Journal of Petroleum Science and Engineering 188 (2020) 106882

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Journal of Petroleum Science and Engineering

journal homepage: http://www.elsevier.com/locate/petrol

Research and application of downhole blowout prevention system while

drilling: A review
Li Wei a, b, *, Xia Yang b, Chen Xi b, Chen Hong c, Li Yumin d, Li Xueqing e
a
State Key Laboratory of Oil and Gas Reservoir Geology and Exploitation, Southwest Petroleum University, Chengdu, Sichuan, 610500, China
b
School of Mechanical and Electrical Engineering, Southwest Petroleum University, Chengdu, Sichuan, 610500, China
c
Sichuan HongHua Petroleum Equipment CO., LTD, Guanghan, Sichuan, 618300, China
d
Sinopec ZhongYuan Petroleum Engineering CO., LTD, Puyang, Henan, 457001, China
e
Sinopec XiNan Oilfield Service Corporation, Chengdu, Sichuan, 610041, China

A R T I C L E I N F O A B S T R A C T

Keywords: With the advantages of blowout prevention technology while drilling, such as “early discovery, early control,
Blowout prevention while drilling rapid killing of overflow and stifling overflow in budding state”, it has gradually become the hot research di­
Overflow monitoring rection of safe drilling well control in sensitive formation. This paper introduces the definition and function of
Well control technology
blowout prevention system while drilling. The development history of sealing module, overflow monitoring and
Application research
rapid early warning module, downhole communication module and post-sealing well killing module of blowout
prevention system while drilling is investigated respectively, and the technical development trend of each
module is analyzed and summarized. The application research of blowout prevention technology in drill pipe and
outer ring air blowout technology of drill pipe while drilling is carried out, and the feasibility of industrial
application of air blowout prevention technology in outer ring of drill pipe is analyzed. It is predicted that the
blowout prevention system while drilling will advance towards intelligence, automation and high efficiency in
the future.

1. Introduction
Oil and gas is an important energy and strategic resource to ensure
the stability of social life, the sustainable development of the national
economy and national security (Li, 2013). In oil and gas exploration and
development, with the increase of drilling depth, the complexity of
drilling technology and the difficulty of drilling, safe and effective
development is particularly important to ensure the vigorous develop­
ment of the whole oil and gas industry (Shen et al., 2009; Yang et al.,
2012a, b, c). As shown in Fig. 1 (a), when the high pressure reservoir is
suddenly encountered under the drilling condition, the reservoir pres­
sure Pp is larger than the effective pressure of the drilling fluid column in
the well, the Ph, formation fluid will invade the wellbore to produce
overflow or well surge, if it is not controlled or operated improperly in
time, a blowout will occur. Blowout prevention system is the most
important well control device to ensure the safety of oil wells. Once the
emergency conditions such as overflow, well surge, blowout and so on
occur in the exploration and development of oil and gas wells, the
blowout prevention system can start and close the well quickly to avoid
the occurrence of malignant accidents such as blowout. The blowout
prevention system is divided into wellhead blowout prevention system
and downhole blowout prevention system according to the placement
position (Yang et al., 2012a, b, c; Chen, 2015). Wellhead blowout pre­
vention system has been widely used in drilling construction, but
because of the lag of overflow discovery reaction, the reliability of well
closing depends on the working experience and sense of responsibility of
the staff, the killing operation after shutdown is more difficult, and the
risk of well control is greater. Wellhead blowout prevention system has
been difficult to meet the requirements of drilling technology (Yang
et al., 2012a, b, c; Chen, 2015; Li et al., 2016a,d). Based on the high
blowout prevention difficulty coefficient, high risk and difficult subse­
quent killing operation of the traditional wellhead blowout prevention
system, the downhole blowout prevention system can quickly and
accurately prevent blowout from near the overflow source, and establish
a new circulation channel in time. It provides convenience for rapid and
accurate killing operation, as shown in Fig. 1 (b).

* Corresponding author. State Key Laboratory of Oil and Gas Reservoir Geology and Exploitation, Southwest Petroleum University, Chengdu, Sichuan, 610500,
China.
E-mail address: liwei867@aliyun.com (L. Wei).

https://doi.org/10.1016/j.petrol.2019.106882
Received 6 August 2019; Received in revised form 20 December 2019; Accepted 29 December 2019
Available online 30 December 2019
0920-4105/© 2020 Elsevier B.V. All rights reserved.
L. Wei et al. Journal of Petroleum Science and Engineering 188 (2020) 106882

The blowout prevention system with drilling is a kind of well control lacks the overall systematic thinking and exploration. This section
device installed at the end of the downhole near the drilling head. Under makes a survey and a summary of the research status and industrial
the condition of drilling, such as sudden overflow at the bottom of the application of the four functional components of the blowout prevention
well, well surge or blowout and other abnormal conditions, the blowout system in the academic field.
prevention system while drilling can block the inner and outer annular
space of the drill pipe quickly, press the well and unseal it, so as to avoid
2.1. Research on sealing module
the occurrence of blowout out of control accident. A complete blowout
prevention system with drilling should include the following functions:
The sealing module of blowout prevention system while drilling is
1) the formation pressure near the bit is monitored, predicted and
mainly used to quickly seal and unseal the inner and outer annulus of
uploaded in real time. 2) the rapid sealing of drill pipe and annular space
drill pipe in order to ensure reliable sealing of annular space and prevent
is realized. 3) the near ground pipe string can quickly establish a new
blowout accidents.
circulation channel after annular sealing. 4) can quickly measure the
formation plugging pressure and upload information to the ground; 5)
2.1.1. Downhole drill pipe inside the channel seal
quickly unseal after killing; 6) do not conflict with the traditional dril­
The inner sealing technology of downhole drill pipe has been
ling technology; 7) under the condition of overflow or blowout while
maturely applied in oil field. At present, the commonly used drill pipe
drilling, the two-way communication between the tools of part of the
internal Packer are: square drill pipe upper, lower plug valve, drill tool
downhole blowout prevention system near the bit and the ground is
check valve, drilling tool bypass valve, drill pipe return pressure Vale,
realized. While drilling blowout prevention is divided into downhole
new drill pipe backpressure valve, drilling fluid automatic blowout
drill pipe inner blowout and drill pipe outer ring air blowout. The
preventer valve and input one-way valve, etc (Li, 2013; Zhang, 1990;
concept of downhole blowout prevention was first put forward by
Chen et al., 2007; Xie et al., 2007). The square drill pipe plug valve is a
American scientist George E. Conover (1976). Following this theory,
kind of auxiliary drilling device which is installed near the square drill
researchers made in-depth research and formed mature blowout pre­
pipe and prevents blowout by manual operation. It can not be used as a
vention technology in drill pipe and a lot of research results, and grad­
tool for downhole blowout prevention system (Li, 2013; Zhang, 1990;
ually became the research focus of well control technology. In this
Chen et al., 2007; Xie et al., 2007; Wang et al., 2013a, b). When the
paper, the research status and application of blowout prevention system
drilling tool check valve is in the event of a blowout or a well swell, the
while drilling are investigated, and its technical difficulties and devel­
high-pressure liquid which can move to the wellhead in the drill rod
opment trends are discussed.
pushes the core of the valve to be in contact with the base body to
generate a seal, so as to play the role of preventing the blowout in the
2. Research status of downhole blowout prevention system
drill rod, but the check valve is often in the open state and suffers the
while drilling
erosion of drilling fluid for a long time. It is easy to cause some problems,
such as low sealing reliability, short life and high risk of well control
Blowout prevention while drilling is a set of comprehensive and
(Chen et al., 2010; Zhang et al., 2013).
complex process system. According to its functional requirements and
The high reliability and high life of drill pipe inner sealing tool is the
composition, it can be divided into sealing module, overflow monitoring
fundamental goal of blowout prevention in drill pipe, and it is also an
and rapid early warning module, downhole communication module and
important factor to ensure drilling safety. Cunningham and Baugh
post-sealing well pressing module (Li, 2013). At present, most of the
(1983) proposed a drill pipe internal blowout prevention tool which can
existing literature is about the design and research of blowout preven­
reduce the fluid erosion of the ball valve and is convenient to replace the
tion structure of downhole annular blowout prevention system, which
internal components. In the same year, Bednar and Petersen (1983) put

Fig. 1. Schematic of blowout prevention system.

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L. Wei et al. Journal of Petroleum Science and Engineering 188 (2020) 106882

forward a kind of blowout proof method to close the inner channel of

drill string by driving baffle valve by spiral rotation of downhole motor.
Cunningham and Stevens (1986) introduced a new type of drill string
blowout preventer. When the reverse flow is encountered to a pre­
determined value, the tool can automatically close the inner channel of
the drill pipe by using its ball valve structure. Andersen and Sivertsen
(2001) developed and tested a downhole blowout preventer that sealed
the drill pipe and opened the circulation channel through a
double-acting hoist valve. Livingstone (2008) proposed a downhole
blowout preventer, which uses electric actuator to control the opening
and closing state of the ball valve to control the opening and closing of
the inner channel of the drill pipe. Pan et al. (2010) put forward a kind of
full diameter drill tool inner blowout preventer, which is driven by
liquid power. Its conical valve plate can be automatically closed to
prevent blowout in the drill. Baker Hughes disclosed a spherical
downhole blowout preventer valve. By controlling the pipeline pressure
of the driving piston so that the ball rotates around its axis to open or
close the valve, the blowout prevention effect in the downhole drill pipe
can be achieved (Bill, 2013).
To sum up, the drill pipe is a hollow channel, and the sealing method
is simple. All kinds of built-in valves are often used as blowout pre­
vention tools in the drill pipe, because of its simple structure, convenient
installation, high safety, reliability and service life. The blowout pre­
vention technology in drill pipe has been widely used, at the same time,
the safety performance of well control in drilling has been improved,
and the great loss and harm caused by blowout accident to oil field and
society have been avoided.

2.1.2. Outer annular sealing of downhole drill pipe
The outer annular sealing technology of downhole drill pipe refers to
the annular space between the outer part of the drill pipe and the shaft
wall, so as to separate the annular channel and prevent the downhole
overflow from spreading to the wellhead. At present, the outer annular
sealing technology of drill pipe has made some achievements, but it
basically stays in the theoretical stage, mostly in the form of patents and
papers, and has not been applied in the oil field (Li, 2013; Chen, 2015).
Under the drilling condition, if the overflow and the well surge are
encountered, the formation fluid will quickly enter the outer annular
channel of the drill pipe, and the annular channel will go straight to the
surface well control system and the solid control system. Because the
reservoir pressure is greater than the effective pressure of the drilling
fluid string in the well, the overflow fluid will move to the surface,
resulting in the high speed return discharge and high pressure state of
the outer annular liquid of the whole drill pipe of the oil well, resulting
in the high operation difficulty coefficient and high risk of the surface
well control system. It is difficult to guarantee the success rate of well
control.
At present, under the condition of drilling, compared with the inner
sealing of drill pipe, the outer annular sealing of drill pipe is in the
research and experimental stage, and the research and development is
more challenging, and the related technology has not yet been popu­
larized and applied. According to the sealing mode of rubber cylinder for
sealing core components, the outer annulus sealing mode of downhole
drill pipe can be divided into compression seal and expansion sealing.
The compression type packer is used for axially compressing the
rubber cylinder by the action of an external force, so that the rubber
cylinder is radially expanded to seal the annular space. Andersen and
Sivertsen (2001) proposed a downhole blowout preventer, which seals
the drill pipe and forms a pressure drop at the circulation port through a
double-acting poppet valve, and the compression rubber cylinder ex­
pands to seal the outer annular space of the drill pipe, as shown in Fig. 2.
Wang et al. (2010b) put forward a mechanical down-hole internal and
external integrated blowout preventer, which is expanded by the gravity
compression rubber cylinder of the upper drill pipe, so that the outer
ring of the drill pipe is sealed. Yang et al. (2012a, b, c) put forward a kind
of downhole operation blowout prevention tool assembly, through the
Fig. 2. Structure diagram of double-acting poppet valve downhole blowout
preventer. Reprinted from Andersen and Sivertsen (2001).
upper and lower screw and the upper and lower cone, the torque is
transferred to the rubber cylinder, so that it can be compressed and
radially expanded to seal the outer annulus of the drill pipe. Zhou et al.
(2015) invented an electrically controlled compression type downhole
blowout preventer, which expanded by controlling the motor to run the
compression cylinder and sat and sealed the outer annulus of the drill
pipe. Zhang et al. (2015a, b) put forward an umbrella downhole blowout
preventer for reducing overflow risk. Through the action of the pressure
difference between inside and outside of the blowout preventer, the
piston rod pushes the variable diameter thruster to compress the sealing
rubber cylinder and the outer ring space of the sealed drill rod. Li et al.
(2016b) put forward a motor-driven extrusion downhole annular
blowout preventer and its communication method, through which the
motor drives the compression cylinder to seal the outer annulus of the
drill pipe, as shown in Fig. 3. Ming et al. (2018) proposed a downhole
annular blowout preventer to seal the outer annulus of drill pipe by
electrically driven hydraulic pump compression rubber cylinder. Ac­
cording to the above research situation, the external force of the
compression type sealing partition is provided by the fluid pressure
difference force, the drill rod gravity and the motor driving force,
However, the tool can only be used in the straight well and the inclined
shaft, and the horizontal well will be limited seriously.
The way of fluid pressure difference force and motor driving force
gets rid of the limit of well condition, in which the action mode of fluid
pressure difference force is simple, but it can not accurately control the
compression state of rubber cylinder. The driving force of the motor can
accurately control the compression displacement of the rubber cylinder,
but the motor needs to be sealed in the normal pressure environment,
and the electric energy supply is required. The fluid pressure difference
force mode has the advantages of low cost, convenient control mode and
good reliability and the like compared with the driving force mode of the
motor.
The expansion type packer is used for filling a certain pressure liquid
into the rubber cylinder in a number of ways, expanding the rubber

3
L. Wei et al.
Fig. 3. Structure diagram of motor-driven extrusion downhole annular blowout preventer. Reprinted from Li et al. (2016b).
cylinder, and performing annular sealing. Liu et al. (2010) put forward a
kind of downhole blowout preventer installed on the drill string and
then controlled downhole. Through the one-way valve on the inner and
outer wall of the blowout preventer, the pressure difference between the
inside and outside of the drill string is automatically compared, and the
valve opening and closing is controlled so that the high pressure liquid
enters the blowout preventer rubber tube. To expand and seal the outer
ring of the drill rod. Wang et al. (2010a) put forward a kind of riser valve
type inner and outer integral blowout preventer, which uses mud
hold-up pressure to make the outer annulus of the expansion seal drill
rod of the rubber cylinder. Yang et al. (2012a, b, c) proposed a downhole
blowout preventer with automatic control and anchoring function.
Under the action of pressure difference between the inside and outside of
the drill pipe, the rubber cylinder was expanded by the pressurized
piston to seal the outer annulus of the drill pipe. Wang et al., 2013a, b
put forward a sliding sleeve type downhole blowout preventer and its
application. The sliding sleeve movement is realized by throwing the
ball, the drilling fluid is pumped into the rubber cylinder on the ground,
and the rubber cylinder expands and seals the outer annular space of the
drill pipe. Shi and Wei (2013) put forward a kind of blowout preventer
near the drill bit, which opened the high pressure drilling fluid into the
sealing pressure chamber and sealed the outer annulus of the drill pipe
through the control of the solenoid valve by single chip microcomputer.
Zhang et al. (2015a, b) put forward a eccentric downhole blowout
preventer with lifting valve. The motor is used to open the liquid inlet
channel of the cylinder, so that the cylinder is expanded and sealed, and
the outer annulus of the drill pipe is sealed. Li et al. (2016c) invented a
pressure expansion type downhole annular blowout preventer and its
communication method were invented one after another, in which the
liquid was injected into the rubber cylinder of the annular blowout
preventer executive module by pressing the slider, so as to realize the
outer annulus of the drilling pipe. Li et al. (2019) proposed an
explosion-induced downhole annulus blowout preventer. By igniting the
explosive under the well, the explosion pushes the piston into the cyl­
inder to press the hydraulic oil to expand the outer diameter of the drill
pipe. According to the expansion type sealing method provided by the
invention, the drilling fluid is used for carrying out pressure-holding and
pressure-holding by using the drilling fluid, and the method has the
advantages of low cost, convenient operation and good safety.
To sum up, the principle of outer annular sealing of drill pipe is
basically consistent with the sealing mechanism of Packer, and the
expansion of rubber cylinder is realized in a certain way, which is in
close contact with casing or shaft wall, and the outer annular channel of
drill pipe is separated, so as to prevent the formation fluid from moving
to the wellhead. In summary, it can be seen that rubber cylinder is an
important part of blowout preventer sealing module with drilling, and
its sealing mode can be divided into two categories, one is compression
sealing, the other is liquid expansion sealing (Nieuwstad, 1987; San­
gesland, 1995; Van-Gils and Boogaart, 1986; Goans, 1983; Koomey,
1982; Hiron et al., 2005; Fidtje, 1999). Compression seal often uses drill
pipe self-gravity extrusion, hydraulic pressure difference action pres­
surized piston push pressure, motor drive push block push three ways to
achieve rubber cylinder compression expansion seat sealing drill pipe
outer annulus. Liquid expansion type sealing often uses wellhead to
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Journal of Petroleum Science and Engineering 188 (2020) 106882
pump high pressure liquid into rubber cylinder or bottom hole high
pressure liquid to make rubber cylinder expand and seal drill pipe outer
annulus. As the core sealing part of sealing module, the future research
should pay attention to the improvement of the packer pressure differ­
ence ability, the ability to adapt to different rock layers undefined
wellbore capacity, the adaptability of well diameter change, the ability
to large gap packer, service life and sealing reliability.
2.2. Research on overflow monitoring and rapid early warning module
The main function of overflow monitoring and rapid early warning
module of blowout prevention system while drilling is to detect and
make early warning at the bottom of the well for the first time, so as to
provide information prediction and reference for the follow-up rapid
and accurate control of overflow, and to avoid the late detection of
overflow. There are no effective measures to deal with the blowout
accident.
Under drilling conditions, when drilling in high-pressure sensitive
reservoirs, it is only 5–10 min from the occurrence of overflow to
blowout in most wells, and some wells even take shorter time, which
results in a very short emergency treatment time when the overflow is
discovered, resulting in a large difficulty coefficient in well control. The
risk of well control is high (Yue et al., 2013; Yue, 2014; Jablonowski and
Podio, 2011). Early overflow monitoring and rapid alarm technology
can buy more operation time for overflow treatment and well control
operation, prevent blowout accidents, and realize drilling safety, effi­
ciency and economy. In 1967, the necessity of early overflow monitoring
technology was discussed, and the surface signs of early overflow and
the instruments for monitoring early overflow were discussed (Griffin,
1967). Letbetter (1975) suggests that monitoring early overflow and
well control depends on the experience and ability of the staff, and
related technical training is particularly important.
In order to make the way of monitoring overflow more objective, to
improve the accuracy of early overflow monitoring, data monitoring
system can be introduced. Mccann et al. (1991) described an intelligent
overflow early warning system consisting of three independent moni­
tors, Field experiments and examples show the effectiveness of the
system. Jardine et al. (1991) introduces a method of predicting the
change of outflow flow rate by using the measured data of drilling rig
movement, and applies the data to compensate the instantaneous flow of
oil well measured by existing sensors adaptively. This technique has
been applied to the overflow monitoring and alarm system. The field
example has proved its effectiveness. However, there are some problems
in the accuracy and timeliness of the above overflow monitoring
methods. For the timeliness of overflow monitoring, a new acoustic
kick-detection tool was described (Hage and Avest, 1994). It can
respond quickly and sensitively to downhole gas invasion, and the
experimental application effect is good. A new method to obtain the
difference between the return discharge mud and the circulating injec­
tion mud is put forward (Doria and Morooka, 1997). In combination
with the comparison between the drilling mud reflux velocity on the
drilling vessel and the calculation of the mud reflux velocity by the
program, the refluxing velocity of the mud can be accurately calculated.
Monitor downhole overflow quickly. An early overflow monitoring
L. Wei et al.
system based on real-time analysis of drilling data obtained from
comprehensive logging is described (Swanson et al., 1997). The system
can quickly monitor and determine the occurrence of overflow, and has
been applied in practice in 1998. In Li’s work (Li et al., 1998), the
propagation theory of acoustic wave and velocity wave in drilling fluid
circulation system is studied, and a method based on velocity wave
detection is proposed to monitor the phenomenon of early gas invasion,
which has been verified by offshore drilling test. The monitoring method
of early overflow under well leakage condition is studied (Schubert and
Wright, 1998). The present situation of the above technical research
shows that the overflow monitoring method has gone through the
transformation from artificial experience to monitoring equipment, and
the monitoring method has developed in a more scientific, objective and
timely direction.
According to the early overflow monitoring methods proposed
above, they all lack the basic theory research on the implementation
mode, and the reliability, effectiveness and automation of the mode
need to be improved. An acoustic device installed on casing valve is
proposed, which can continuously monitor the liquid level in annulus
and upload it to the ground. The early overflow is determined by
automatic analysis of the rise and fall of the liquid level. In Hargreaves’s
work (Hargreaves et al., 2001), a new sensitive overflow monitoring
system was studied. The detector is based on the Bayesian probability
framework and determines whether the overflow occurs according to
the noise drilling data, and has been verified by the field test. In Jong­
geun’s work (Jonggeun et al., 2004), It is pointed out that U-tube effect
can be used in Subsea mudlift drilling to effectively monitor downhole
overflow by comparing surface and seafloor velocity. In Nas’s work
(Nas, 2011), It is pointed out that the combination of reliable mass
Flowmeter and accurate riser pressure sensor can make MPD (Managed
Pressure Drilling) system monitor overflow automatically under the
condition of RCD (Rotating Control Device) sealing top wellbore. Ali
et al. (2013) studied an automated flowback monitoring technology
based on pit volume change, instead of early manual identification
abnormal reflux technology. Related intelligent alarms can help drillers
to monitor early overflows more quickly. Fraser et al. (2014) identified
two key performance indicators related to overflow risk: the Kick
Detection Volume and the Kick Response Time, and provided the Dril­
ling Mode Kick Frequency, It can effectively help drilling operations to
determine the possible location of early overflow and evaluate the
reliability of overflow monitoring methods. Brakel et al. (2015) intro­
duced an intelligent overflow monitoring system. After detailed fault
tree sensitivity analysis, a new sensor for monitoring outflow flow,
inflow flow and slurry pool liquid level was debugged and installed,
equipped with corresponding overflow alarm. The field application
verifies the effectiveness of the system. In Fu’s work (Fu et al., 2015), an
overflow monitoring method based on Doppler principle and ultrasonic
device is proposed to monitor the annular velocity of deep water oil
wells, and an early kick detection prototype is developed. The effec­
tiveness of its test function is verified. The above overflow monitoring
methods gradually develop in the direction of intelligence, showing the
advantages of good accuracy and reliability, but most of them are based
on theoretical research, and the field practical application is not yet
mature.
The downhole parameters can be used as the data analysis source for
the overflow evaluation of the early overflow monitoring system. It is of
great significance to use these parameters for overflow monitoring. In
2016, a series of experimental devices for automatic overflow moni­
toring and alarm were proposed by studying the monitoring methods of
downhole parameters and oil-base muds related parameters, the effec­
tiveness of its early overflow monitoring function is verified (Ibarra
et al., 2016; Linga et al., 2016; Nayeem et al., 2016). Andia and Israel
(2018) introduced a new early overflow monitoring method, which is
based on the combination of physical modeling and Bayesian mathe­
matics to detect subtle changes in noise and uncertain measurements.
The network physics method is used to improve the identification speed
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Journal of Petroleum Science and Engineering 188 (2020) 106882
of overflow in drilling operation, and the real-time test effect is good. In
Samuel’s work (Samuel, 2018), it is found that the high frequency
downhole vibration data contain more hidden information than the low
frequency ground vibration data, and the reasons for the influence of
acceleration sensor detection in the early overflow monitoring system
are discussed. In this paper, a method based on the combination of
minimum entropy deconvolution and Teager-Kaiser energy operator is
proposed to remove the unnecessary sensor values and the possibility of
false prediction. In Alouhali’s work (Alouhali et al., 2018), based on the
progress of data analysis technology and a large number of data
generated in drilling process, a system for automatically monitoring
overflow in drilling process is developed. For decision tree, K-nearest
neighbor (KNN), sequence minimum optimization (SMO) algorithm,
Five models of artificial neural network (ANN) and Bayesian network
are evaluated and compared. The decision Tree and K-Nearest Neighbor
are selected. The accuracy and practicability of the monitoring system
can be improved by using the relevant mathematical methods to study
and analyze the obtained downhole data, but the types and quantities of
downhole data are complex and numerous, so it is difficult to extract the
available data, so it is difficult to form a set of accurate early overflow
judgment standards.
To sum up, the overflow monitoring methods can be divided into
drilling fluid pool liquid level monitoring, inlet flow rate and return
discharge flow difference monitoring, annular liquid level monitoring,
gas invasion monitoring, downhole multi-parameter monitoring while
drilling. Integrated logging parameter monitoring and monitoring based
on Bayesian probability model, the existing overflow monitoring tech­
nology has gradually developed to fully automatic and systematic, and
has independent self-assessment and rapid early warning ability. Over­
flow monitoring and rapid early warning technology has gradually
evolved from the most original manual monitoring drilling fluid
composition and drilling fluid pool liquid level change to automatic
discrimination and early warning, which improves the reliability of
overflow monitoring technology and reduces the risk of overflow
monitoring. The overflow early warning time is increased, which pro­
vides technical support and parameter reference for timely detection of
overflow and related well control operations. In the future research,
attention should be paid to the characteristics of the early overflow, and
the common points of the downhole data before the overflow are widely
summarized, and the accuracy and the timeliness of the overflow
monitoring system are improved.
2.3. Research on downhole communication module
The downhole communication module of blowout prevention system
with drilling is mainly responsible for receiving the signal transmitted
from the ground and transmitting the downhole signal to the ground for
the function of two-way communication between the ground and the
underground. With the use of downhole communication technology, the
signal transmission of blowout prevention system with drilling has
better real-time, observability, large capacity and reliability.
According to its transmission medium, downhole communication
technology can be divided into three ways: wired, wireless or wireless
and wired. Downhole communication technology has experienced many
years of development and innovation, experienced low-speed to high-
speed, one-way to two-way, wired to wireless transmission of great
progress. The earliest downhole communication technology is to trans­
mit the parameters measured by downhole instruments to the ground by
cable, and has been applied in the production process, but its field
application is very limited. The researchers later focused on wireless
transmission. MWD technology was proposed in Karcher’s work
(Karcher, 1935) for logging, but the reliability and accuracy of signal
transmission channels and measuring instruments at that time were
difficult to guarantee. Arps and Arps, (1964) invented a wireless
communication mode of mud pulse. The transmission of downhole in­
formation to the ground has been successfully realized. In the 1970s and
L. Wei et al.
1980s, Teleco Oilfield Service Company began an experimental project,
which can transmit the data to the ground through mud pulse telemetry.
Based on previous studies, Schlumberger Company has continuously
improved and improved, and has also produced a set of more practical
MWD instruments, and has been successfully used in the field (Grosso
et al., 1983; Tanguy and Zoeller, 1981).
Bednar and Petersen (1983) put forward a principle scheme of
transmitting control signal to downhole blowout preventer by acoustic
wave, and then the blowout preventer acted accordingly. Nieuwstad
(1987) put forward a way of passing mud pulse. The acoustic model of
drilling fluid loop was established in 1993, and the signal transfer
function under the coupling of annulus and drill string was taken into
account, and the principle scheme of ground control downhole blowout
preventer was presented in 1993. In this paper, the acoustic model of
drilling fluid loop was established in Kytomaa’s work (Kytomaa, 1993).
The transfer function can provide technical reference for the effective
transmission of mud pulse signal.
Taking into account the diversity and transmission efficiency of
communication signals, a downhole-ground communication channel
consisting of a long vertical cylinder rod and an isolated underground
straight cylindrical electrode buried in a uniformly grounded ground is
studied in Trofimenkoff’s work (Trofimenkoff et al., 2000). The effect of
conductor impedance and electromagnetic signal propagation is
analyzed. The performance of the signal channel can be evaluated. The
necessity of closed loop control of channel signal is studied in Zhou’s
work (Zhou et al., 2000). The signal “100 or “000 is used to indicate the
obvious difference of vibration of drill pipe during operation and stop,
and on this basis, the signal is encoded and transmitted from the ground
to the well. Both indoor and field experiments can realize the normal
transmission of signals. Harper et al. (2003) discussed a SRO system
which makes use of acoustic technology, cable and wireless transmission
technology. The system obtains bottom hole SRO data by collecting
wireless acoustic signals from wired probes arranged underground. In
Gao’s work (Gao et al., 2008), the characteristics of drill string signal
channel, the influence of signal attenuation and noise are studied in
detail, the influence of signal channel on the design of acoustic telemetry
system is discussed, and a communication technology close to realizing
high speed telemetry is introduced. In 2008, The development and uti­
lization of RFID technology are discussed in Snider’s work (Snider and
Doig, 2008). It is proposed that this technology has the potential to
supplement or replace the existing coiled tubing, optical fiber, cable and
electromagnetic telemetry communication technology. Joseph et al.
(2011) introduced a new remote communication technology for
surface-to-underground tools, in which the downhole tool is communi­
cated by using a flow-induced signal mode or a signal mode generated
by a sound source on the surface, the vibration and pressure signals
generated match the sensors in the tool to activate the tool.
Based on the higher and higher requirements of field application for
signal transmission, coupled with the limitation of wellbore space, the
reliability of wireless transmission mode is facing great challenges, and
has become a research hot spot with the help of wired transmission
mode. Mijarez-Castro et al. (2013) proposed a two-way communication
system between downhole high temperature and high pressure (HP/HT)
logging tools and surface equipment, and the communication medium is
cable. The system adopts a communication algorithm which automati­
cally changes the carrier frequency, and the experimental results are
good. In Li’s work (Li and Sturgeon, 2013), an example of successful
operation of coiled tubing downhole real-time communication system
on oil well is introduced, and the superiority of coiled tubing downhole
real-time communication system over traditional coiled tubing is dis­
cussed. In Trane’s work (Trane et al., 2015), it is proposed that the
traditional RF communication scheme can not transmit the signal
through the metal shell surrounded by corrosive gas and liquid. A PPM
guided wave communication system is opened, and the
corrosion-resistant 4H18 multi-wire cable is used as the communication
medium. In Tran’s work (Tran et al., 2015), a high bit rate downhole
6
Journal of Petroleum Science and Engineering 188 (2020) 106882
telemetry system is proposed for transmitting and receiving high bit rate
data on multi-conductor power transmission cables. Zheng et al. (2017)
proposed a vibration wave downhole communication technology. The
vibration wave is transmitted through the pipeline, and the downhole
communication system of vibration wave is developed, which is well
used in layered water injection. In 2018, a new intelligent drilling
communication system based on capacitance coupling was proposed
(Liu et al., 2018), and the system model was established. The correctness
of the mathematical derivation is verified.
To sum up, wireless communication is mainly composed of mud
pulse communication, acoustic wave communication, electromagnetic
wave communication, vibration wave communication and RFID
communication, while wired communication mainly consists of cable
and coiled tubing communication. At present, downhole communication
technology is more mature and widely used in mud pulse communica­
tion and coiled tubing communication. According to the working con­
dition while drilling and the principle of blowout prevention, the
downhole communication module of blowout prevention system with
drilling can use mud pulse communication or coiled tubing communi­
cation technology to communicate quickly and bidirectionally between
the ground and the downhole, but in order to make it earlier, It is urgent
to develop a new downhole communication technology suitable for
blowout prevention system with drilling because of faster and more
reliable communication between ground and downhole.
2.4. Research on well pressing module after sealing
The well pressing module of the blowout prevention system while
drilling is mainly responsible for replacing the original mud in the
annulus and drill string with the heavy mud with suitable density, so as
to balance the formation pressure and make the drilling work continue
to advance normally.
Generally speaking, the method of killing well can be divided into
conventional well killing and special killing well. Conventional well
killing is a method in which the surface can close the well normally
when overflow or blowout occurs, and the bottom hole pressure is
slightly higher than the formation pressure by pumping drilling fluid.
According to the operation mode, the conventional killing method can
be divided into driller’s method, engineer’s method and circulation
while weighting method. Driller’s method: in the first cycle, the original
drilling fluid circulation is used to discharge the drilling fluid invaded by
gas in the ring, and in the second cycle, the drilling fluid after the first
cycle is replaced with the aggravated drilling fluid, and the drilling fluid
pressure system in the wellbore is re-established. Engineer’s method:
equip the drilling fluid with the required killing well density, recycle the
drilling fluid which is invaded by gas in annulus at one time, and
establish a new drilling fluid pressure system. Special well pressing re­
fers to the method of killing well without conventional killing method,
such as natural gas well pressing, no drilling tool killing well in the well,
and injection and leakage co-storage killing well. In recent years, pres­
sure return method and low throttle well killing method have appeared.
The pressure-return method is to pump the new drilling fluid from the
annulus and return all the fluid which is invaded by overflow in the ring
air to the formation. The method of low throttling fracturing refers to the
fact that the casing pressure of the well can not be closed during
blowout, and the casing pressure has exceeded the maximum casing
pressure, and the control casing pressure is close to the maximum casing
pressure.
As the sealing module of downhole blowout prevention system is
located near the drill bit, the sealing module after sealing should balance
the sealing module near the high pressure overflow of the drilling head,
and then unseal the sealing module after balancing the formation
pressure to continue the follow-up drilling work. Most of the above
traditional well killing methods can not be applied to this working
condition. The common methods are as follows: when the sealing
module of the blowout prevention system while drilling is completely
L. Wei et al.
sealed in the annulus and in the drill pipe, the bypass valve of the
downhole blowout prevention system is opened; The corresponding
density drilling fluid is pumped from the drill pipe through the sealing
pressure value transmitted to the ground by the communication module
until the annular fluid in and near the surface of the drill pipe is
completely replaced. At this time, close the by-pass valve of downhole
blowout prevention system and unseal the sealing rubber cylinder, so as
to achieve the effect of killing well.
3. Study on the application of blowout prevention system while
drilling
At present, with the development of blowout preventer system while
drilling, the internal blowout prevention technology of drilling tool has
been mature and widely used in industrial production, while the outer
ring air blowout prevention technology is still in the research stage.
3.1. Study on the application of blowout prevention in drill pipe
In order to avoid blowout accident in drill pipe, it is necessary to
prevent and install blowout prevention tool in drill pipe in advance. At
present, the anti-blowout tools in drill pipe widely used in oil field
include square drill rod plug valve, drill rod check valve, drill tool by-
pass valve, drill pipe return pressure valve, new type drill pipe back
pressure valve and drop-in one-way valve and so on. The application
effect is good. The blowout accident in the drill pipe is effectively
avoided. Square drill pipe upper and lower plug valve, drill pipe check
valve is the most representative blowout prevention tool in oil field. On
the square drill pipe, the lower plug valve is connected to the square drill
pipe, the lower ends are at the upper end of the wellhead, and when the
normal drilling, the ball valves on the square drill pipe and the lower
plug valve are open. When the overflow in the well is found, the ball
valve is rotated 90 � with a special wrench. Close the inner channel of the
drill pipe, the structure diagram of the lower plug valve on the square
drill pipe is shown in Fig. 4. According to the structure of the valve core,
the drill pipe check valve is divided into arrow check valve, spherical
check valve, butterfly check valve, drill tool floating valve and drop-in
check valve, in which the drop-in check valve is formed by wellhead
drop or pump into position joint to form an internal blowout prevention
tool. The rest of the valves are installed at the upper end of the drill
collar near the end of the drill head. When drilling normally, all the
valves are in circulation. When the overflow or well is drilled, the valve
core is forced to be in close contact with the valve seat due to the back
discharge of the fluid acting on the differential pressure. In order to
achieve the function of internal sealing, the sealing principle adopts the
working principle of single flow valve, and the structure diagram of drill
rod check valve is shown in Fig. 5. Because the valve core of drill rod
check valve is eroded and corroded by mud positive circulation for a
long time, the sealing effect of valve core and valve seat will be weak­
ened and the service life will be shortened, so it is necessary to check the
sealing property of drill rod check valve and maintain it every time. On
the other hand, the research on high hardness, wear resistance and
corrosion resistant materials can be strengthened to improve the me­
chanical properties and life of valve core.
Under the condition of drilling, when the high pressure oil and gas
Fig. 4. Structure diagram of the lower plug valve on the square drill pipe. Reprinted from Xie et al. (2007).
7
Journal of Petroleum Science and Engineering 188 (2020) 106882
Fig. 5. Structure diagram of drill rod check valve. Reprinted from Zhang
et al. (2013).
reservoir is drilled and the overflow accident occurs, it is required that
the blowout prevention system while drilling can quickly separate the
overflow in the downhole position, and facilitate the implementation of
the subsequent killing operation. Therefore, the drilling pipe blowout
prevention tool in the blowout prevention system while drilling can only
use the sealing tool near the bit, such as the drill pipe check valve.
3.2. Study on the application of blowout prevention in the outer ring of
drill pipe
At present, the mature scheme of outer annular blowout prevention
of drill pipe is to use wellhead blowout preventer to seal annulus to
prevent blowout accident, and the reliability of blowout prevention
performance has also been verified in the field (Cress et al., 1992; Zhang
et al., 2018; Li and Zhang, 2012). Annular blowout preventer and
rotating blowout preventer are widely used wellhead blowout preventer
groups in oil fields, and they are also indispensable well control equip­
ment to ensure drilling safety. Wellhead blowout preventer groups are
shown in Fig. 6.
Although the mature wellhead blowout preventer group can prevent
blowout accident and ensure drilling safety, the blowout prevention
scheme has the disadvantages of not timely discovery of overflow or well
surge, slow annular sealing reaction, low sealing pressure difference and
high risk of well control operation. With the drilling blowout prevention
system as a new type of well control equipment, in order to achieve early
detection of overflow, early control, from the source of the rapid reso­
lution of blowout risk.
Li et al. (2016a,d) carried out laboratory experimental research and
test well experimental study on the outer annular sealing of drill pipe in
blowout prevention system with drilling. Both laboratory experiments
and test well experiments verify that the outer annulus sealing ability of
drilling pipe of blowout prevention system under drilling is feasible.
Laboratory experiment and test well experiment of drilling pipe external
packer for blowout prevention system while drilling are shown in Fig. 7.
The experimental results show that, compared with the traditional
L. Wei et al.
Fig. 6. Wellhead blowout preventer groups.
annular sealing technology, it is feasible to deal with the early overflow
and prevent the blowout accident in time with the outer annular sealing
of the drill pipe in the blowout prevention system while drilling.
At present, the blowout prevention technology of the outer annulus
of the drill pipe in the downhole blowout prevention system while
drilling is only studied by laboratory experiments and test wells, which
is lack of industrial application and promotion. The reasons are as
follows:
1). When the oil well temperature is more than 150 � C and the
sealing pressure difference is greater than 40 MPa, the drilling
condition is bad. The reliability of the outer annular sealing
technology of the blowout prevention system while drilling is
low.
2). At present, in the outer annulus sealing scheme of drilling pipe
with blowout prevention technology, the life and reliability of
drill pipe outer annular sealing tool of blowout proof system are
easily affected by the vibration of bottom hole bit, which can
quickly react and seal the outer annulus of drill pipe. The prop­
erties of the existing sealing materials are difficult to meet the
industrial requirements.
Fig. 7. Laboratory experiment and test well experiment of drilling pipe
external packer for blowout prevention system while drilling.
8
Journal of Petroleum Science and Engineering 188 (2020) 106882
3). At present, most of the outer annular sealing schemes of drill pipe
with blowout prevention system while drilling are made of rub­
ber material as the main sealing parts, and the sealing reliability
is weak under the condition of large open hole clearance.
The outer annular sealing technology of drill pipe for while drilling
blowout prevention system has more extensive research space and
economic value, and provides a new type of technology and technology
for prevention and treatment of blowout accident under drilling condi­
tion. Moreover, there is no conflict between this technology and tradi­
tional well control technology. If downhole blowout prevention is not
successful, more processing time will be won for wellhead control
operation, and the reliability and safety of the whole well control
operation will be enhanced.
4. Development direction of blowout prevention system while
drilling
Downhole blowout prevention system with drilling is a new type of
blowout prevention system, which is composed of annular sealing
technology, overflow monitoring technology, downhole communication
technology and well killing operation technology. With the compre­
hensive development and application of artificial intelligence and
automation technology in various industries, oil field equipment has
also been updated and reformed (Helmy et al., 2017; Ahmadi and
Bahadori, 2016; Choubineh et al., 2017; Stavinoha et al., 2014; Algina
et al., 2017). Blowout prevention system with drilling will be combined
with intelligent drill pipe technology to achieve high-speed, reliable
two-way downhole communication; Through more advanced moni­
toring technology, the formation pressure near the bit is monitored in
real time, and the prediction and risk assessment of early overflow ac­
cident are achieved. By combining the motor drive to complete the
sealing and unsealing of the rubber cylinder, the execution measures of
the annular sealing are simplified, and the adaptability of the rubber
cylinder to the diameter of the sealing well is improved. By combining
the downhole data obtained by downhole communication technology,
the density and volume of drilling fluid required for well killing oper­
ation can be solved automatically on the surface, and the drilling fluid
automatic adjuster can intelligently configure the drilling fluid to
complete the follow-up killing operation.
With the future of blowout prevention system with drilling, it will be
gradually promoted in the direction of intelligence, automation and high
efficiency, and the development prospect is wide. The blowout pre­
vention system while drilling will have the advantages of high safety,
good reliability, simple operation and cost saving, which will provide
new technological innovation for the safe and reliable development of
oil and gas fields.
5. Conclusion
1) The concept of downhole blowout prevention has been put forward
for more than half a century. Researchers have also put forward a
variety of schemes for blowout prevention with drilling. The inner
sealing technology of drill pipe has been mature and applied, but up
to now, the downhole annular sealing technology has not yet been
used in industry. The popularization and implementation of this
technology has great technical difficulties. It mainly includes: large
downhole annulus clearance near the drill bit, rougher borehole
wall, and poor rubber packing performance; the timeliness of early
overflow warning needs to be improved; it is difficult to achieve fast
and efficient two-way communication between the bottom of the
well and the surface during drilling.
2) Combined with the existing downhole blowout prevention theory
and experimental research and analysis, when drilling in sensitive
formation, the blowout prevention system while drilling is theoret­
ically feasible for overflow control and blowout accident prevention,
L. Wei et al.
and can improve the reliability of well control operation, security
and timeliness.
3) At present, with the more research results of blowout prevention
system while drilling, the blowout prevention in drill pipe has been
mature and used in industrialization, and the downhole communi­
cation technology and post-sealing well killing operation basically
meet the existing technological requirements. However, both the
outer annular sealing technology and the early overflow monitoring
or prediction technology are in the research stage, and the feasibility
of many technical schemes put forward at present is yet to be
verified.
4) Based on the analysis of the existing research status of blowout
prevention system while drilling, the blowout prevention system
while drilling will be combined with intelligent drilling technology
in the future to use electric drive mode to locate and unseal the outer
annulus of drilling pipe to predict the bottom hole overflow accident
in advance. As the blowout prevention system while drilling de­
velops towards the direction of intelligence, automation and high
efficiency, the well control technology is continuously optimized in
the direction of low risk.
Acknowledgments
This work was supported by the National Key R&D Program of China
(2018YFC0310201-06), and the State Key Laboratory of Oil and Gas
Reservoir Geology and Exploitation (Southwest Petroleum University).
The authors are grateful for the comments from anonymous reviewers of
this paper.
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