WELL CONTROL

Well Control

Primary Well Control

• Drilling fluid density is the primary source of Well security.
• The fluid must prevent the influx of any formation fluid into
the wellbore, during conventional drilling operations.
• The Fluids Engineer must :
- Ensure adequate Fluid densities.
- Ensure Active volumes are monitored continuously,
especially during trips, by Driller, Mud Loggers and Mud
Crew.
- Investigate Changes in density, volumes and flow rates
immediately.
Causes of Kicks

• Failure to fill the hole properly while tripping reduces the borehole
fluid level and therefore the hydrostatic head.
• Swabbing, this reduces the effective hydrostatic head. This occurs
due to high pulling speeds or high viscosities.
• Lost circulation will reduce the hydrostatic head.
• Insufficient mud weight due to :
- drilling into an overpressured zone.
- accidental dilution of the drilling fluid.
- reduction in density due to influxes of :
• formation fluids (especially gas).
• settling of weight material, more likely in deviated holes.
• failure to displace the riser to kill mud after circulating out a kick.
• Loss of riser drilling fluid due to accidental disconnection, riser
damage or displacement to seawater.
Warning Signs of abnormally Increasing Formation Pressures

• Increase in ROP - overpressured formations drill faster.

• Increase in Pit volume can indicate an influx.
• Increase in trip gas, connection gas or background gas.
Trip gas may be high due to swabbing, as well as loss of
ECD. Connection gas is a very good indicator of
overpressure.
• Decrease in pump pressure can indicate an influx.
• Increase in torque and drag, this may be due to the
formation heaving or sloughing due to overpressure.
• Reduction in String weight.
• Change in cuttings size and shape, cuttings (Splinters)
from overpressured shales are usually long and splintery.
 Increasing Formation Pressure and ROP

• ROP is often used to evaluate

changes in Pore pressure

Reduction of D
exponent
• Change in d exponent. indicating
overpressure
log (R/60 N)
d= Depth
log (12W/ 10 6 D) Trend
line

R= rate of penetration. (ft/hr)

N = rotary speed. (r.p.m.)
W= weight on bit. (lbs)
D = bit size. (ins) D exponent
d = d exponent.
Increasing Formation pressure (ctd)

• Chloride Concentrations, these increase in overpressured

formations. This can be detected by:
- measuring the chlorides.
- measuring the resistivity.
- LWD.
• Shale density normally increase with depth.

Overpressured
formation
Depth

Trend
line

D exponent

• Temperature measurement, are higher in overpressured

formations. Temperature is also affected by dilution rates and
circulation times.
Shallow Gas

• This is gas found above the setting point of the first

casing string capable of pressure containment.
• Kicks are usually diverted because shutting in the well
could cause formation breakdown and cratering of the
wellbore. Kill mud is often kept on hand to deal with
shallow gas.
• Shallow gas is:
- difficult to detect early due to varying R.O.P's and constant
dilutions.
- Accumulates in shallow sedimentary formations with a high
porosity and permeability.
- Slightly overpressured. A pilot hole, 9 7/8" or less is often
drilled to test for shallow gas - One application of CTD in
Venezuela.
Well Control Procedures - Tripping

• Most kicks occur during trips, the following precautions are

required:
- Circulate bottoms up before all trips.
- Flow Check on bottom - 10 mins.
- The mud should be in good condition to avoid swabbing.
- There should be no losses or gains.
- The mud difference in density in and out should be less than
0.1 ppg.
- The trip tank should be functional.
- A trip sheet should be used.
- Safety valves should be on the rig floor.
- The work string should be slugged - avoid wet trips.
- A mud bucket should be available.
Trip Sheet

TRIP SHEET
RIG: DATE:
WELL:
TIME:
DRILLER: DEPTH:

REASON FOR THE TRIP:

Number of stands to have top of DC's pm DP stand below BOP's:

tick DISPLACEMENT: DC1 DC2 OTHER HWDP DP1 DP2

PULL ON:
Size
EVEN
i/m or
SINGLE
l/stand

DOUBLE x m or stand

+ 100
= vol. (m3)

STAND TRIP CALCULATED

Hole Fill
MEASURED DISCREPANCY REMARKS
Nb TANK (litres) Hole Fill
per Increment
GAUGE (litres)
per Inrem' Accumul. per Inrem' Accumul.
1 2 3 4 5 6 7 8
0
During trips :

• If incorrect hole fill is observed:

- Flow check immediately.
- Inform the man in charge.
• If irregularities cannot be explained, RIH to bottom and
circulate B/U to check for an influx.

• A flow check should be carried out at the shoe, as well as

when the BHA is reached.

• Some operators spot a heavy pill at the shoe, for additional

safety (Shell).
 When running in:

• Monitor returns.

• Break circulation at the shoe, this will reduce high surge

pressures.

• If the string includes a float valve fill the pipe every 10 -15
stands. This will avoid air slugs being introduced into the mud.

• During the first circulation after tripping avoid making any

changes to the active so volumes can be closely monitored.

• Always test B/U sample.

Well Control Procedures - Drilling

• Flow check all drilling breaks (ie. when ROP increases).

• A flow meter should give a visual and audible alarm.
• Monitor the pit volumes at all times. The derrick man should
note all pit volumes every 30 mins. Any gain or loss should
be investigated.
• A marker (string and bolt) should be kept in the pit room as a
further indicator of pit levels.
• A decrease in pump pressure and pump stroke increase
indicates an influx into the wellbore, pump problems or a
washout. Investigate!
• Monitor the density, the derrick man should record the mud
density in and out, every 15 mins.
Secondary Well Control

• The use of Blow out preventers (BOP's) to control the well.

• The earlier a kick is detected, the less the severity of the

kick. The size of the kick depends on:
- The degree of underbalance,
- The formation permeability.
- The length of time the well remains underbalanced.

• Smaller kicks provide lower choke and annular pressure

both upon initial closure and later when the kick is at the
shoe.
 Instructions For Shallow Gas Kicks

(For land rigs, swamp barges, tenders and jack ups)

• At first sign of flow:
- Open diverter line.
- Increase pump strokes to maximum.
- Switch suction on mud pumps to heavy mud.
- If well appears to be dead, stop and observe.
- If the flow continues, continue pumping heavy mud, mud, and
finally water. Prepare heavier mud if possible. Do not stop
pumping as long as well is flowing or you will lose hydrostatic
head and make the situation worse.
Shallow Gas Kicks

(For floating units)

• Most attempts to divert will fail due to leaking slip joints.

Therefore the options are to:
- Shut the well in.
- Move the rig off location.
• Riserless top hole drilling is the preferred method of drilling
top hole.
 Well Control

Hydrostatic pressure = Depth x Density x .052.

(psi) (ft) (ppg)
0.052 is a conversion factor.
• The depth must be the true vertical depth (TVD), not the
measured depth of the hole.
• The influx can be gas, oil or water.
• There are two common techniques for dealing with kicks:
- The DRILLER'S Method )
)Concurrent method is combination of both.
- The WAIT and WEIGHT Method )
 Driller’s Method

• Kick is Controlled in two stages : ICP

• Shut in Well and check SICP Then : SICP

• A. Circulate Out Kick with Original Weight

Mud
MUD
- Open choke, bring pump up to kill speed while
maintaining constant casing pressure (SICP).
- With the pump at kill speed, switch to drillpipe Drill pipe

pressure, maintain constant ICP on the

drillpipe by manipulating choke.
- After kick is circulated out, close - in well while Gas Influx
maintaining constant casing pressure.
- When the well is totally closed - in, SICP must
be the same as the original SIDPP. If not, BHP
resume circulation until all the influx is
circulated out.
 Drillers Method (ctd)

• B. Displace Original Mud with Kill Mud

ICP

- Reset stroke counter, open choke, bring

SICP
pump up to kill speed while maintaining
constant casing pressure.
- Maintain constant casing pressure until the
heavy mud reaches the bit. At this point DP MUD
pressure will be at FCP.
- Continue pumping while maintaining
constant FCP on the drillpipe until the heavy Drill pipe
mud reaches the surface.
- Stop pump. Check for flow.
• ICP = Initial circulating pressure Kill Mud
• SICP = Shut in casing pressure
• SIDP = Shut in drill pipe pressure
• FCP = Final circ. pressure BHP
 Drillers Method Well Control Pressure Plot

• Assumed gas kick would look like this :

Kill mud at bit

Circulate kick out of Hole Kill Mud in Annulus
Kick Rising in Ann

ICP
Pressure

Kick out of hole

FCP DP Pressure
MAASP

Kill mud at surface

Circulate
DP to Kill
Kick at surface

Mud
Ann Pressure
SICP

VOH
VDP
VANN VANN

Choke must be adjusted to follow solid line

Wait & Weight Method

Circulate Out Kick with Weighted Mud

ICP

• Open choke, bring pump up to kill SICP

speed while maintaining constant
casing pressure.
• Follow DP Press vs. Pump Strokes MUD
schedule to adjust DP pressure as
kill weight mud travels to the bit. Drill pipe

• When the heavy mud is at the bit,

stay with DP pressure and maintain
constant FCP on the DP until the Gas Influx
kick is expelled and the heavy mud
reaches the surface.
BHP
• Stop pump. Check for flow.
 WAIT and WEIGHT Method Plot

• Assumed gas kick would look like this :

Kick out of hole

Circ DP to
ICP Kill Mud in Annulus
Kill Mud

Kill mud at surface

Pressure

FCP
DP Pressure

MAASP

Kick at Surface
Kill Mud at Bit

SICP

Ann Pressure

VDP VAnn
VOH
VAnn

Choke must be adjusted to follow Solid Line

Comparison

Weight & Wait Method Driller's Method

Advantages: Advantages:

- Lowest casing pressure - Can start immediately.

at surface. - Easier to learn.
- Sometimes lowest casing - Best option if you have to wait
pressure at the shoe. on Barite.
- Only one circ. to kill well.

Disadvantages: Disadvantages:

- Long waiting time, cuttings - Need two circulations.

could settle, could get stuck. - Highest casing pressure for
- Gas can migrate. longest period of time.
- Usually highest casing shoe
pressure.
Typical Rig Choke Manifold

•To Degasser
•DECO RIG 160

• Choke/Kill Manifold 12 •MV

9
•Manual Choke
E •BPV
•MV

•MV
D •HCR
•MV 2
•Hydraulic Choke

•Cameron

10
C •MV 1 •MV 3
•MV
•MV • MV •To Flareline

4
7
8 14
•MV •HCR •MV
5 •MV

B A 6 •MV

•MV

•Manual Choke
11

13 •MV

•Blind Flange
High Side working pressure 10,000 psi
Volumetric Kill

• Occasionally it is not possible to circulate out the kick, eg,

a washout, plugged bit or underground blow out, or the
string is out of the hole.
• If the gas is allowed to migrate in an uncontrolled manner
excessive pressures will develop which could break down
the formation.
• The volumetric method ensures the bottom hole pressure
(BHP) is slightly above the formation pressure while the
gas migrates. ie Bleeding mud out to allow for controled
expansion of the gas bubble.
Example of gas Influx on BHP

Gas Influx :
• A gas influx was taken at 10 00 ft.
379 psi The hole diameter is 8 1/2".
Gas density = 2.3 ppg.
Mud density = 11.2 ppg.
Influx = 8.52 x 870 = 61 bbls
9130' MUD
1029.4

• The pressure below the gas

= 5 800 psi.

• The pressure above the gas

= 5 800 - (870 x 2.3 x .052)
870' GAS = 5696 psi.

• Balance of pressures.
9130 x 11.2 x .052 = 5 317 psi
BHP = 5800 psi 870 x 2.3 x .052 = 104 psi
Surface pressure = 379 psi.
BHP = Bottom Hole Pressure
Example of Gas Influx on BHP

As the gas percolates up the hole without

expansion, the pressures increases.
eg, The pressure at the top of the bubble
2 784 psi will remain the same, 5 696 psi, therefore
MUD
the surface pressure would be:
5 000'
5 696 - (5 000 x 11.2 x .052) = 2 784 psi.

Summary of pressures.
5000 x 11.2 x .052 = 2912 psi
870 x 2.3 x .052 = 104 psi
870' GAS
4130 x 11.2 x .052 = 2405 psi

4 130' MUD Surface pressure = 2784 psi

Total Pressure
on Bottom = 8205 psi
Volumetric Kill

• The migrating gas will increase the surface pressure, the

following action is required:
- Allow the casing pressure (CP) to increase 100 - 200 psi
above the original casing shut in pressure (CSIP).
- Calculate the hydrostatic pressure exerted by each bbl of
mud.

eg: for a 10 ppg mud,

1 bbl = 6.85 ft x 10 ppg x 0.052 = 3.4 psi

0.1446 bbl/ft
 Volumetric Kill

• Hold the casing pressure constant until the calculated volume is

bled off. Keep a record of time, pressures and volumes bled.
• This sequence is repeated until the gas is at the surface.
• Pump a selected volume of mud to fall through the annulus.
(This mud could be heavier than the mud in the hole to try and
put a heavy cap on the well.)
• Allow the mud to fall through the gas. A small pressure
increase may occur due to the gas being compressed by the
incoming mud.
• Bleed gas off allowing the CP to fall an amount equal to the
hydrostatic pressure of the mud pumped into the wellbore.
• Continue adding mud and bleeding off the equivalent gas until
all the gas is out of the hole.
Slow Circulation Rates

• Slow circulating rates are required to allow for a smooth

weight up and degassing of the mud, and to maintain
pressures at a minimum.

• Slow circulation rates are taken:

- at the beginning of every tour.
- any time the mud weight is changed.
- any time the bit nozzle configuration is changed.
- after bit changes.
• The slow circulating rate gives the pressure losses in the
system for a given pump rate.
Maximum Allowable Annular Surface Pressure (MAASP)

• Any surface pressure above the MAASP would result in

formation breakdown at the weakest point in the well,
usually the formation below the shoe.
• The following options can be taken if the MAASP is
approached.
- Continue the kill exceeding the MAASP risking formation
breakdown.
- Allow the MAASP to increase in successive steps while
monitoring for signs of gas or losses.
- Continue with kill procedures, but open the choke as
needed to maintain pressure equal to MAASP, risking an
additional influx.
- Bullhead the influx back into the formation.
- Use tertiary control methods (barite/cement plugs.)
 Leak Off Test

• These are performed after drilling out the shoe and 10 ft of

new formation. The mud weight must be even.
Leak off point

Pressure

Volume pumped

The MAFP = Surface pressure + pressure due to hydrostatic

column at the leak off point.
The equivalent mud weight in ppg (EMW)
= MAFP
Depth x .052
• This assumes the weakest point is just below the shoe.
(MAFP = Maximum Allowable Formation Pressure)
LOT (ctd)

• Kick tolerance is the maximum kick that can be controlled

without breaking down the formation. For this calculation
the size and type of kick has to be estimated.
• As a general rule, drilling should not proceed if the mud
weight is less than 0.5 ppg below the EMW calculated from
the L.O.T.
• If the kick occurs off bottom, every effort should be made
to strip back to bottom before killing the well.
Example of Surface Stack Assembly

One annular and three rams - 10 m and 15 m.

BAG TYPE

RAM TYPE

RAM TYPE

KILL SPOOL CHOKE

RAM TYPE
Loss Detection

• Losses are often hard to detect during well kill operations

due to:
- Barite additions.
- Transfers of mud.
- Gas breaking out of the mud and gas expansion.
• If losses occur:
- Continue killing the well if losses are small, once the influx
passes the loss zone the problem may solve itself.
- Add lost circulation material to the kill mud.
- Stop pumping and shut well in. This will give time for the hole
to cure itself as well as give time to mix more mud.
- Reduce the annular pressure and risk a further influx.
Snubbing and Bullheading

• Snubbing is the term given to forcing the pipe through the

BOP's. This may be required if the wellbore pressure is
greater than the weight of the buoyant pipe.
• Bull heading is forcing the influx and some mud back into
the formation. This should be considered if:
- H2S or high pressure gas influxes cannot be handled safely
by rig personnel or equipment.
- Normal circulation is not possible due to: the pipe shearing,
string off bottom, blocked string, washed out or parted
string.
- A combined kick and loss situation is experienced.
- Kick calculations show that the casing pressure will exceed
the MAASIP or casing burst pressure.
Mud Precautions

• During kill operations the pipe is stationary for long periods

of time. There is a high risk of sticking the pipe.

• Maintain adequate fluid loss properties to maintain a strong

filter cake.

• Maintain sufficient viscosity and gel strengths to hold the

barite.
Oil Based Mud

• When drilling with OBM, a gas kick will often dissolve into
the OBM with a negligible volume change. A flow check
will reveal no flow. However gas will continue to enter the
well bore.

• As the dissolved gas is pumped up the well bore, the

hydrostatic head is reduced and it will come out of solution.
Thus a gas kick may not be detected until the gas is almost
on surface and the remaining mud in the hole is
contaminated with dissolved gas.

• Drilling breaks may need to be circulated out to check for

gas.
Tertiary Well Control

• These are last resort methods and usually lead to partial or

complete abandonment of the well.
• There are two widely used procedures.
• Barite plugs are a slurry of barite in water or diesel which is
spotted in the hole to form a bridge that will seal the blowout.
Other weighting materials can be used. The slurry needs to
have the following properties.
- The viscosity and yield point should be as low as possible to
ensure rapid settling.
- The slurry should have a high density, at least 3 ppg greater
than the mud.
- The fluid loss should be high to allow rapid dehydration.
- A thinner should be added to ensure easy pumping.
• Barite settlement is a big mixing problem.
Cement Plugs

Cement plugs are the final option.

• Cement plugs can be used to shut off a downhole flow but
this often results in the abandonment of the well and loss
of most of the drilling tools.

• Quick setting cement reduces the possibility of gas cutting.

 Poor Boy Degasser

• The poor boy degasser is run when circulating out kicks. the
feed line is connected to the choke.
Gas Out

Mud + Gas in
(from choke)

Mud Out
 Degasser

• This can be run at any time and in conjunction with the poor
boy degasser. It reduces the gas in the mud.
Suction motor removes air

Suction
Line
(in desander )
pit)

Venturi

Centrifugal Returns
pump