WELL CONTROL MANUAL

Drilling & Workover October 2002

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SECTION E – WELL KILLING PROCEDURES

Table of Contents

1.0 Constant Bottomhole Pressure .................................................. E-2

2.0 The U-Tube Principle ................................................................... E-2
2.1 Basic Well Control Equations (Static Conditions) .............................E-3
2.2 Basic U-Tube Concept ..........................................................................E-4
3.0 The Driller’s Method .................................................................... E-6
4.0 The Engineer’s Method ............................................................... E-6
5.0 Comparison of the Methods ....................................................... E-8
6.0 Other Well Control Methods.......................................................E-10
6.1 The Volumetric Control Method.........................................................E-10
6.2 The Low Choke Pressure Method .....................................................E-10
6.3 Bullheading ..........................................................................................E-11
7.0 Underground Blowout ................................................................E-12
7.1 Barite Plugs .........................................................................................E-13

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Current Revision: October 2002 E-1 3 Edition
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SECTION E – WELL KILLING PROCEDURES

1.0 Constant Bottomhole Pressure

Saudi Aramco recommends two well killing methods; the Driller’s Method and the
Engineer’s Method. Both of these methods are discussed later in this section. These
methods are designed to remove the influx from the wellbore while maintaining a constant
bottomhole pressure equal to or slightly greater than the formation pressure. These
procedures prevent additional influx from entering the well while the kick is being circulated
out.

Constant bottomhole pressure is maintained by pumping at a constant kill speed and using
the drillpipe and casing pressure gauges to monitor the bottomhole pressure. The surface
pressures on both gauges are adjusted by manipulation of the drilling choke orifice size.
The constant bottomhole pressure method offers several advantages. It allows the person
controlling the kick to observe or to calculate pressures throughout the system. It provides
the minimum pressure needed to balance the reservoir pressure, which lessens the
chances for a second fluid influx, yet holds surface pressures low enough to prevent
formation breakdown and lost circulation.

All methods discussed in this guide, except for volumetric control, require circulation to
remove the influx and kill the well. In each case, efforts are made to maintain a constant
bottomhole pressure by adjusting the combination of surface and hydrostatic pressures. As
discussed in Section A 1.6, when circulating through a well, bottomhole pressure is
increased due to annular friction and is expressed as equivalent circulating density (ECD).
As the value of equivalent circulating density (ECD) is very difficult to calculate and can
vary greatly from one situation to another, the effect of equivalent circulating density (ECD)
is not taken into account in any of the methods. The point to remember is that equivalent
circulating density (ECD) will be in effect when performing these methods, thus holding
more back-pressure than required:

• Is not necessary to prevent taking an additional influx

• Could result in formation breakdown and lost circulation

2.0 The U-Tube Principle

A thorough understanding of the relationship between bottomhole pressure, casing
pressure and drillpipe pressure is necessary to effectively use the well control procedures
discussed in this volume. Perhaps the best way to illustrate this relationship is through the
concept of a U-tube.

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Current Revision: October 2002 E-2 3 Edition
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SECTION E – WELL KILLING PROCEDURES

Figure E.1 shows the cross section of two vertical tubes of the same size connected at the
base by a horizontal tube. When a fluid of uniform density is added to the system, the
levels will equalize in columns A and B. This assembly is often referred to as a U-tube
because its shape resembles the letter U. The U-tube is a convenient way to represent
conditions in the wellbore with drillpipe in the hole. The inside of the drillpipe can be
represented by column A and the annulus by column B. The opening at the base of the U
can be thought of as the opening through the nozzles in the bit. The pressure at the bottom
of column A is equal to the pressure at the bottom of column B, which can be thought of as
the bottomhole pressure.

Figure E.1
Simple U-Tube Analogy

2.1 Basic Well Control Equations (Static Conditions)

Two equations, provided earlier, are needed to understand and explain the concept
of the U-tube. These are shown again below.

Bottomhole Pressure = Hydrostatic Pressure + Surface Pressure

Hydrostatic Pressure = 0.007 x Mud Weight x True Vertical Depth

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Current Revision: October 2002 E-3 3 Edition
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SECTION E – WELL KILLING PROCEDURES

2.2 Basic U-Tube Concept

In all U-tubes where the fluid levels are static, the bottomhole pressure generated by
column A is equal to the bottomhole pressure generated by column B. This
relationship is stated mathematically as:

Basic U-Tube Concept

Hydrostatic Pressure (Column A) + Surface Pressure (Column A)

is equal to

Hydrostatic Pressure (Column B) + Surface Pressure (Column B)

is equal to

Bottomhole Pressure

U-tubes are rather boring when the same density fluid fills both columns. In this
instance, the hydrostatic pressure and surface pressure of both columns are equal.
Such is the case when a bit is run to the bottom of the hole and the drillpipe and
annulus are filled with the same weight drilling mud. The fluid levels remain static at
the top of the well, the surface pressure on both the casing and drillpipe side is zero,
and the hydrostatic pressure on the drillpipe side is equal to the hydrostatic pressure
on the casing side.

U-tubes get very interesting when fluids of different densities occupy both columns.
In these instances, both the hydrostatic pressure and surface pressure of both
columns are likely to be different. Such is the case when a kick is taken with the bit
on bottom. The well kicked because the bottomhole pressure was greater than the
hydrostatic pressure generated by the mud in the well. When the well is shut in, the
well stops flowing, and the amount of pressure under-balance is reflected as a
surface pressure on the drillpipe gauge. However, the fluid in the annulus is no
longer composed of drilling mud alone; it also includes lighter weight formation fluid,
which reduces the total hydrostatic pressure in the annulus. Therefore, the annulus
side is more under-balanced than the drillpipe side, so the resultant shut-in casing
pressure is higher than the shut-in drillpipe pressure. This effect is shown in Figure
E.2.

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Current Revision: October 2002 E-4 3 Edition
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SECTION E – WELL KILLING PROCEDURES

In Figure E.2, a 10,000 ft. well with 75 pcf mud has penetrated an over pressured
sand with a reservoir pressure of 5,740 psi and taken a 30 bbl kick. Since the
hydrostatic head of the 75 pcf mud is only 5,250 psi (10,000' x 75 pcf x 0.007 =
5,250 psi), the drillpipe is under-balanced by 490 psi which is reflected on the shut-in
drillpipe gauge and at the top of column A of the U-tube. The hydrostatic pressure on
the annulus side is equal to the sum of the hydrostatic pressure of the mud in the
annulus and the hydrostatic pressure of the gas in the annulus. Since 30 barrels of
annular mud has been displaced by the lighter weight gas, there is less total
hydrostatic pressure in the annulus than in the drillpipe. The hydrostatic pressure
generated by 30 barrels of mud is 140 psi more than the hydrostatic pressure
generated by 30 barrels of gas in this wellbore configuration. Therefore, the shut-in
casing pressure and the pressure at the top of column B is 140 psi higher than the
value indicated on the drillpipe gauge.

Figure E.2
Example of U-Tube Effect

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Current Revision: October 2002 E-5 3 Edition
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SECTION E – WELL KILLING PROCEDURES

3.0 The Driller’s Method

The Driller’s Method of well control requires two complete and separate circulations of
the drilling fluid in the well. The first circulation removes the influx from the annulus
using the mud density in the hole at the time of the kick. Casing pressure is held
constant until the pump is at kill rate. Then drillpipe pressure is held constant to maintain
bottomhole pressure equal to, or slightly greater than formation pressure. If the kick
contains gas, it will expand in the annulus under controlled conditions as it nears the
surface. Therefore an increase in casing pressure and pit volume should be expected.
Drillpipe pressure and pump rate must be held constant. At any time during or
immediately after this first circulation, the well can be shut in and the drillpipe pressure will
read the same as it did originally.

After the kick fluid has cleared the choke, the well can be shut in. At this time, shut-in
drillpipe and casing pressures will be the same, assuming all of the influx has been
removed and mud hydrostatic is the same inside the drillpipe and the annulus. The original
shut-in drillpipe pressure is converted to an equivalent density at the bit, and the mud
density is increased accordingly.

During the second circulation, bottomhole pressure is held constant by first

maintaining casing pressure equal to the shut-in value while filling the drillpipe with
the kill mud. When the drillpipe is filled, as determined by the number of strokes pumped,
the drillpipe pressure is recorded and control shifts to maintaining a constant drillpipe
pressure while the annulus is filled with heavy mud. When the kill mud reaches the
surface, the pressure on the choke should be minimal. The pumps can be stopped while
holding casing pressure constant and the well checked for flow.

Any time a well under pressure is circulated, the start-up and shutdown procedures are
critical and should be done with exceptional care. Whenever the pump speed is increased
or decreased (including start-up and shutdown) the casing pressure must be held constant
at the value it had immediately before the pump speed change was initiated. This ensures
that bottomhole pressure remains constant. This procedure is valid because casing
pressure should be the same whether the well is closed-in or being pumped. However, the
drillpipe pressure must vary depending upon the circulating pressure loss in the system,
which is a function of the pump speed. The casing pressure cannot be held constant for
very long though due to the changing height of the influx caused by the irregular annulus
and gas expansion.

4.0 The Engineer’s Method

The Engineer’s Method of well control requires only one complete circulation. The kill
mud is circulated at the same time the influx is removed from the annulus. After the well
has been shut in, the pressures recorded, and pit volume increase recorded, the mud
density in the pits is increased and a drillpipe pressure schedule is created. The schedule
must be prepared in order that drillpipe pressure can be properly adjusted downward as kill
mud fills the drillpipe. A sample drillpipe schedule with an internal drillpipe volume of 800
strokes is provided in Table E.1.

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Current Revision: October 2002 E-6 3 Edition
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SECTION E – WELL KILLING PROCEDURES

Table E.1

Sample Drillpipe Pressure Schedule for the Engineer's Method

Strokes Drillpipe
Pumped Pressure Comment

0 540 Well is shut in

100 520 100 strokes of kill mud pumped
200 500
300 480
400 460 Kill mud halfway to the bit
500 440
600 420 600 strokes of kill mud pumped
700 400
800 380 Kill mud reaches the bit

Once the kill mud reaches the bit, the drillpipe pressure should be held constant until kill
mud reaches the surface. Bottomhole pressure will be equal to, or slightly greater than
formation pressure throughout the procedure as long as pump rate is maintained at the
predetermined rate.

If the kick contains gas, it will expand in the annulus, under controlled conditions, as it
nears the surface. Therefore, an increase in casing pressure and pit volume should be
expected. However, the drillpipe pressure and pump rate must be held at the
predetermined level.

As with the Driller’s Method, any time a well under pressure is circulated, the start-up and
shutdown procedures are critical and should be done with exceptional care. A prior
paragraph on this topic warrants repeating here. Whenever the pump speed is
increased or decreased, (including start-up and shutdown) the casing pressure must
be held constant at the value it had immediately before the pump speed change was
initiated. This ensures that bottomhole pressure remains constant. This procedure is valid
because casing pressure should be the same whether the well is closed-in or being
pumped. However, the drillpipe pressure must vary depending upon the circulating
pressure loss in the system, which is a function of the pump speed. The casing pressure
cannot be held constant for very long though due to the changing height of the influx
caused by the irregular annulus and gas expansion.

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SECTION E – WELL KILLING PROCEDURES

5.0 Comparison of the Methods

Both the Driller’s and Engineer’s Methods provide relative advantages and disadvantages,
depending on the general conditions of the area of operation or the specific conditions in
the subject well. The choice of kill method is determined through discussions between the
Drilling Foreman on location and the Drilling Superintendent.

Figures E.3 and E.4 illustrate a gas kick being circulated to the surface using both the
Driller’s and the Engineer’s Methods. Observing both figures, it is noted that when the gas
bubble reaches the casing shoe the Driller’s Method results in a surface casing pressure
which is higher than the initial casing pressure, whereas the Engineer’s Method is less. In
the Driller’s Method, the hydrostatic pressure in the annulus is reduced as the gas bubble
expands while being circulated out of the well. The bottomhole pressure is being held
constant; therefore, the surface casing pressure must increase. Since the hydrostatic
pressure above the shoe is the same as it was when the well was initially shut in, as long
as the bubble is below the shoe, the pressure at the shoe will be increased an amount
equal to the increase in the surface casing pressure plus any circulating friction generated
in the annulus above the shoe. This increase in pressure could be sufficient to cause a
formation breakdown at the shoe. Consequently, the maximum pressure at the casing
shoe occurs when the top of the bubble reaches the shoe if the Driller’s Method is
used.

Conversely, when the Engineer’s Method is used, the maximum pressure at the shoe
will generally occur when the kill mud reaches the bit.

Figure E.3
Removing Gas Influx with the Driller's Method

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Current Revision: October 2002 E-8 3 Edition
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SECTION E – WELL KILLING PROCEDURES

Figure E.4
Removing Gas Influx with the Engineer's Method

Three exceptions to this are:

1) When the kick volume fills the well above the shoe.
2) When a small kick volume does not increase the casing pressure as it rises
into a larger annular area at the top of the collars by the time kill mud reaches
the bit.
3) Any time the top of the bubble reaches the shoe before the kill mud reaches
the bit.

The introduction of kill mud into the annulus through the bit increases the hydrostatic
pressure. In order to maintain constant bottomhole pressure, the surface pressure must be
reduced; therefore, the pressure at the shoe is reduced.

In both methods, once the top of the bubble reaches the shoe, the shoe pressure is
decreased until the bottom of the bubble rises above the shoe. Once the bottom portion of
the bubble rises above the shoe, the shoe pressure remains constant with the Driller's
Method but continues to decline until the kill mud reaches the shoe with the Engineer's
Method (provided bottomhole pressure is constant). Therefore, the pressure at the shoe
when using the Engineer’s Method will always be less than or equal to the shoe pressure
when using the Driller’s Method.

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Current Revision: October 2002 E-9 3 Edition
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SECTION E – WELL KILLING PROCEDURES

A summary of the advantages and disadvantages of both methods is provided in Table

E.2.

Table E.2
Kill Method Comparison
Method Advantages Disadvantages
Driller’s Simplicity, few calculations Requires two circulations
Can be used until barite arrives. Higher surface pressures
Circulate quickly, reduce Higher casing shoe pressures
sticking and gas migration.

Engineer’s One circulation required More complex calculations

Lower surface casing pressures Waiting may stick pipe
Lower casing shoe pressures Waiting allows gas to migrate
Mud mixing capabilities

6.0 Other Well Control Methods

6.1 The Volumetric Control Method

This method is used when the pumps are inoperative or when the drillpipe is either
out of the hole, plugged, or has a hole in it. This is not a kill method but simply a
method of controlling bottomhole and surface casing pressures as the gas
migrates up the hole. The gas is allowed to expand as it migrates up the hole. A
(relatively) constant bottomhole pressure is maintained by bleeding off mud with an
equivalent hydrostatic head equal to the rise in pressure caused by the migrating
gas. The basis of the method is equating pit volume change and annulus pressure.
This procedure is discussed in detail later in this volume.

6.2 The Low Choke Pressure Method

This method is used if pressures threaten to become excessive while a well is

being killed. Choke pressure must be reduced sufficiently to prevent casing burst or
formation breakdown while circulating out. In kick situations requiring weight
increases, the mud weight should be increased as soon as practical. Kicks occurring
while drilling tight formations or after trips where tight formations have been drilled
may be circulated out using this method without increasing the mud weight.

It is important to realize that the formation will continue to flow until the combined
effect of the new kill mud, of light weight mud, and low choke pressure all balance
the formation pressure. Formations with high permeability cannot be effectively
killed by this method; the influx will exceed that controllable by even the maximum
rate used to circulate out the kick. The corresponding reduction of hydrostatic
pressure will prevent the killing of the well and possibly cause loss of the hole.

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Current Revision: October 2002 E - 10 3 Edition
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SECTION E – WELL KILLING PROCEDURES

Numerical analysis of the Darcy Equation indicates that this method is of

questionable value where formation permeabilities are greater than 200
millidarcys. This method should not be used when there is uncertainty about
formation permeability, and is therefore, not generally recommended.

6.3 Bullheading

If normal well killing techniques with conventional circulation are not possible
or will result in critical well control conditions, bullheading may be considered
as a useful method to improve the situation. Mud/influx are displaced/squeezed
back downhole into the weakest exposed open hole formation.

When to consider bullheading:

Bullheading may be considered when the following well control situations occur:
(1) Rig personnel and equipment cannot handle H2S or high-pressure gas influx
safely.
(2) Normal circulation is not possible because:
- Pipe has been sheared or no pipe in the hole
- String is off bottom
- String is blocked
- String is washed out or parted
(3) A combined kick and losses situation is experienced (downhole annulus
bullhead rates must exceed the gas migration rate to ensure the situation does
not deteriorate further).
(4) Kick calculations show that casing pressure during conventional kill operations
will probably result in a detrimental well control situation. (in this case, only the
influx needs to be squeezed back).
(5) The casing is set near the reservoir, avoiding other loss zones, and reservoir
permeability is high, enabling lower bullhead pressures, as in Arab-D wells.

Bullheading is not a routine well control method. In many cases, it will be doubtful
whether the well can be killed by squeezing back the influx into the formation and
lost circulation may be induced by bullheading kill weight fluid immediately below the
shoe into the formation. The method should in most cases be considered only as a
last resort.

In some instances, bullheading will be considered as the prime method; in such

case, the choice of bullheading should be made clear in the well plan. Examples of
such cases are high pressure/high temperature or H2S wells, wells in populated
areas, killing of well after a well test, or before workover operations.

Prior to Bullheading

- Consider using the volumetric method to eliminate the complication of

migrating gas. If the gas can be largely removed this way, the bullheading
operation is likely to be much easier and more effective in killing the well.

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SECTION E – WELL KILLING PROCEDURES

- Pressure limitations of pumping equipment, wellhead equipment and

casing must be kept in mind throughout.

- If a gas influx is suspected (shut in pressures continue to rise indicating

migrating gas), pumping rate for bullheading must be fast enough to
exceed the rate of gas migration. If pump pressures increase instead of
decreasing, it is an indication that the pumping rate is too low to be
successful. This can be a problem in large diameter holes. Note that
increasing the viscosity of the kill mud may or may not be helpful in
controlling this problem, and could possibly even make it worse.

- There is often a chance, particularly with relatively long open hole

sections beyond the last casing shoe, that bullheading could
breakdown the formation at the shoe rather than at the producing
formation. In this event, rather than killing the well, this procedure may
aggravate the development of an underground blowout, which could pose
risks to nearby wells in communication with the formations involved. It
could also increase risk of a blowout around casing in place with
subsequent obvious risks. Thus, bullheading should be considered
when these associated risks are the lesser of the potential evils.

- A check valve is recommended between the pumping unit and the well to
act as a failsafe valve in the event surface equipment should fail during the
procedure. If possible, the cementing unit should be used for better
control and adequate pressure rating.

- Large mud volume and LCM pills should be available in case major losses
are experienced during the operation.

7.0 UNDERGROUND BLOWOUT

An underground blowout occurs when the formation fluid from one zone flows into another
(see Figure E.5). The most common cause is the breakdown of a weak formation during a
kick, either at the instant the BOPs are closed or while heavy mud is being circulated to kill
the kick. This is common when drilling below uncased, depleted formations.

The method of killing an underground blowout depends on many factors. Stuck drill pipe
will complicate the situation. If an underground blowout is even suspected, the first thing
that should be done is to locate the zones kicking and taking fluid. This can normally be
done with a temperature survey inside the drill pipe.

If the drill pipe is free, normally its end is near the zone that is kicking, usually at the bottom
of the hole. Sometimes circulating a very heavy mud pill between the two zones can shut
off the flow. The pill’s volume should exceed the hole volume between the two zones. It is
sometimes desirable to simultaneously pump mud down the annulus.

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Current Revision: October 2002 E - 12 3 Edition
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SECTION E – WELL KILLING PROCEDURES

Figure E.5
Underground Blowout

7.1 Barite Plugs

The most successful method of controlling a high rate underground blowout is to

spot a barite plug (approx. 150 pcf) just above the flowing zone. Course-ground
barite is better suited for this application than finer grind because of faster settling.
In extreme cases, several barite pills may be required to shut off the flow.

The barite plug consists of barite, water and lignosulfonate, and caustic soda. The
lignosulfonate deflocculates the slurry and allows settling of the barite to form a
plug in the wellbore. The caustic soda provides a high pH (10-11) environment for
the lignosulfonate to be effective.

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A typical formulation for a 150 pcf barite plug is as follows,

0.54 bbl water
690 lbs/bbl barite
8 lbs/bbl lignosulfonate
1 lbs/bbl caustic soda

Slurry volumes will depend on the open hole interval and severity of the kick.
Typical volumes range from 40 bbls to 400 bbls.

The following flow chart summarizes the operations involved in controlling an

underground blowout with barite plug(s) and cement. This method involves
cementing a section of the drillstring in place.

Figure E.6
Underground Blowout Operation

PUMP BARITE SLURRY

1. OVER DISPLACE THRU BIT

2. PUMP ¼ BBL THRU BIT @ 15
MIN. INTERVALS
3. WAIT 6-10 HOURS
4. RUN TEMPERATURE SURVEY
5. WAIT 4 HOURS. RUN SECOND
SURVEY

WELL IS NOT FLOWING WELL IS FLOWING

1. SQUEEZE CEMENT SLURRY THRU 1. PUMP SECOND
THE BIT. LEAVE SOME CEMENT IN BARITE SLURRY
THE PIPE OR SET BRIDGE PLUG
PUMP IN DP
2. WOC & PRESSURE TEST
3. PERFORATE NEAR THE TOP OF
THE BARITE PLUG. ATTEMPT TO
CIRCULATE

WELL CIRCULATES WELL WILL NOT CIRCULATE

1. CIRCULATE CLEAR OF INFLUX 1. SQUEEZE CEMENT SLURRY THRU
2. SPOT CEMENT SLURRY THRU PERFORATION. CUT DISPLACEMENT
PERFORATION CUT DISPLACEMENT SHORT OR SET BRIDGE PLUG IN DP
SHORT OR SET BRIDGE PLUG IN DP 2. WOC & PRESSURE TEST
3. WOC & PRESSURE TEST

RUN FREEPOINT LOG. PERFORATE ABOVE FREEPOINT AND

CIRCULATE ANNULUS CLEAR

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