi

If the flexible hose to the kick single assembly has been disconnected
(eg:- for racking back purposes), pressure test the connection against
the plug valve to 15k.

(iii) Open the kelly cock.

(iv) Check the space out and close the upper pipe rams (using reduced
operating pressure).

(v) Land the drillstring on the upper pipe rams and close the ram-locks.

Note: Remember to increase the operating pressures back to normal again

after landing.

Circulate the influx out (using the original mud weight).

 (b) If gas reaches surface before the bit is on bottom, stop stripping in then
install the kick single assembly and land off as detailed above in Section
6.6.2a, steps I to v.

Circulate out the gas (using the original mud weight) from where the bit is
positioned, maintaining constant standpipe pressure. Thereafter, continue
stripping in until gas reaches surface again or the bit reaches bottom.

Once the bit is on bottom, install the kick single assembly and land off as
detailed above in Section 6.6.2a, steps i. to v.

Circulate the influx out (using the original mud weight).

6.7 Kick With Pipe Out of Hole

If the well starts to flow without any pipe in the hole:-

(1) Close the shear rams, and close the (shear) ram-locks.

(2) Open the failsafe valves in the upper kill-line.

(3) Record time and initial closed-in pressure.

(4) Inform the Company Representative and Contractor Toolpusher onboard.

Remember that once a well is closed in following a kick:-

(a) All work permits shall be withdrawn.

(b) The following parties shall be informed:-

- Standby boat
- Drilling Superintendent)
- Rig Manager

The OIM will also have responsibilities about whom to inform (eg:-
coastguard) in accordance with his own emergency procedures.

(c) Crews should be mustered and all personnel to be informed of the status.

There are several options now, namely:-

- Stripping in, taking into account heave, pressure, buoyant weight of BHA in
riser, etc.
- Volumetric method
- Bullheading
 From the closed-in pressure readings measured against time, the migration rate can
be estimated as follows:-

Migration Rate (ft/hr) = Pressure Increase (psi/hr)

Mud Gradient (psi/ft)

If the estimated migration rate is less than 1000 ft/hr, then the well may be
bullheaded dead after confirmation with Base.

If the estimated migration rate is more than 1000 ft/hr, the gas will be allowed to
migrate to surface.

The closed-in pressure should be allowed to build up by a safety margin of say

100 psi. This margin is recommended to reduce the chance of the well becoming
underbalanced. Where a low MAASP prevents excess pressures being applied to
the wellbore, this margin may have to be reduced. Thereafter, mud has to be bled
off in order to allow the gas to expand. Subsequently, to compensate for the loss
in hydrostatic head, additional closed-in pressure, (Pw as in the stripping case),
has to be applied. Conversely, when gas reaches surface, the situation is reversed.
As gas leaves the well it has to be replaced by mud. To compensate for the gain in
BHP, pressure has to be bled off.

For example, using 0.92 psi/ft mud in 9.5/8” x 72 lbs/ft casing:-

Pw (psi/bbl) = Mud Gradient (psi/ft) = 0.92

Casing Capacity (bbl/ft) 0.0641

= 15 psi

For each barrel of mud bled off, an additional 15 psi should be applied and
maintained on top of the closed-in pressure.

Once the gas reaches surface the reverse applies. For every 15 psi pressure bled
off, 1 bbl of mud should be pumped into the well to compensate for the reduction
in pressure.

(Refer to EP 89-1500, Section 2.3.8.2, “String Out of Hole”, for a detailed

example).

6.8 Stripping-In Procedures

Rig specific stripping procedures should be in place as part of the Drilling Contractor’s
own standard operating procedures. Check that there are agreed:-

- strip drill procedures

 - stripping checklists
- stripping calculation sheets
- stripping sheets for recording parameters such as pressures, tank levels, time,
stand number, etc.

7 HPHT CONTINGENCY PROCEDURES

7.1 Drilling Fluid Losses

This section can also apply to combined losses and gains situations.

Even given a formation strength at the deep intermediate casing shoe that is capable of
containing the expected overpressures, it is still possible that fluid losses occur.

Losses could start while drilling through a weak zone between the formation at the
casing shoe and the objective.

Once drilling through the objective, the overbalance over the formation pressure will
increase with depth, due to the large difference between the mud and formation fluid
gradients. This increasing overbalance could subsequently be the cause of losses deeper
in the well.

Losses can also be induced by surge pressures; mainly when running in and especially
when using highly viscous, heavy muds. If losses occur in this situation, it is difficult to
establish where the loss zone is, and, depending on the position of the drillstring in the
hole, it may be difficult to place curing material across the loss zone.

Drilling ahead shall not continue if dynamic losses of greater than 10 bbl/hr persist.

Other points regarding losses should be noted:-

(1) Where the ECD is a contributing factor to a loss situation, experience has shown
that drillstring rotation can cause the ECD to increase, thereby exacerbating the
situation.

(2) On a round trip it is advisable during running in (say half-way) to circulate in

order to establish whether a (theoretical) ECD can be achieved.

For the same reason, this exercise should be repeated at the shoe. Being at the
shoe is seen as the best compromise in case losses are actually induced; the
drillstring is not in open hole, and the bit should be close enough to bottom for the
placement of cement.

While mudweights are designed to overbalance expected (virgin) formation, if losses

have occurred the formation may be supercharged and as such could give back fluid. If,
 in the process of giving back fluid, hydrocarbons are also flushed out of the formation,
the wellbore will have taken an influx without it being recognisably induced.

7.1.1 Mudweight reduction in a loss/gain situation

Planned reductions of mud weight shall be carried out in stages in a controlled manner,
and shall include a short trip for each stage to confirm that sufficient overbalance exists.
For each stage, the (static) bottom hole pressure that existed with the mud weight being
circulated out shall be maintained when circulating in the new (lower) mud weight by
taking returns through the choke. While maintaining bottom hole pressure, dynamic
losses should be avoided and much will depend on the circulating rate (ECD) and
pressure drop across a fully open choke when determining appropriate back pressure (if
any).

It may be necessary at the end of each stage prior to commencing the short trip to
observe the well closed-in in order to check for any pressure build-up. If pressure is
registered it could be due to supercharging. To ascertain if this is so, the pressure should
be bled back (possibly to zero) by ensuring that an equivalent safe (manageable) influx
volume of say 5 bbls. Is not exceeded. This volume should then be circulated out again
maintaining bottom hole pressure yet avoidi8ng dynamic losses. The influx can be
checked at surface for the presence of hydrocarbons. This process of bleeding back and
circulating out the volume may have to be repeated several times to reduce to zero any
pressure due to supercharging. If it becomes apparent that the pressure is caused by
being underbalanced, the well shall be killed.

7.2 Emergency Cement Plugs

A situation involving losses may necessitate the performing of a cement squeeze through
the bit. A combination of fluids to spot may comprise:-

- spacer (if required)

- pre-flush
- slurry (including tracer if required)
- post-flush
- spacer (if required)
- mud

As an option an LCM pill can be included after the mud, but this has to be taken into
account when spotting the fluids.

An outline of the method (for a short open hole section) would be as follows.
Appropriate variations may be required dependent on the rate of losses incurred before
and during execution:-

(1) With the bit inside the shoe, spot the fluids in such a way that the pipe is pulled
back further while the cement is filling the void below the bit.
 (2) Pull back an additional stand (say) to ensure that the bit is above the top of the
cement.

(3) Make sure the drillstring bore is clean by circulating partial or even full string
contents at a high rate. The resultant ECD during this circulation will provide
some squeeze pressure and therefore the rate of circulation may have to be
adjusted to suit.

Remark: It is important to remove all the cement from the drillstring before
closing in and applying squeeze pressure in case the string becomes
plugged as a result.

(4) Close-in on the upper annular preventer: (ideally the annulus below the BOP
should be full).

Note: Any cement that has strayed above the bit needs to be circulated out
conventionally while keeping the string moving. Again, the resultant
ECD during this circulation will provide some squeeze pressure and
therefore the rate of circulation may have to be adjusted to suit.
Additional squeeze pressure can be achieved by circulating over the
choke.

(5) Apply squeeze pressure. The annulus pressure can be monitored via the kill or
choke line in order to monitor the squeezing process.

(6) Check for losses and /or imbalance, then open up well. Ensure that the drillstring
is kept free and clear by movement/circulation.

In a long open hole section or in a situation of sudden severe losses it may not be
possible to pull the bit back to the shoe. Again though, cement should be spotted in
such a way that as the pipe is pulled back cement fills the void below the bit.

7.3 Operating the BOP and Loss of Control

In all cases where a well control situation in deteriorating, the Emergency Response
Procedures (which recognise the OIM as being the ultimate level of responsibility on the
rig) must be adhered to.

(1) A well should always be closed-in initially using the upper annular preventer. The
lower kill line should not be used to take returns and the inner and outer failsafe
valves on the lower kill line should be kept closed. This will allow the bottom
(pipe) rams to be a last line of defense, whereby if they are closed, any leak that
may have developed in the choke line will be isolated. (See overall stack
configuration in section 5.2.3).
 In the event that this occurs, a decision will be made in conjunction with Base
regarding the options, including:-

(a) Bullheading the well.

(b) Continuing well killing operations utilising the lower kill line.
(Although not recommended, the well kill could be very near to completion
of phase 3 or 4).

(c) Pump cement down the drillpipe with returns via the lower kill line.

(2) At some point it may become necessary due to loss of control to abandon the
situation and move the rig off the well. The exact method of how the situation is
abandoned will depend upon the circumstances whereby loss of control occurred,
but well containment should obviously take precedence. In b terms:-

(a) The shear rams should be closed.

(b) The riser disconnected from the well.

(c) The rig pulled in an optional direction (ie: upwind/up-current) off location
using the anchors.

(d) In consultation with the OIM consider further/total evacuation of the rig.

Note: In order to give the shear rams the best possible chance of shearing the
pipe, regulated pressure to the shear rams should be increased to the
full 3000 psi accumulator pressure (by opening the by pass valve). On
some systems the act of closing the shear rams may automatically apply
the full unregulated accumulator pressure. The remote panels at the
evacuation points should be checked to determine whether they are able
to operate the shear rams on full unregulated accumulator pressure.

Consider for example the following situation:- if the lower pipe rams are closed to
protect a failed choke line and then the pipe is sheared, the drillstring will slip through
the lower pipe rams and the well will blow out through the failed choke line. In such an
instance it may be better to land off on the lower pipe rams, close the middle pipe rams,
pull string tension with the tooljoint against the bottom of the close middle pipe rams,
then close the shear rams.

The message being conveyed is that there may be preferable ways of abandoning
the situation. Remember, closing the shear rams does not automatically secure the
well.

7.4 Repairs to Surface Equipment

 Situations may arise where it is necessary to effect repairs to vital surface equipment
with pipe in the hole. If these repairs prevent the hoisting equipment or circulation
system being used then the situation is exacerbated.

Bear in mind that with the drillstring set in the slips on a heaving rig, the mechanism
(especially if not circulating) for swabbing exists. Developing procedures to cover
every possible scenario is virtually impossible. As such, the following precautions are
listed and can be applied wherever necessary:-

(1) Ensure an accessible string IBOP is installed.

(2) If possible maintain circulation and monitor pit volumes.

(3) If unable to circulate, continuously monitor the fluid level in the drillstring and
annulus.

(4) Consider closing-in the well with the drillstring hung off in the BOP, and monitor
closed-in pressures.

(5) The Company DSC should ensure that all relevant personnel are briefed on the
potential for well control problems, and that the drillfloor is manned constantly by
personnel capable of taking the appropriate action.

(6) Especially after completing an extended period of repairs, circulate the drillstring
plus annulus volume to check for hydrocarbons.

Note 1 By filling the hole with a measured amount of light fluid, and estimation of
the formation strength can be made and used to possibly reduce the mud
gradient, depending on formation pressures. Water, KCL-premix or oil can
be used as light fluid, depending on the mud system in use.

Note 2 After filling up the annulus with light fluid, the well could be flowing because
of the loss of overbalance due to the lighter column, or due to the influx that
entered the well before the annulus was filled up.

Note 3 By squeezing LCM down the annulus the light fluid below the BOP’s will be
displaced into the loss zone followed by the LCM.

Note 4 In case the losses cannot be reduced by LCM, a cement squeeze should be
tried. To increase the chances of success the string should be as close as
possible to the loss zone, hence strip in to the casing shoe. If there are any
indications that gas is migrating up, contamination of the complete annulus
should be avoided by squeezing mud down the annulus at a rate equivalent to
the migration rate.
Note 5 If the loss zone is below the producing zone, any influx that may have entered
the well will be squeezed away and given that the losses are cured, full
balance has been restored.

Note 6 If the well is still presurised after the losses are cured, this could mean that
there is still an influx in the well bore ie. The loss zone was above the
producing zone. To remove this influx from the well, the string needs to be
stripped in to below the influx to circulate the influx out.