Bullheading

Objective

• Identify and explain each step of the bullheading procedure.

• Use the necessary bullheading calculations required to kill a well by completing an example.
• Recognize and be able to clarify the pressure limits when bullheading.
 Bullheading definition

• Pumping into a shut-in well in order to increase BHP and cause injection of fluid into the
formation.
– Fracking is a form of bullheading over fracture pressure
• Most common method to kill well prior to workover or remedial operations
 Well Control Methods

Well Control
Methods

Bullheading Constant BHP

Circulating Non-circulating

Forward Reverse Lube and Volumetric

Circulation Circulation Bleed Method
 Bullheading Advantages/Disadvantages

• Advantages
– Minimize formation fluids at surface
– Not handling H2S on surface
– No need for choke operation

• Disadvantages
– High surface pressures
– Condition of tubulars
– Burst rating of tubulars
– Gas migration
– Potential to fracture formation
 Pump Pressure
Pump
Pressure

FrPSurf
ON What are the components of pump pressure?

Pump Pressure =
+ Friction Pressure in Surface Lines
FrPTub
+ Friction Pressure in Tubing String
+ Friction Pressure Across Perforations
+ Formation Pressure
Tbg HP - Tubing Hydrostatic Pressure

FrPperfs + FrPform

Formation Pressure
 Pump Pressure, (Continued)

Factors affecting pump pressure:

• Formation and perforations exposed
• Formation permeability
• Formation skin
• Formation fluid
• Pump rate
• Casing and tubing size and length
• Reservoir pressure
• Kill fluid density and composition
 Pump pressure limitations
• Surface pressure limitation for bullheading down tubing / casing:
- Formation fracture pressure
- Tubing / casing burst rating (adjusted for condition)
- Wellhead or tree rating
- BOPE rating

• Safe working pressure of the pumping system will be dependent on lowest pressure rating of the
system:
- Pump rating
- Lines
- Hoses
- Valves
- Tubular, etc.
 Considerations
• Planning:
‒ Poor permeability may prevent bullheading.
‒ Handling of formation fluid may require bullheading.
‒ Determine if fracturing the formation is an option.

• Operational:
‒ Pressure differential across packer and seal assembly could be a concern.
‒ Pump speed must exceed gas migration rate.
‒ Consider possibilities for reducing required surface pressure.
‒ Check the pump and relief valve pressure
‒ Do not over displace well
– Pumping a couple barrels over calculated displacement is acceptable and common practice
but excessive displacement could damage formation or potentially cause fracturing
 General Procedure for Bullheading
1. Calculations:
• Determine required density (ppg) and volume (bbl) to bullhead
• Establish surface pressure limitations (psi)
2. Pressure test all equipment lines
3. Bring the pump on slowly
4. Once injectivity is established, increase the pump speed without exceeding the surface
pressure limit
5. Monitor and record pressures and volumes during the procedure
6. Shut down when sufficient volume has been pumped
7. Read, record and monitor SITP
8. If SITP exists, determine if it is due to trapped pressure or underbalanced
 Bullheading Surface Pressure Limitation Calculations

Max Initial Surface Pressure Max EOT Surface Pressure Max Final Tubing Surface Pressure
Pump Pressure = 4460 psi Pump Pressure = 2014 psi Pump pressure = 1936 psi
SITP = 2,500 psi

Max Surface Pressure = Fracture Pressure - ∑ HP

 Bullheading Example – Calculations Part 1

Formation Pressure = Formation Pressure Gradient x Top Perf TVD

SITP = 2,500 psi
= 0.450 psi/ft x 9,800 ft = 4,410 psi

Formation Fracture Pressure = Formation Fracture Gradient x Top Perf TVD

= 0.650 psi/ft x 9,800 ft = 6,370 psi

Initial HP = Formation Pressure – SITP

= 4,410 psi – 2,500 psi = 1,910 psi

Initial Av Fluid Density = Initial HP ÷ 0.052 ÷ Top Perf TVD

= 1,910 psi ÷ 0.052 ÷ 9,800 ft = 3.75 ppg

Packer = 9,300 ft

EOT = 9,500 ft

Top Perfs = 9,800 ft

Bottom Perfs = 10,000 ft
Formation Fracture Gradient = 0.650 psi/ft
Formation Pressure Gradient = 0.450 psi/ft
 Bullheading Example – Calculations Part 2
Kill Weight Mud = Average Fluid Density + (SITP ÷ 0.052 ÷ Top Perf TVD)
SITP = 2500 psi = 3.75 ppg + (2,500 psi ÷ 0.052 ÷ 9,800 ft) = 8.7 ppg

As fluid begins to enter the tubing, HP increases

▪𝐵𝐻𝑃𝑙𝑖𝑚𝑖𝑡 = 𝐹𝑟𝑎𝑐𝑡𝑢𝑟𝑒 𝑝𝑟𝑒𝑠𝑠𝑢𝑟𝑒 = 𝑆𝑃 + 𝐻𝑃
▪𝑆𝑃 ↓ +𝐻𝑃 ↑ 𝑚𝑢𝑠𝑡 𝑏𝑒 𝑙𝑒𝑠𝑠 𝑡ℎ𝑎𝑛 𝐹𝑟𝑎𝑐𝑡𝑢𝑟𝑒 𝑃𝑟𝑒𝑠𝑠𝑢𝑟𝑒
▪Max Surface = Fracture Pressure - ∑ HP

Max Initial Surface Pressure = Formation Fracture Pressure – Initial HP

=6,370 psi – 1,910 psi = 4,460 psi

Packer = 9,300 ft
EOT = 9,500 ft

Top Perfs = 9,800 ft

Bottom Perfs = 10,000 ft
Formation Fracture Gradient = 0.650 psi/ft
Formation Pressure Gradient = 0.450 psi/ft
 Bullheading Example – Calculations Part 3

SITP = 2500 psi

Calculations:
Max EOT Pressure = Formation Fracture Pressure – (KMW x 0.052 x EOT TVD)
– Initial Average Fluid Density x 0.052 x (Top Perf – EOT TVD)

Max EOT Pressure = 6,370 psi – (8.7 ppg x 0.052 x 9,500 ft)
– 3.75 ppg x 0.052 x (9,800 ft– 9,500 ft)
= 2,014 psi

Packer = 9,300 ft

EOT = 9,500 ft

Top Perfs = 9,800 ft

Bottom Perfs = 10,000 ft
Formation Fracture Gradient = 0.650 psi/ft
Formation Pressure Gradient = 0.450 psi/ft
 Why use top of the perforation TVD?
Top Perf
SITP = 2500 psi Max Final Tubing Pressure = Form Frac Pres – (KMW x 0.052 x Top Perf TVD)
0.65 psi/ft x 9,800 ft– (8.7 ppg x 0.052 x 9,800 ft) = 1,936 psi

Bottom Perf
Max Final Tubing Pressure = Form Frac Pres – (KMW x 0.052 x Bottom Perf TVD)
0.65 psi/ft x 10,000 ft – (8.7 ppg x 0.052 x 10,000 ft) = 1,976 psi

What is the final tubing pressure limit?

1,936 psi
Packer = 9,300 ft

EOT = 9,500 ft

Top Perfs = 9,800 ft

Bottom Perfs = 10,000 ft
Formation Fracture Gradient = 0.650 psi/ft
Formation Pressure Gradient = 0.450 psi/ft
 Bullheading Example – Calculations Part 5
Pressure drop (psi/stroke increment)
SITP = 2500 psi While Displacing Tubing =[(Max Initial Surface Pressure – Max EOT Pressure) ÷ Tubing Strokes] x Stroke
Increment
[(4,460 psi – 2,014 psi) ÷ 1554 strokes] x 100 strokes = 157.4 psi/100 Strokes

Answer ONE of the following:

Displacing EOT to Top Perforations (if EOT to Top Perf Strokes are greater than 100)
= [(Max EOT Tubing P – Max Final P) ÷ Strokes from EOT to Top Perf] x Stroke Increment
[(2,014 psi – 1,936 psi) ÷ 256 Strokes] x 100 Strokes = 30.5 psi/100 Strokes

Displacing EOT to Top Perforations (if EOT to Top Perf Strokes are less than 100)
= Max EOT Pressure – Max Final Tubing Pressure - Not needed, Strokes greater than 100

Packer = 9,300 ft Volume Strokes Bbls

EOT = 9,500 ft Tubing - Surface to EOT 1554 69.8

Casing - EOT to Top Perf 256 11.48
Top Perfs = 9,800 ft
Casing - Top Perf to Bottom Perf 170 7.65
Bottom Perfs = 10,000 ft
Formation Fracture Gradient = 0.650 psi/ft
Formation Pressure Gradient = 0.450 psi/ft
 Bullheading Example – Identifying Pressure Limits
5,000

4,000
Fracture
Pressure Limit (psi)

3,000

2,000 Desired Range

End of Tubing

Bottom Perf
Top Perf
1,000

0
0 500 1,000 1,500 2,000
Displacement Volume Pumped (strokes)
 Bullheading Example
5.000
Max Initial Tubing Pressure Fracture Zone

4.000
Pressure Limit (psi)

Max EOT Pressure

Max Final Tubing Pressure
3.000

Bullhead Zone
2.000

End of Tubing
Shut in Tubing Pressure

Bottom Perf
Top Perf
1.000

Flow Zone
0
0 500 1.000 1.500 2.000
Displacement Volume Pumped (strokes)
 Bullheading Example

5.000 Slope Based on

Pressure Drop Per 100 Fracture Zone
Strokes (tubing)
(157.4 psi/100 strokes)
4.000
Pressure Limit (psi)

Slope Based on
Pressure Drop Per 100
3.000 Strokes (Casing)
(30.5 psi/100 strokes)

Bullhead
2.000
Zone

End of Tubing

Bottom Perf
Top Perf
1.000

Flow Zone
0
0 500 1.000 1.500 2.000
Displacement Volume Pumped (strokes)
 Bullheading Example
5.000
Fracture Zone

4.000
Fracture likely
Pressure Limit (psi)

Pressure increase due

3.000 to higher density fluid at
perfs

2.000
Bullhead

End of Tubing
Zone

Bottom Perf
Top Perf
1.000

Flow Zone
0
0 500 1.000 1.500 2.000
Volume Pumped (strokes)
 Turning Point Question 1

Using the current well data, calculate the tubing pressure limit once KWM has reached 2000 ft.

KWM = 8.7 ppg

Original Weight Fluid = 3.75 ppg
Top Perf = 9,800 ft
Formation Pressure Gradient = 0.450 psi/ft
Formation Fracture Gradient = 0.650 psi/ft

1. 3,944 psi
2. 1,984 psi
3. 6,370 psi
4. 1,936 psi
 Turning Point Question 2
Calculate the initial pressure limit.
Well information:
SITP: 1500 psi
SICP: 0 psi
Top perforation: 7600’ MD/TVD
Bottom perforation: 7700’ MD/TVD
Formation fracture gradient: 0.658 psi/ft
Formation pore pressure gradient: 0.47psi/ft
Packer Depth: 7600’ MD/TVD

1. 2057 psi
2. 2682 psi
3. 2928 psi
4. 4739 psi
 Turning Point Question 3
Calculate the final pressure limit.

Well information:
- SITP: 1500 psi
- SICP: 0 psi
- Top perforation: 7600’ MD/TVD
- Bottom perforation: 7700’ MD/TVD
- Formation fracture gradient: 0.658 psi/ft
- Formation pore pressure gradient: 0.47 psi/ft

1. 0 psi
2. 1,143 psi
3. 1,404 psi
4. 1,428 psi
 Turning Point Question 4

Calculate the Minimum Fluid Volume. 1. 62.1 bbls

Tubing: 2 7/8” – 2.441” ID 2. 75.3 bbls
Casing: 7” – 6.331” ID 3. 93.2 bbls
4. 114.2 bbls

Packer = 8,300 ft

EOT = 8,700 ft

Top Perfs = 9,000 ft

Bottom Perfs = 9,800 ft
 Turning Point Question 5

Bullheading cannot be applied in which one of the following situations:

1. There is no pipe in the hole for circulation.

2. Formation fluid is difficult to deal with at surface.
3. Gas kick contains H2S.
4. Formation permeability is extremely low and
fracturing formation is prohibited.
 Bullheading Example

Fracture Zone

End of Tubing

Bottom Perf
Top Perf
Flow Zone
 Bullheading Kill Sheet Example
Bullhead Pressure Schedule
Class Example Why is it important to keep a log of the bullheading
Injection Wellhead
5000
operation?
Pressure Limit

Calc Max Pressure

Casing Actual Tubing
Notes Strokes SPM Tubing Increase

•
Pressure Pressure

Start 0
Pressure

4,460 − 2,500 =
Fracture

1,960
Ensure pressure limitations are not exceeded
Surface Lines Filled 22 50 497 4,460 − 4,040 = 420
• Identify problems during bullheading
122 50 497 4,303 − 3,980 = 323
222 50 497 4,145 − 3,950 = 195
322 40 498 3,988 − 3,780 = 208 operations
422 30 499 3,830 − 3,320 = 510
522
622
40
50
499
499
3,673
3,516
−
−
3,280
3,400
=
=
393
116
• Identify leaks in tubing/casing
722 50 501 3,358 − 3,520 = -162
822 40 501 3,201 − 3,070 = 131 • Identify failure of packer, seal assemblies,
922 30 501 3,043 − 2,750 = 293
1022 30 501 2,886 − 2,440 = 446
1122 40 502 2,729 − 2,480 = 249 sliding sleeves, safety valves, etc.
1222 40 502 2,571 − 2,380 = 191
1322
1422
40
40
502
503
2,414
2,256
−
−
2,230
2,150
=
=
184
106
• Ensure adequate displacement volumes
1522 40 503 2,099 − 1,920 = 179
EOT 1576 40 503 2,014 − 1,650 = 364
1676 40 503 1,984 − 1,570 = 414
1776 40 503 1,953 − 1,550 = 403
Top Perf 1832 40 503 1,936 − 1,720 = 216
Fracture likely
Bottom Perf 2002 40 503 1,936 − 1,740 = 196
− =
− =
− =
 Drilling Applications

• Applications:
– Force influx back into the formation:
• H2S kick
• HPHT gas kick
– Reduce surface pressures:
• Bullheading heavy mud prior to stripping
• Gas kick volumes beyond well design limits (MASP)
Note: Surface pressure is usually limited by the open hole weak point.
 Review of Learning Objectives

• Identify and explain each step of the bullheading procedure.

• Use the necessary bullheading calculations required to kill a well by completing an example.
• Recognize and be able to clarify the pressure limits when bullheading.