OTC 7248

Outer Continental Shelf Drilling Blowouts, 1971-1991

E.P. Danenberger, Minerals Management Service

This paper was presented at the 25th Annual OTC in Houston, Texas, U. S.A., 3-6 May 1993,

This papar waa aelectad for presentation by the OTC Program Committee following review of information contained in an abstract submitted by the author(s). Contants of tha papar,
aa presented, have not baan reviewed by the Offshore Technology Con farance and are aub)ect 10 cmrraction by tha author(a). The material. aa DraSentad. does not nacessarilv reflect
any position of the Offshora Technology Con farance or ita officers; Permission to copy Is restr;ctad to an abstract Of not more than 300 words. Iilustfationa may not ba copied, The ~bstract
should contain conspicuous acknowledgment of whare and by whom the papar is presanted,

ABSTRACT expensive, and feared operational hazard.

At best, they result in costly delays in
From 1971 through 1991, 87 blowouts drilling programs. They also may lead to
occurred during drilling operations on the fires, explosions, casualties, serious
Outer Continental Shelf of the United property damage, and pollution.
States. During this 21-year period, 21,436
wells were drilled. Eleven of the blowouts The Minerals Management Service maintains
resulted in casualties (61 injuries and recordg on all blowouts resulting from oil,
25 fatalities). Most of the blowouts were gas, and sulfur operations on the Outer
attributable to shallow gas influxes and Continental Shelf (OCS) of the United
were of short duration. The overall States. (Two previous Department of the
blowout rate was one per every 246 wells Interior reports addressed OCS blowouts
drilled (one per 256 wells drilled if [Danenberger, 1980 and Fleury, 1983].) The
sulfur wells are excluded). The rate for information in this report is derived from
blowouts with casualties and fatalities was a review of a total of 87 blowouts that
significantly lower. occurred during drilling operations in
Federal offshore waters from January 1,
INTRODUCTION 1971, through December 31, 1991. This
report covers blowouts that occurred at any
The control of underground pressures is the phase of a drilling operation but does not
most important concern in the planning and consider blowouts that occurred during
conduct of oil and gas drilling operations. completion, workover, or production
Improper well-control procedures can result operations. Four of the blowouts occurred
in the sudden, uncontrolled escape of during sulfur well drilling; the remainder
hydrocarbons. Such a loss of well control involved oil and gas drilling operations.
is commonly referred to as a blowout. All of the blowouts were in the Gulf of
Blowouts are the most spectacular, Mexico (GOM) where 95.8 percent of all new
OCS wells were drilled during this period.
References, tables, and figures at end of Casualties (61 injuries, 25 fatalities)
paper. resulted from 11 (12.6 percent) of the
blowouts. Because oil was not associated

415
2 OUTER CONTINENTAL SHELF DRIILING
with any of the natural gas influxes that
triggered these drilling blowouts,
pollution and environmental damage were
minimal.
SHALLOW GAS
Although development wells accounted for
62.6 percent of the oil and gas drilling
during this period (table 1), 46 (55.4
percent) of the 83 nonaulfur well blowouts
occurred during exploratory drilling
(figure 1). The greater incidence of
blowouts during exploratory drilling may be
attributable to the relative absence of
geologic information and drilling data.
Because’ most exploratory wells are not
commercially producible, the occurrence of
drilling blowouts in the GOM may not be
strongly linked to well producibility.
This judgment is further supported by
information on the well depths at the time
the blowouts occurred (table 2 and figure
2). Fifty-eight (66.7 percent) of the
blowouts occurred before the wells had been
drilled to a depth of 5,000 feet and were
not triggered by hydrocarbon influxes from
commercially productive intervals. These
wells flowed shallow gas that was over
pressured, undetected, or improperly
controlled.
Although the rate of blowout occurrence
during development drilling was lower, a
slightly greater proportion of the events
involved shallow gas. Despite the
availability of more detailed geologic data
during the development drilling phase, 25
of the 37 (67.6 percent) development
drilling blowouts flowed gas from shallow
zones. This blowout rate is further
evidence of the important role of shallow
gas in drilling blowouts.
CONTRIBUTING FACTORS
An influx of gas into the wellbore was a
precursor to each of the blowouts.
Blowouts resulted when an event or, more
typically, a series of events led to an
uncontrolled release of gas from the well.
Occurrences or circumstances that
contributed to such losses of well control
416
BLOWOUTS, 1971-1991 OTC 7248
are summarized in figure 3.
One or more contributing factors were
identified for 70 of the 87 blowouts.
Unintentional swabbing, or the lifting of
well fluids while pulling the drill string
from the wellbore, was identified as a
contributing factor in 21 (24.1 percent) of
the blowouts. Other important contributing
factors included the fracturing of sub-
surface formations allowing gas to escape
to shallow sediments or to the seafloor (21
blowouts or 24.1 percent), equipment
failures (16 blowouts or 18.4 percent), gaa
migration during or after the cementing of
well casing (16 blowouts or 18.4 percent),
casing leaks or ruptures (5 blowouts or 5.7
percent), drilling into or inducing
communication with other wells (5 blowouts
or 5.7 percent), and stuck pipe (3 blowouts
or 3.4 percent). No attempt was made to
quantify the. extent to which human error
contributed to each of the blowouts.
BLOWOUT DURATION
Most of the blowouts were of short duration
(figure 4); 18 (20.7 percent) ceased
flowing in less than an hour, a cumulative
of 50 (57.5 percent) in less than a day,
and a cumulative of 73 (83.9 percent) in
less than a week. Figure 5 helps to
explain the short durations. Most (62 or
71.3 percent) of the wells stopped flowing
when sediments in the uncased portion of
the well bridged or sealed the well. If
the uncased portion of the well includes an
unconsolidated section of sufficient
length, this bridging action often occurs
shortly after the well starts flowing. Of
the 62 flowing wells that bridged, 55 did
so in less than a week.
Of the wells that did not bridge, all but
two were controlled by pumping mud or
cement or by actuating mechanical well-
control equipment. The two exceptions
involved trapped gas that dissipated upon
release. Although relief wells were
initiated during several of the blowouts,
all of the flowing wells were controlled by
other means prior to completion of the
relief wells.
OTC 7248 ELMER P. DANENBERGER
BLOWOUT RATES AND EFFECTS
During the 21-year study period, oil and
gas drilling blowouts occurred at a rate of
one per every 256 wells drilled (figure 6).
The rate for exploratory wells was one per
173 wells drilled; for development wells,
the rate was one per 359 wells drilled.
Four blowouts occurred while drilling 197
sulfur wells. The high blowout rate for
sulfur wells is attributable to shallow gas
drilling problems at a major sulfur
discovery in the GOM. Casualties from
blowouts resulted from one well per 1,948
wells drilled. One of every 3,573 wells
resulted in fatalities from blowouts (857
wells per fatality).
Six of the 11 casualty events occurred
during development drilling. Fourteen of
the 25 drilling blowout fatalities and 40
of the 65 injuries resulted from these 6
incidents. One of these incidents, a 1980
shallow gas blowout, resulted in 6 fatal-
ities and 29 injuries.
Figure 7 depicts the number of blowouts and
wells started from 1971 through 1991.
These data do not indicate a significant
improvement in the blowout record over the
study period. However, there is evidence
of a lessening in the consequences of
blowouts. No fatalities or serious
injuries resulted from drilling blowouts
during the last 7 years of the study
period. A total of 6,450 wells were
drilled (well footage of more than 65
million feet) during this 7-year period.
Significant volumes of liquid hydrocarbons
were not associated with any of the
drilling blowouts. Records on file
indicate two spills associated with
drilling blowouts before 1971: the Santa
Barbara blowout in 1969, which released an
estimated 80,000 barrels of oil into the
Santa Barbara Channel, and a 1965 gas
blowout in the GOM, which released 1,700
barrels of condensate.
WATER DEPTH
Table 1 and figure 8 present the number of
417
3
wells drilled and the number of blowouts by
water depth. For”water depths of 200 feet
or less, an average of 334 wells were
drilled per blowout. For wells in water
depths of greater than 200 feet, the
blowout frequency increased to one for
every 176 wells drilled. One possible
explanation for the difference in blowout
rates is the increased presence of shallow
gas, sourced in the thick, overlying
organic-rich Recent sediments (Ray, 1992),
in the Pleistocene trend of the GOM, much
of which is in water depths of more than
200 feet. Figure 9 is a map of shallow
gas blowouts by production trend. The map
and data provided in table 3 indicate a
higher risk of shallow gas blowouts for
Pleistocene trend wells. Other possible
explanations for the higher blowout rate
include the lower fracture gradients for
wells in deeper water and the increased use
of floating drilling rigs and seafloor
blowout prevention equipment.
The high blowout rate for wells in 501 to
1,000 feet of water (table 1) is largely
attributable to four blowouts at a single
facility. Without these incidents, the
occurrence rate would have been comparable
to that for the 201- to 500-foot depth
range. Interestingly, the blowout record
for wells drilled in depths greater than
1,000 feet has been comparable to that for
shallow (<200 feet) water depths. Blowout
trends by water depth will receive further
scrutiny as more deep-water wells are
drilled.
RIG TYPE AND DIVERTER SYSTEMS
?
Of the 53 blowouts involving wells drilled
with mobile units (figure 10), 30 were
being drilled with jackups. Although this
exceeds the number of blowouts for wells
drilled with other types of mobile units,
jackup rigs conduct most of the exploratory
drilling in the GOM. Veritas (1990)
reports 1,691 jackup unit-years in the GOM
during the period 1970-1989. This number
represents 66.1 percent of all mobile
drilling activity (2,558 unit-years) during
this timeframe. Assuming that jackup use
was at least as dominant during the entire
4 OUTER CONTINENTAL SHELF DRILLING BLOWOUTS, 1971-1991
1971-1991 study period, jackups would have
the lowest blowout frequency per unit-year.
The consequences of blowouts from jackups
and other bottom-founded rigs have been
more severe than those for floating
drilling units. Only 1 of the 18 blowouts
that occurred during drilling operations
from floating rigs (semisubmersibles and
drillship) resulted in casualties and
major property damage. In contrast, 10 of
the 69 blowouts attributed to drilling from
bottom-founded structures (platforms,
jackups, and submersibles) resulted in
casualties, and 15 rigs incurred major
property damage. Although more complex
well-control operations may increase the
risk of gas blowouts in deeper waters,
floating rigs and their employees appear to
be less endangered.
The stability of bottom-founded rigs can be
affected by disturbances to the seafloor.
Such drilling structures can collapse if a
shallow gas influx fractures the uncased
portion of the hole and forms a crater
around the wellbore. To prevent such
occurrences, many operators prefer not to
shut in shallow gas influxes but to allow
the gas to flow to the surface where it is
directed downwind through diverter lines.
Such diverter systems are intended to
provide time for the evacuation of rig
personnel, to deplete the shallow gas sand,
or to allow the well to bridge. Because
capabilities for controlling diverted gas
flows are extremely limited, all of the gas
diversion events during the study period
were counted as blowouts.
●
As indicated in figure 11, the failure rate
for diverter systems has been high.
Diverters were used during 41 of the
drilling blowouts. Nineteen of the 41
diverter uses were considered failures
because the desired venting of gas could
not be sustained until the wells bridged or
were satisfactorily controlled. Figure 12
presents annual data on diverter use and
performance and indicates an improvement in
diverter performance in recent years.
During 1989-1991, seven of the eight
diverter uses were successful.
418
OTC 7248
Information on the problems Jthat
contributed to the diverter failures is
summarized in figure 13. Table 4 presents
information on diverter use and failures by
rig type. As would be expected, the main
use of diverters has been on bottom-founded
rigs. Table 4 also indicates a superior
performance record for diverter systems on
platforms.
The failure rate for diverters would have
been lower if each diverter use that
allowed sufficient time for the safe
evacuation of personnel was deemed to be a
success. Seven more diverter uses (four on
platforms, two on jackups, and one on a
semisubmersible) would qualify as
successful under these less demanding
criteria.
CONCLUSIONS
Drilling data do not indicate a significant
reduction in blowout frequency over the
period 1971-1991. The failure to reduce
drilling blowout occurrence rates is
largely attributable to difficulties in
drilling through shallow gas sands. Given
the serious limitations in methods for
controlling shallow gas influxes, more
emphasis on improved gas detection and
avoidance capabilities may be needed.
Although recent data suggest some
improvement in the performance of diverter
systems, such systems have not proven to be
a sufficiently reliable means of handling
shallow gas influxes. The risks in
allowing gas to flow to the surface and be
diverted must be carefully weighed against
the risks of shutting in the well.
Although electing not to divert a shallow
gas influx may increase the risk of gas
channeling back to the seafloor and forming
a crater, this risk may be low if the
operator has confidence in the integrity of
the wellbore or unimportant if the well is
being drilled from a floating rig. In any
case, thorough consideration of gas
handling procedures is required before
drilling operations are initiated.
Swabbing, a perennial drilling problem,
OTC 7248 ELMER P . DANENBERGER 5

remains an important contributing factor in 2. Fleury, Mark G. R.: Outer

drilling blowouts. Training programs must Continental Shelf Oil and Gas
continue to stress mud conditioning, Blowouts 1979-1982, U.S. Geological
attention to mud volumes in the wellbore, Survey, Open-File Report 83-562 (Aug.
and controlled drill etring withdrawal 1983) .
rates. It is hoped that the expanded use
of top drive drilling systems, which permit 3. Ray, Kumkum: Personal communication
more rapid response to gas influxes while (1992) .
tripping, and other improvements in
drilling systems will reduce the number of 4. Veritas Offshore Technology and
blowouts triggered by swabbing. Services A/S: Worldwide Offshore
Accident Databank, WOAD Statistical
The large number of blowouts during or Report, Norway (1990).
after cementing operations merits
attention. Improved methods and procedures
for preventing and detecting gas migration
during cementing activities may be needed.
Additional consideration should also be
given to the detection of gas trapped
beneath the casing when drilling resumes.

A surprising number of blowouts (five) were

triggered by drilling into adjacent wells.
Proper well planning and execution should
preclude this type of incident. Equipment
(not including diverter systems) and casing
failures were identified for less than one-
fourth of the blowouts and have generally
been less prevalent in recent years. A
more detailed review of equipment perform-
ance is planned.

The most favorable and encouraging trend is

the absence of casualties from drilling
blowouts during the last 7 years of the
study period. This result may be partially
attributable to prompt evacuations of
personnel and improvements in diverter
performance. Casualty figures are the most
important performance indicator. Continued
success will be dependent upon sustained
efforts by industry and Government to
improve the performance of personnel and
equipment.

REFERENCES

1. Danenberger, Elmer P.: Outer

Continental Shelf Oil and Gas
Blowouts, U.S. Geological Survey,
Open-File Report 80-101 (1980).

419
6 OUTER CONTINENTAL SHELF DRILLING BLOWOUTS, 1971-1991 OTC 7248

Table 1 - Boreholes with spud dates of 1971 through 1991

WELLS
WATER TOTAL TOTAL WELLS PER
DEPTH EXP . DEV . SULFUR WELLS BLOWOUTS BLOWOUT

● o- 200 ft 4,744 8,120 148 13,012 39 334

● 201 - 500 ft 2,312 4,599 49 6,960 38 183
. 501 - 1,000 ft 395 351 746 8 93
● > 1,000 ft 496 222 718 2 359

Total all Depths 7,947 13,292 197 21,436 87 246

(average rate)

‘able 2 - OCS Drilling blowouts by well depth, 1971-1991

BLOWOUT DEPTH NUMBER OF BLOWOUTS

S 2,000 feet 15

2,001 to 3,000 feet 15

3,001 to 4,000 feet 15

4,001 to 5,000 feet 13

5,001 to 6,000 feet 5

6,001 to 7,oOO feet 3

7,001 to 8,000 feet 1

8,001 to 9,000 feet 3
9,001 to 10,000 feet 3

10,001 to 11,000 feet o

11,001 to 12,000 feet 3

12,001 to 13,000 feet 3

13,001 to 14,000 feet 3

14,001 to 15,000 feet 2

15,001 to 16,000 feet 2

> 16,000 feet 1

420
 ELMER P. DANENBERC3ER 7

1991

GEOLOGIC AGE OF WELLS DRILLED SHALLOW GAS WELLS PER AVERAGE DEPTH
PRODUCTION BLOWOUTS BLOWOUT (FT) TO TOP
OF PRODUCTION

Pleistocene 9,892 37 267 6,781

Pliocene 3,831 12 319 9,344

Miocene 6,723 8 840 9,815

Table 4 - Diverter use by rig type, 1971-1991

TYPE OF RIG DIVERTER USES FAILURES

Platform 24 8

Jackup 11 8

Semisubmersible 4 3

Submersible 1 0

Drillship 1 0

421
 Deep
dawlopment 63% development 45%

.xploratlon 37% ●xploration 55%

wells drilled blowouts

[<5,000
ft]
Figure 1 - Percentage of oil and gaa wdla drilled and blowoute 67%
occurring by type of drilling, 1971-1991 Figure 2- Percentage of blowouts by well depth, 1971-1991

FormatIon Fracturea
1-6 hours

Equipment Failures

Cementing
6-24 hour
Caaing Failure 18%
aya

Drill Into Other Well

Stuck Pipe
, , I
o 5 10 15 20 25
26%
Number of Blowouts
Figure 4 - Percentage of blowouts by their duration,
Figure 3- Factors contributing to blowouts, 1971-1991
 Mud/Cemertt/Mechanical Exploratory well blowout
d Gas Dkipated (excludes sulfur wells)
2%

All blowouts
(excludes sulfur wells)

Development well blowout. 359

(exoludes sulfur wells)

Blowout w/ casualties- 1,948

(s11wells)

71% Blowout w/ fetellties -

(all wells)

o 1,000 2,000 3,000 4,000 5,000

Figure 5- Techniques used to controlblowout~ 1971-1991 Figur. 6 - Wolla drillad par lnold.n~ 1971.1991

A
N
0
Blowouts Well Starts
12 1,400

1,200
10
201-500 ft
1,000 44% <200 ft
8
45%
800
8
600
4
400

2 200
9% 2%
0 ~~ $’ ~~
1971 1976 1961 1988 1991

~“
Figure 8- Percentage of blowouts by watsr depth, 1971-1991
Figure 7- Number of well starts and drilling blowouts, 1971-1991
10 OUTER CONTINENTAL SHELF DRILLING BLOWOUTS, 1971-1991 OTC 7248

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\

Flgurall - Dlvorter usa, 1971-1991

Urm Dmnagui

Valve Fall od

Lln. Plugged

Annular Pr.v.ntor Fall.d

Flow Ignlt.d

Broach.d Casing

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Number of Incidents
Flgur. 13- Contrlbuthrg factors Irr dlv.rtor failur.s