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Maersk Training Centre: Well Control Training Manual
Maersk Training Centre: Well Control Training Manual
Maersk Training Centre: Well Control Training Manual
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Well Control
Training Manual
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Table of content:
01
Page 007
02
Page 019
03
Page 028
04
Page 033
05
06
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07
Wellbore kicks
01.07
02.07
03.07
04.07
05.07
06.07
Page 053
Kick occurrences
Warning signals
Warning signals while drilling
Warning signals while tripping or making connection
Procedure for shutting in the well
Pressure after shut in
08
09
Page 094
10
Lost circulation
01.10
02.10
03.10
04.10
Page 097
General
Causes of lost circulation
Well control with partly lost circulation
Well control with total lost circulation
11
12
Page 102
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13
Page 119
14
Page 126
15
Pulling Pipe
01.15
02.15
03.15
04.15
05.15
Page 138
Introduction
Pumping slug
Inadequate hole fill
Hole not taking correct amount of fluid
Hole not giving correct amount of fluid
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Abbreviations:
A
Atm
BHA
BHP
BOP
Cap
DC
DP
EDC
EFD
EOB
FCP
FOSV
Ft
G
Gal
GMD
GMR
GPM
HCR
HPHT
H2S
ICP
ID
KMW
KOP
Lb
Lbs/ft
LOT
MAASP
MD
MW
MWF
OBM
OD
OH
OMW
P
PA
Pc
PDP
Pf
Ph
PL
PPG
M:\IWCF Surface\3\1\Section 5.doc
Area
Atmosphere
Bottom hole assembly
Bottom hole pressure
Blow out preventer
Capacity
Drill collar
Drill pipe
Equivalent circulating density
Equivalent formation density
End of build
Final circulating pressure
Full opening safety valve
Feet
Pressure gradient psi/ft
Gallons
Gas migration distance
Gas migration rate
Gallons per minute
High closing ratio
High Pressure/High Temperature
Hydrogen sulfide
Initial circulating pressure
Inside diameter
Kill mud weight
Kick off point
Pounds
Pounds per feet
Leak off test
Maximum allowable annular surface pressure
Measured depth
Mud weight
Final mud weight
Oil base mud
Outside diameter
Open hole
Original mud weight
Pressure
Pressure annulus
Pressure dynamic
Pressure drill pipe
Pressure formation (pore pressure)
Pressure hydrostatic
Pressure loss
Pound per gallon
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01.01 Sedimentation:
The theory behind the pressure being present in the different depths in the earth rock
formations are based on the historic development during millions of years where settling of
particles has taken place in the ocean.
Large and small rock particles are transported by rivers and streams, ice and wind and
deposited on the seabed offshore. In the sea several different chemical substances are
present which also separates from the water and sink to the seabed. Amongst others
carbonates, sulphates and chlorides are known to be dissolved in the seawater. Small
organisms which live in the sea has a life cyclus and when they die their solid remains also
sink to the seabed.
When this process continues during millions of years the layers of settling will obtain a
considerable thickness on the sea floor.
02.01 Compression:
The rock particles and solid matter will eventually become more and more compacted as
they bear more and more weight from the overlaying deposits. As this process continues the
water that is found between the rock particles will usually escape. However there will usually
be small cavities left between the particles, which contain the remaining water. These cavities
or void spaces make the rock formations more or less porous. A porous formation can
contain fluids, gas or hydrocarbons.
As compression and compaction continue during time, combined with thermal and chemical
processes the unconsolidated particles will eventually become rock formations within the
earth crust.
These sedimentary rock formations are generally porous, and the pores are filled with a fluid
or gas.
SHALE Porous/
impermeable
Porous/
SANDSTONE permeable
Tight and
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If communication between the cavities or pores in the formation is present this allows the fluid
to flow away and escape. Under certain conditions the formation fluid can become trapped. If
a porous fluid-bearing formation becomes covered with an impermeable layer of rock such as
a clay stone, the fluid becomes trapped.
03.01 Pressure
Before describing the conditions in which the formation fluids are found at different depths in
the rock formations the terms mass, density, force, energy and pressure will be
considered.
Mass
Mass is defined as the term for a quantity of matter. The unit of measurement that is used is
the pound.
Density
Density is an expression giving the mass of gas, fluid or solid matter in relationship to its
volume, E.I. mass per unit volume. Other means to express density is the term relative
density. By relative density is understood, the mass of a particular volume of substance
divided by the mass of an equal volume of fresh water. Due to the definition of the relative
density it remains dimensionless.
In this lecture mass in pounds, and volume in gallons is used, therefore the density is given in
pounds per gallon (ppg).
Force
When a mass hangs by a string, a force will keep the string in tension. The product of
gravitational acceleration and the mass causes the force itself.
Mass
Power
Fig 02
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This force can be measured by a dynamometer, Fig. 03. This instrument consists of a spring.
One end is fixed and the other end shows on a scale how much gravity force is exerted.
Scale
Pointer
Fig 03
9,831
= 1.0025 [ pounds ]
9,80665
9,781
= 0,9974 [ pounds ]
9,80665
In practice this variation in gravitational acceleration is ignored and a one pound mass is
considered to exert a one pound-force influence.
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Pressure
Pressure is defined in physics as force per area unit.
Force
Area unit
Pressure =
The total force, which acts on a plane, is divided by the area of the plane. The result is called
pressure.
The unit for force is pounds-force and the unit for area is square inch. Therefore the unit for
pressure will be:
Pressure =
Pounds
[pounds per square inch ]
Square inch
M = 1 pound
G = 1 pound ( 45 latitude North )
g = 9,80665 m/s2
A = 1 inch2
M
G
Pressure (P) = P x
G
1
=
= 1
A
1
Fig 04
1 inch
8.34 x 7,48
pounds / inch3
1728
Fig 05
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11
1
pounds
gallon
ft 3
x 7,48
x
x 120 inch3 = 4,33 pounds
3
3
gallons
1728 inch
ft
The pressure at the base of the fluid column is caused by gravitational acceleration that acts
on the fluid column divided by the fluid columns' cross sectional area.
Ph =
4.33 pound
= 4.33 psi
1 inch 2
It is important to realise that the pressure at the bottom of a static fluid column is only
depending on the vertical height of the column and the density of the fluid.
05.01 Pressure gradient
Considering a porous and permeable rock formation in which the pores are filled with fresh
water (density 8.34 ppg).
It is now possible to calculate the pressure at 5000 feet depth Ph =
4,33 x 5000
= 2165 psi
10
It is also possible to calculate the pressure increase that every foot of depth will represent.
Pressure increase per ft =
2165
= 0.433 psi pr ft
5000
This quantity which represents pressure increase in psi/ft is named Pressure Gradient 8G.
When the pressure gradient for a fluid or gas is known it is easy to calculate the pressure at
any given depth.
From the shown example of freshwater (8.34 ppg) and pressure gradient (0.433 psi/ft) it is
possible to calculate the pressure gradient for a fluid or for a gas with a density of 1 ppg.
Pressure gradient for 1 ppg =
0,433
= 0,052 psi / ft
8,34
With this new figure it is now possible to calculate the pressure gradient for any fluid or gas.
Pressure gradient = 0.052 x density in ppg
Example:
Calculate the pressure gradient for a fluid with the density 10.4 ppg.
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Calculate the pressure exerted from this fluid at a depth of 4000 ft Answer:
Fig 06 shows different pressure gradients and illustrates how pressure increases with
depth-
DEPTH
0
2500
6
5000
1000
2000
3000
4000
5000
PRESSURE
Fig 06
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POROUS SANDSTONE
BELOW CAP ROCK
HYDROSTATIC
PRESSURE
FROM
FORMATION
WATER
COLUMN
Fig 07
Under compaction
Let us consider that at a particular period in a rock formations' development it was not
possible for the formation fluids to escape since an impermeable formation type placed on
top prevents this from happening. Therefore the rock particles can not be compacted and
consolidated sufficiently to carry the weight of the overlying rock. Since the fluid trapped in
between the particles could not escape the fluid will be exposed to compressing forces.
These forces result in an increased formation fluid pressure, which is abnormal at the given
depth. It can be realised that the trapped formation fluid has to carry the weight of the
overlaying formation, along with the formation rock in which it is trapped. In a situation such
as this the formation pressure will be greatly different from a calculated normal
pressure/depth forecast.
Example:
A formation at 5000 ft depth contains formation fluid. The formation fluid has
communication to the surface through porous and permeable formation rock. See fig.
08
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14
5000 ft
5000 ft
2325 psi
Impermeable
zone
5147 psi
Fig 08
If it is considered that this formation fluid was trapped in an earlier period in the sedimentary
process and therefore could not escape the later compaction process, it is possible that the
fluid may be exposed to the weight of the overlying rock mass.
Assuming formation fluid is 10% and an equivalent formation density of 21 ppg this results in
the following formation pressure P f = ( 0.1 x 5000 x 8.95 x 0.052) + (0.9 x 5000 x 21 x 0.052)
Pf = 5146.7 psi
This formation fluid is over-pressured or abnormal. Over-pressured formations are often
encountered with thick salt sediments and salt domes. Salt does not have the same structure
as normal rock formations. Salt is termed a "plastic" formation, which means that it is not
self-supporting, it can move and deform under pressure, and (this is not necessarily a rapid
process). When pressure is applied to a salt formation it behaves more as fluids rather than
as solid matter. The relative strength of salt is very low compared to other rock types.
Because of the salt's qualities the weight from the overlying formation including the weight of
the salt layers themselves will be transferred to the formation below the salt. The pressure in
the salt and in the formation below it will often have a pressure gradient of 1 psi/ft instead of
the normal pressure gradient for formation fluid, which is 0.465 psi/ft.
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Abnormal pressures can also occur when an encapsulated and normal pressured formation
for the particular depth at a later stage in history with movements or surface erosion is
brought closer to the surface.
The particular formation in question can be found deeper or shallower in relation to its original
position. If it is the case that the formation pressure cannot adjust to its new depth it will hold
its original pressure.
Example:
If a sandstone formation at 4000 ft depth is considered it will have a normal pressure
of 1860 psi. On account of geological processes the area of sandstone becomes
isolated by impermeable rock. Through earth movements the formation moves to a
shallower depth of 2500 ft. In this situation the sandstone will retain it's original 1860
psi pore pressure but he surrounding formation has a pore pressure of 1160 psi.
Such an isolated zone is called a high-pressure zone or abnormal pressured zone.
It may as well be the case that the isolated sandstone by earth movements was brought
down to 5000 ft depth. The normal pressure for 5000 ft would be 2325 psi and the isolated
sandstone area with its 1860 psi would become a low-pressure or subnormal-pressured
zone.
2500 ft
4000 ft
1160 psi
1860 psi
1860 psi
5000 ft
1860 psi
2325 psi
1860 psi
Fig 09
Abnormal pressured formations can also develop because of differences in the contained
formation fluid and gas densities.
Figure 10 shows an anticline. An anticline is the geological term for an area of formations
which, due to earth movements has been pushed upwards to take a shape like a dome.
In the figure the anticline consists of porous sandstone which contains gas. A layer of
impermeable shale that prevents the gas from escaping caps the sandstone. The
formation surrounding the anticline has a pore content of salt water and a base depth of
5000 ft. The formation pressure is considered to be normal. Formation pressure of the salt
water bearing rock at 5000 ft will therefore be:
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3000 ft
Anticline
1395 psi
2125 psi
Porous
with
water
Sandstone
with gas
5000 ft
Tight
Shale
2325 psi
Fig 10
If the sandstone in the anticline contained salt water instead of gas, the formation pressure at
the very top of the anticline would be exactly the same as the formation just above.
Example:
Pf = 3000 x 0.465 = 1395 psi
The sandstone however is containing gas, which has a pressure gradient of 0.1 psi/ft. This
results in the pressure at top of the anticline to be substantially higher than the calculated
1395 psi for a salt-water formation.
The reason is that the hydrostatic pressure of gas within the anticline is much lower than the
corresponding hydrostatic pressure of salt water on the outside.
Pressure from the 2000 ft high gas column will be:
Ph = 2000 x 0.1 = 200 psi
Therefore the formation pressure at the very top of the anticline below the cap rock will be:
Pf = 2325 - 200 = 2125 psi
Formation structures of this type give a real problem if the formations above and/or below will
not withstand the 12.45 ppg hydrostatic pressure from the drilling fluid that is required to
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balance the zone at 2000 ft. It may be necessary to set several casing strings in order to
isolate the pressure.
High-permeability limestone formations have small formation strength gradients, and lost
circulation may be the result when the bottom well pressure exceeds formation pressure by
as little as 200 psi. This value may be less than the dynamic pressure drop in the annulus or
less than a safe trip margin. Such conditions can be risky if insufficient information is
available.
Transition zones and under compacted shale
Wherever massive shale formations are found the risk for transition zones and high pressure
is present. This is caused by thick impermeable shale restricting the disposal of formation
fluid. Due to new sediments are settled on the seabed increasing weight load is exerted on
the shale from the formation above. The water, gas or oil trapped within the shale cannot
escape. The result is the development of abnormal pore pressures. The terminology under
compacted shales is used to indicate these circumstances.
A seal of harder rock often caps the top of the abnormal pressured shale. Just after the cap is
penetrated the Rate of Penetration (ROP) increases. The reason is that the shale is easier to
drill since the differential pressure between drilling fluid hydrostatic pressure and the
formation pressure decreases. A reduction in overbalance results in a faster drilling rate.
When the Driller maintains his drilling
parameters constant t.i. constant rotary
speed, constant weight on bit and constant
pump rate, the Rate of Penetration should
be constant as well, unless changes in the
drilled formation takes place.
The indication of changes in the formation
can therefore be observed by the Driller by
means of changes in Rate of Penetration.
To confirm whether the well is still in balance,
the Driller must stop and observe if the well
is static. The terminology for this operation is
"flow checking the well".
UNCONSOLIDATED
SHALE-DENSITY INCREASES WITH DEPTH - WATER ESCAPES
Fig 11
Whenever thick shales are encountered it is important to be careful and expect abnormal
pressure in the formation. Shale related abnormal pressures can occur at any depth from
surface to very deep and is the most common reason for abnormal formation pressure.
Because the formation fluid in under compacted shale is unable to escape, a typical trend will
indicate that the cuttings density decrease with depth. The density decrease with depth can
indicate that abnormal pressure is encountered.
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UNDERGROUND
BLOWOUT
FAULT ZONE
Pf
Pf
Fig 12
Fig 13
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hydrostatic pressure exerted by the drilling fluid is higher than the formation pressure the
bottom hole pressure is in overbalance.
The relationship between differential pressure and Rate of Penetration shows that Rate of
Penetration increases when the differential pressure decreases. Penetration is given in feet
per minute and differential pressure in psi.
Ft/min
15
Rate of Penetration
12
6
4
3
psi
1000
2000
P = Differential Pressure
3000
Fig 14
The graph is interesting in several ways. Assume drilling with a differential pressure of 2430
psi in a particular formation with constant drilling parameters E.I. :
- Constant Weight on Bit
- Constant drilling fluid density
- Constant rotary RPM and
- Constant pump rate
it can be seen that the penetration rate is 4 ft per minute.
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21
Without changing any other parameters imagine that the formation pressure increases by
980 psi. This results in a new differential pressure of 1450 psi and a corresponding increased
penetration rate to 6 ft per minute.
It is realised that when the differential pressure decreases the penetration rate will increase.
05.02 Drilling break
An increase in Rate of Penetration (ROP) with constant drilling parameters is called a drilling
break.
It should be known that a drilling break is an early warning of a kick. If the Driller reacts on the
observation by making a flow check the well may still be overbalanced with the pumps
stopped.
Even that an increase in Rate of Penetration may be caused by other factors than a change
in differential pressure, the Driller should always play safe and perform a flow check in order
to confirm that the well is in balance. A natural reaction must also be to inform the
supervisors of any drilling breaks.
06.02 Necessary overbalance
By means of the graph it is seen that to obtain the highest possible penetration rate the
degree of overbalance has to be as small as possible. In practice a sufficient overbalance
must be used to avoid kicks from taking place.
07.02 Trip margin
A situation that can bring the well in underbalance is when the drill string is pulled upwards
during a connection and when tripping the string out of the well. The lower part of the drill
string acts as a piston that results in reducing the pressure below the string when pulling
upwards.
When the pressure in the wellbore is reduced the formation fluids can enter the well
underneath the bit.
To what extent this occurs is dependent on:
- How quickly the drill string is pulled upwards
- The dimension of the wellbore
- Dimensions of the drill string
- The rheological characteristics of the drilling fluid
- Other factors like degree of balling of the Bottom Hole Assembly etc.
To prevent formation fluids from being swabbed into the wellbore caused by any of these
reasons in combination a necessary overbalance is used. This small degree of overbalance
is called a trip margin.
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Formation
Strength
Fluid
Density
Formation
Pressure
Surge
Pressure
Swab
Pressure
Fig 15
Fig. 15 shows the conditions when drilling in normal pressure conditions. The tolerance area
(given by the area between the formation strength pressure and the formation pressure) is
relatively large.
When the drilling fluid density is adjusted to be in the centre of the area, there is only a small
risk for swabbing in connection with a trip. There is also allowance for a relatively large surge
pressure in excess of the hydrostatic pressure without risk for exceeding the formation
strength.
Surge pressure in the well is the result of lowering the drill string too quickly. The piston effect
results in increasing the pressure below the drill string.
Fig 16 and 17 shows different measurements taken with a PWD tool under normal
tripping conditions.
SWAB PRESSURE
Pulling
Speed
(mins/stand
SURGE PRESSURE
Start
EMW
(G)
End
EMW
(G)
0.965
0.956
140
0.964
0.956
0.962
0.962
Fig 16
Pressure
Drop
psi
Running
Speed
(mins/stand
Pump
Rate
0 gpm
Pump
Rate
180 gpm
Pump
Rate
250 gpm
295 psi
651 psi
837 psi
124
124 psi
434 psi
636 psi
0.958
62
93 psi
356 psi
527 psi
0.960
31
Fig 17
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09.02 Relationship between hydrostatic pressure, drilling fluid density and true
vertical depth
Example:
Well depth TVD
Drilling fluid density
6000
10.5
ft
ppg
3276 psi
Ph = 3276 + 500 =
3776 psi
12.1 ppg
1.6 ppg
With the new drilling fluid density drill to 9000 ft TVD and calculate the bottom hole pressure
at this depth?
Answer:
5663 psi
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Pressure Gradient
G Drilling Fluid = Drilling Fluid Density ppg x 0.052 psi/ft
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26
6000 ft
900 psi
900 psi
Fig 18
Hydrostatic pressure
Closed-in pressure
Bottom hole pressure
11 x 0.052 x 6000
=
=
=
3430 psi
900 psi
4330 psi
Which drilling fluid density must be used if the above bottom hole pressure shall be
maintained by using only hydrostatic pressure?
MW =
4330
= 13.9 [ppg]
6000 x 0.052
The calculated drilling fluid density is called the equivalent drilling fluid density.
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This means that the original 11.0 ppg drilling fluid must be replaced by a drilling fluid which
has a density of 13.9 ppg if the same bottom hole pressure shall be present without extra
pressure being applied at the top of the well.
Pressure in all depths in the well will be different in the two examples.
This can be confirmed by simple calculation.
What is the pressure at 3000 ft in the two examples?
Example with closed-in pressure on surface:
1. P h = 11 x 0.052x 3000 = 1716 psi
Applied Static Pressure = 900 psi
Total Pressure = 2616 psi
It must be realised that pressures throughout the well will be lower, if a particular bottom hole
pressure is achieved only by drilling fluid density, rather than using a lower drilling fluid
density combined with a static pressure applied at the surface.
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80
40
1280
1220
60
1170
50
370
800
800
Fig. 19. shows a circulating fluid system where the initial pressure at the pump is 1400 psi
and the final pressure is 0 psi at the flow line. It is seen that the 1400 psi represents the
energy required to overcome the friction that is present against the flow of the fluid in the
system. Large obstructions to flow give large pressure losses. By means of pressure gauges
placed in the system the pressure losses in the different parts of the system can be
monitored.
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Applying these considerations to the circulation of drilling fluid the Fig. 20. shows a pipe
system in which the drilling fluid pump ( mud pump ) shall pump drilling fluid through. This
simplified pipe system consists of drill pipe, drill collars, bit nozzles and annulus. The drilling
fluid enters the top of the drill string with a pressure of 2200 psi. On the way down through
the string some of this pressure is lost depending on
- The dimensions of the drill pipe (Internal diameter)
- The characteristics of the drilling fluid.
DRILL COLLARS
ANNULUS
DRILL PIPE
NATIONAL
PSI
BIT
P1
P3
P2
P4
P5
Fig 20
P1
P2
P3
P4
P5
=
=
=
=
=
(2200 psi)
(1900 psi)
(1700 psi)
(130 psi)
( 0 psi)
The largest pressure loss in the well system takes place when fluid flows through the bit
nozzles that have a relatively small flow-through area.
On the way towards the surface through the annulus, the pressure loss will be the lowest in
the system, because the friction is not at all large on account of the large cross-sectional area
of the annulus.
The pressure figures used in Fig. 20. are based on average calculations for a simple rotary
assembly, and they show that 94% of the total pressure loss occurs in the drill string and bit
nozzles.
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The figures show that to circulate the drilling fluid from the bottom of the well up to the
surface it is only necessary to use approximately 6% of the total pump pressure. This
dynamic pressure will be transmitted to the bottom hole pressure.
When the pump is running and circulation takes place there will be a higher bottom hole
pressure than when the pump is stopped.
With the pumps stopped only hydrostatic pressure is present in the well to balance the
formation pressure.
02.03 Dynamic pressure in the wellbore ( Circulating Pressure)
Dynamic Pressure ( PC ) is dependent on three factors:
- Components in the flow system
(Flow area, length of drill string, nozzles size etc)
- The fluid characteristics ( Rheology )
- The flow rate
(SPM, liner size, pump efficiency etc)
Change in drilling fluid characteristics ( such as viscosity and gel-strength ) can change the
friction against flow in a system.
A fluid's flow resistance is largely depending on the drilling fluid density. In well control
calculations it is accepted that dynamic pressure loss is proportionally depending on drilling
fluid density.
PC 2 = PC 1 x
PC1
PC2
=
=
MW 2
[psi]
MW 1
The expression for the relationship between circulation pressure and drilling fluid density has
proved to be realistic in most practical cases. See fig. 21.
PSI
High fluid dens
ity
Low fluid dens
ity
PC2
PC1
Fig 21
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Example:
At 100 SPM the pump pressure is 1000 psi with a drilling fluid density of 10 ppg.
What would the pump pressure be at 100 SPM if the drilling fluid density was
increased to 12 ppg??
New pump pressure:
P C 2 = 1000 x
12
= 1200 [psi]
10
To calculate the new pump pressure it is required to know the original pump pressure, which
is read just after the pump ( standpipe pressure ).
The third factor that affects the circulation pressure is the speed of the flow of drilling fluid.
This velocity of flow is directly related on the pump speed ( SPM = strokes per minute).
The relationship between pump speed and dynamic pressure can be expressed as:
SPM 2
PC 2 = PC 1 x
SPM 1
1.86
Where SPM is the number of strokes per minute in the two cases.
Example:
Circulation pressure is 1200 psi with 40 SPM.
What will the circulation pressure be if the pump speed was increased to 80 SPM?
Answer:
80
P C 2 = 1200 x
40
1.86
= 4356 psi
It is realised that if the pump speed is increased to twice its original value the dynamic
pressure will be increased almost fourfold. The graph in Fig. 22 illustrates this fact.
The power 1.86 is an experience figure, which is obtained from experiments. However in well
control calculations it is generally accepted to use the power 2 in stead of 1.86.
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SPM 1
Pc
4000
3000
2000
1000
SPM
10
20
30
40
50
60
70
80
90
Fig 22
Fig. 23. shows circulation pressures and pressure losses between the drill string and annulus
with three different pump rates.
Pc
4000
80 spm
3000
60 spm
2000
1000
40 spm
Fig 23
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PDP
PA
PA
BOP
DRILLSTRING
ANNULUS
DRILL STRING
ANNULAR
A
DRILLCOLLAR
Fig 24
Fig 25
02.04 U-tube
A simplified and equal system can be represented by two tubes standing upright side-by-side
and connected at the bottom. The example is called a U-tube. See. Fig. 25.
The pressure in the same horizontal levels in the connected system is always the same if
fluid density is the same, when no circulation is taken place and no pressures are closed in
on the top on any of the two legs.
It is seen that the hydrostatic pressure at the bottom of such a U-tube system, irrespective of
which leg of the U-tube column is considered will be equal. This is easily confirmed by a
simple calculation:
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34
Example:
True vertical depth =
Drilling fluid Density =
10000
10
ft
ppg
Both drill pipe and annulus are open at the surface and the U-tube is in balance. Bottom hole
pressure Ph at the point A can be found either by the drill pipe or by the annulus when drilling
fluid density is uniform :
P h = Drilling Fluid Density ppg x 0.052 x True Vertical Depth ft [psi]
P h = 10 x 0.052 x 10000 = 5200 [psi]
If the BOP is closed on the annulus and the drilling fluid in the annulus is replaced with
saltwater
( 8.34 ppg ) the following can be calculated:
The internal contents of the string ( drill pipe and drill collar ) has not changed so PH at A is
still 5200, but the hydrostatic pressure in the annulus is only (Fig 26):
P ha = 8.34 x 0.052 x 10000 = 4337 psi
P a = 5200 - 4340 = 860 psi
PA
PA
9 ppg
10000 ft
DRILL STRING
ANNULUS
10000 ft
8.34 ppg
DRILL STRING
10 ppg
PDP
ANNULUS
PDP
8.34 ppg
Fig 26
M:\IWCF Surface\3\1\Section 5.doc
Fig 27
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35
Example:
Considering the same well with the same bottom hole pressure, but now with 9 ppg drilling
fluid in the drill string and upper 7000 ft of annulus, while there remains saltwater in the lower
part of the annulus (Fig 27).
When PSIDP = Pressure ( Shut in drill pipe )
When PSIA = Pressure ( Shut in annulus )
P SIDP = 5200 - ( 9 x 0.052 x 10000 ) = 520 [psi]
P SIA = 5200 - ( 7000 x 9 x 0.052 + 3000 x 8.34 x 0.052 ) = 623 [psi]
The example represents a typical kick situation, where insufficient drilling fluid density has
resulted in a saltwater influx into the annulus. The influx has replaced a quantity of drilling
fluid. Notice that the drill pipe bottom hole pressure consists of two parts, first the PSIDP value
and secondly the hydrostatic pressure of the drilling fluid. The annulus bottom hole pressure
consists of three parts. The PSIA value, the hydrostatic pressure of drilling fluid and the
hydrostatic pressure of the saltwater.
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36
5
M:\IWCF Surface\3\1\Section 5.doc
10
15
20
25
30
35
40
45
50
55
60
65
70
75
80
VOLUME
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37
This means that when a given volume V1 with an absolute pressure P1 is changed in
pressure or volume we get a new pressure P2 with a new volume V2.
Example:
V1 = 5 gal
V2 = 3 gal
Calculate
P1 = 170 psi
P2
P1 x V 1 = 170 x 5 = 283 [psi]
P1 x V 1 = P 2 x V 2 _ P 2 =
3
V2
It must be noted that the temperature to use is an absolute temperature which is given in
Kelvin degrees, (K ) for the Centigrade system.
If the Fahrenheit system is used the absolute temperature must be given in Rankin (R )
degrees.
K is obtained by addition of 273 to the temperature given in Centigrade C.
T K = t C + 273
Example:
V1 = 12 gal
V2 = 12 gal
P1 = 90 psi
T2 = 80C
P2 =
T1 = 20C
P 1 x V 1 x T 2 90 x 12 x (273 + 80)
=
= 108 [psi]
(273 + 20) x 12
T1 xV 2
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Example:
The formula, which relates to the properties of gasses, is here used in a practical example.
The well has a depth of 10000 ft and there is a swabbed gas bubble on bottom. The drilling
fluid density is 12.5. The well is open and in balance. Consequently no closed-in pressure at
the surface. The pressure in the gas is therefore equal to the hydrostatic pressure at 10000 ft
Ph.
Hydrostatic pressure Ph is 6500 psi.
If the BOP is closed and the gas is allowed to rise upwards ( migrate ), the gas volume will
not change and in accordance with the gas law the pressure will also remain unchanged.
Assuming the temperature is constant the gas would retain its original volume and pressure
all the way to the surface.
0 psi
6500 psi
3250 psi
PA
PA
PA
6500 psi
12.5 ppg
12.5 ppg
5000 ft
12.5 ppg
10000 ft
6500 psi
5000 ft
10000 ft
12.5 ppg
6500 psi
6500 psi
9750 psi
13000 psi
Fig 29
Considering that the gas has migrated halfway up the wellbore it will still have a pressure of
6500 psi. The pressure at surface ( annulus ) at this stage would be: (See Fig 29.)
P SIA = 6500 - 12.5 x 0.052 x 5000 = 3250 [psi]
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When the gas is allowed to rise all the way to the surface without expanding, the pressure at
the surface would be 6500 psi.
Bottom hole pressure would be:
P bottom = 6500 + 12.5 x 0.052 x 10000 = 13000 [psi]
This extreme pressure throughout the wellbore cannot be controlled, and it is not reasonable
to assume that the situation would develop all the way as described. The weakest point in the
wellbore is normally believed to be at the casing shoe level. When the pressure increases
above the strength at the weakest point the formation at that point will fracture. The risk for an
underground blow out is high.
A gas kick can never be allowed to migrate up through the annulus without expanding. A
skilled drill crew must take proper and timely action to avoid the dangerous situation that is
likely to occur.
In the given example the temperature influence neither the changed height due to annulus
geometry was taken into account since these factors only have a small influence in practice.
03.05 Expansion of Gas
Although some kicks are predominantly salt water or oil, at least some gas is usually present.
Because salt water and oil do not expand as pressure decreases, they are not as
troublesome as gas. It is important for the persons who control blowouts to understand the
behaviour of gas in a well.
The gas volume change as a result of pressure change is predictable, and this allows
calculation under illustrative conditions of changes in bottom well pressure as gas rises
through the drilling fluid. When the pressure of a given mass of gas is doubled, the volume is
halved. When the pressure is halved the volume is doubled. This relationship between
pressure and volume results in the greatest expansion of the gas in the upper part of the well.
See Fig 28.
Although gas-cut drilling fluid is one of the early indicators of abnormal pressure, minor gascutting results in only a small reduction in the hydrostatic head. In a gas-cut column of drilling
fluid, the pressure increases rapidly with depth, so that the volume of gas scattered through
the well bore is very small, and reduces the overall drilling fluid density in the well very little.
A slug of gas in the bottom of a well is potentially dangerous, because it will expand greatly
when it rises or is pumped up. Under low pressure near the surface, it will displace a large
amount of drilling fluid from the well and consequently greatly reduce bottom hole pressure
giving risk for a blowout.
The safe handling of a gas kick requires knowledge about the principle of gas expansion and
consequently lowering the pressure in the gas bubble as it is circulated up through the
annulus in order to maintain the correct and constant bottom hole pressure. The theoretical
knowledge requires practice as well as knowledge about well control equipment.
When the gas in a well control situation is circulated to the surface and expanding, more
drilling fluid must be allowed to flow out of the annulus than is pumped into the drill pipe.
Thus, the pit level will increase.
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The expected drilling fluid volume increase should be known prior to circulating out the kick.
This detail is discussed in the kick control section.
To control a correct and constant bottom hole pressure, the surface pressures are used as a
parameter for control. This is done by means of the choke in connection with a stroke counter
for the mud pumps, and simple recognised procedures.
04.05 Formation strength
From the previous examples it is realised that pressure throughout the wellbore increases
when gas rises up the annulus in a closed-in well. Gas must be circulated out of a well under
control. One of the most important limitations that should be known is the maximum pressure
the formation ( or weak point ) can withstand before it fractures and allows the drilling fluid to
flow into the formation.
If the formation strength is exceeded in a kick situation there is a high risk for an underground
blow-out and perhaps complete loss of control of the well.
The formation strength is recorded by means of a leak-off test.
05.05 Leak-off test
A leak-off test can be carried out in various ways. The aim is to find the surface annulus
pressure value for when the drilling fluid begins to seep into the formation, without at the
same time to cause an actual fracture of the formation. The less drilling fluid volume that is
pumped into the formation, the less damage there is caused to the formation. After the test
the formation should easily heal again as a result of the drilling fluid's wall building effect.
A leak-off test is carried out just after casing has been set and cemented.
A leak-off test may be conducted as follows:
Between 10 and 30 feet is drilled below the casing shoe to expose virgin hole.
The well is circulated to obtain a representative and accurately known drilling fluid density in
the well.
The well is closed-in and drilling fluid is pumped into the well at a very slow rate.
The cement pump is generally used since they have a smaller displacement and thus are
easier to control and are fitted with very accurate low pressure gauges.
Accurately measured volumes are pumped into the well, one barrel in this example, until an
increase in casing pressure is registered. At this point pumping is stopped for about one
minute, until the surface annulus pressure has stabilised. When no pressure decrease is
observed the pressure is plotted on a graph paper. The pumping is resumed and the same
volume is again pumped. The pumps are stopped and the new pressure is plotted after it has
stabilised. This procedure is repeated until it is observed that the pressure increase per
volume portion is no longer proportional.
This is easy seen on the plotted graph at the point where the straight line begins to bend.
The pressure on the graph where this happens is the annulus surface leak-off pressure. See
Fig. 30.
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41
PRESSURE
ANNULUS
DEPTH
1100
1000
900
800
700
*
*
600
*
*
400
300
100
S
H
O
E
500
200
* * *
*
V
O
L
*
U
M
1 2 3 4 5 6 7 8 9 101112131415
E
*
Ph
Max
Pshoe
P
R
E
S
S
U
R
E
Fig 30
The leak-off test should be interrupted at this point. If the pumping is continued the pressure
will decrease as a result of an increasing amount of drilling fluid which is injected into the
formation. Furthermore the formation strength will be reduced. It has been proven that a
leak-off test performed too far has damaged the formation. In that case a second leak-off test
will indicate a lower formation strength.
Fig. 30 shows the results from a leak-off test carried out after casing has been cemented at
3000 ft. Drilling fluid density was 9.6 ppg. The leak-off pressure is seen to be 720 psi. The
combined pressure the casing shoe is exposed to is the hydrostatic pressure of the drilling
fluid and the surface leak off pressure and this combined pressure becomes the maximum
allowable shoe pressure at any given time.
Calculate the maximum allowable pressure at the casing shoe:
Answer:
P shoe = 9.6 x 0.052 x 3000 + 720 = 2218 [psi]
When we know the maximum allowable shoe pressure, we are able to calculate the
equivalent drilling fluid density or maximum allowable drilling fluid density
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2218
= 14.22 [ppg]
3000 x 0.052
Ph
MAASP
DOWN
DOWN
=
MAASP
UP
Ph
UP
Fig 31
As illustrated in Fig 31 the MAASP will increase if pressure hydrostatic inside the casing
decrease for whatever reason and visa versa.
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One important issue when circulating out a kick is to monitor the Initial MAASP value. If the
Initial MAASP is approached before the kick is circulated into the casing the responsible rig
management must take safe action. It may be impossible to avoid exceeding the Initial
MAASP, but the competent and responsible management may decide to evacuate the rig for
non-essential personnel until the situation has proven to be safe.
Once the influx is inside the casing the initial value can be exceeded.
We will look on how MAASP behave during circulating out a kick later in chapter 08.
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In routine operations as well as during well control operations it is necessary to know the total
drilling fluid volume and the volume for the individual sections in the circulating system.
How much volume does the drill string contain and what is the volume in the different parts of
the annulus?
These questions can easily be answered if the dimensions of the different components in the
drill string and annulus are known. There are two ways to find the different capacities and
volumes:
- By calculating the volumes
- By reading tables
01.06 Calculating drilling fluid Volume - Capacities
The internal capacity of drill pipe and drill collars is calculated based on formulas for
cylinders.
For a cylinder with a diameter d (inches) and a height of 1 foot the volume will be:
D
V=Axh
p x d2x h
[ ft 3 /ft]
V=
4 x 144
1 ft
2
p x d 2 x 0.1781
d
=
bbl / ft
4 x 144
1029.4
Fig 32
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45
2
2
2
2
OD
ID
OD - ID
=
[ bbl / ft ]
1029.4
1029.4
1029.4
1 ft
Example:
OD
= 9-7/8 in
= 5.000 ft
Drill pipe
Drill collars
= 4.600 ft
= 400 ft
Fig 33
(4 1 / 4)
V drill pipe =
= 0,01754 bbl / ft
1029,4
(2 13 / 16)
V drill collar =
= 0,00768 bbl / ft
1029,4
(9 7 / 8 )2 - 52
= 0,0704 bbl / ft
1029,4
Total Volume between casing and drill pipe = 0.0704 x 4600 = 323.84 bbl
V drill collar =
(9 7 / 8 )2 - 7 2
= 0,04713 bbl / ft
1029,4
Total Volume between casing and drill collars = 0.04713 x 400 = 18.85 bbl
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It is common practice to use tables that give capacities in bbl/ft or litre/meter for different
sizes of pipe and casing. These tables are made taking into consideration the physical outline
of the pipes
( tool-joint etc. ).
Tables of this kind can be found in different Data Handbooks or in the Drilling Data
Handbook
( DDH ) sixth edition 1991. Section D Capacities and Annular Volumes and section G
Pumping and Pressure Losses.
All the tables in DDH is in SI-units, but at the bottom of each table a conversion factor is
found in order to convert to oil-field units.
Fig 34
Drill Pipe
5 - 19.5 lbs/ft
10000 ft
Casing 9-7/8
- 47 lbs/ft
7500 ft
Open Hole
- 8-5/8
3000 ft
Drill Collar
7 x 2-13/16
500 ft
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= 688.06 bbl
By making the above calculations the exact quantities of drilling fluid contained in the different
parts of the well is known.
03.06 Surface-to-Bit Strokes & Bit-to-Surface Strokes
The exact number of strokes required to pump from the surface through the drill string to the
bit, is known as surface-to-bit strokes.
The number of pump strokes required to pump from the bottom of the well to the surface, is
known as bit-to-surface strokes.
These values can be calculated when the pump displacement per stroke is known. Pump
displacement can be found in the DDH Section G table G6.
Given:
National pump 12-P-160. w/ 6" liners. The number 12 represents the stroke length in
inches. Volumetric efficiency 97 %.
From the table is read 16.68 l/stroke with volumetric efficiency of 100 %. At the bottom
of the table a conversion factor is found to convert into bbl.
16.68 x 0.264
= 0.1048 bbl / stroke
42
By using the capacity figures in fig. 34 we can now calculate surface-to-bit strokes as follows:
Total inside volume of drillstring
= Strokes
Mud pump output per stroke
Surface-to-bit strokes
Respectively bit-to-surface strokes is now calculated.
177.61
Surface bit strokes =
= 1746 strokes
Bit-to-surface strokes
0.1017
MTC
DOCUMENT ID
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ORIGINAL DATE
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48
The circulating time required is controlled by the speed of the drilling fluid pump. In case of a
pump speed of 30 strokes per minute ( SPM ) the result would be:
Surface bit time =
Bit surface time =
1746
= 58.2 minutes
30
6765
= 225.5 minutes
30
Another volume that is often necessary to know is the bit-to-shoe time and the corresponding
pump strokes.
Considering fig. 34 it can be seen that:
Bit shoe strokes =
117.12 + 12.38
= 1273 strokes
0.1017
Therefore:
Bit shoe time (at 30 SPM) =
1273
= 42.4 minutes
30
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The theoretic and actual quantity of barite used to effect a drilling fluid density increase can
be calculated beforehand by using the initial drilling fluid density MW ( ppg ) and the drilling
fluid density required MWf ( PPG ) (final drilling fluid density). The units will be number of 100
lb sacks per 100 bbl of drilling fluid.
Example:
An active drilling fluid system contains 900 bbl of drilling fluid with a weight of 10.5
ppg. We want to increase this density to 13.5 ppg by adding barite. How many sacks
will be used?
MWf - MWi
0
100 lb Sacks
Theoretical
MWf
9
10
100
2
3
4
5
6
7
8
9
10
100 lb Sacks
Actual
0
11
200
300
400
12
200
13
300
14
400
15
500
16
600
700
800
900
100
17
18
19
500
600
700
800
900
1000
1200
1400
Fig 35
l.
2.
In the homograph fig 35 a straight line is drawn on the scale from 13.5 ppg MWf (final
drilling fluid density) to 3.0 ppg on the scale to get MWf - MWi(final drilling fluid density
minus initial drilling fluid density).
The scale reads 204 sacks per 100 bbl on the scale for theoretical use of 100 lb
sacks.
By taking the point on the scale for theoretical use where the first line crosses (i.e. 204
sacks) and by drawing a horizontal line across to the scale for actual use from this
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point, the actual true value is seen to be 224 sacks (100 lb sacks) per 100 bbl of
drilling fluid to effect the desired increase.
3.
Therefore
224 x
900
= 2016 sacks
100
2016 sacks in the 900 bbl system is required to increase the drilling fluid weight to the
desired level.
The theoretical quantity of sacks per 100 bbl of drilling fluid can be calculated by the following
expression:
S = 1490 x
where S
MWf
MWi
MW f - MW i
35,5 - MW f
The volume increase (in barrels per 100 bbl of drilling fluid in the system) can also be
calculated by initial drilling fluid weight MWi (ppg.) and final drilling fluid weight MWf (ppg.).
Example: An active drilling fluid system contains 900 bbl of drilling fluid with a weight of 10.5
ppg. We want to raise this weight up to 13.5 ppg. by adding barite.
In the homograph fig. 36 we draw a straight line between 13.5 ppg. on the scale for
MWf and 3.0 ppg. on the scale for MWf - MWi, and we notice where this line crosses
the Pivot Line.
2.
Where our first line crosses the Pivot Line we draw a horizontal line across to the
scale for volume increase and we can read-off that there will occur a 22.5 bbl per 100
bbl increase in drilling fluid volume.
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MWf - MWi
0
MWf
9
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01
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51
Volume
Increase
0
10
12
20
13
30
14
40
15
2
1
E
LIN
OT
PIV
7
8
16
17
18
10
19
50
60
70
80
90
100
120
140
Fig 36
3.
22.5 x
900
= 202,5 bbls increase volume
100
Therefore total volume = 900 + 202.5 = 1103 bbl after completion of weight increase.
The volume increase can be calculated with the help of the following expression:
V = 155 x C x
MW f - MW i
35.5 - MW f
where
V
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MWi
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This expression assumes that 1.5 gallons of water are used per sack of barite to replace
water lost on account of hydration, and a dry barite volume factor of 14.9 sacks per bbl.
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WELLBORE KICKS
A kick can occur when the formation pressure becomes higher than the hydrostatic pressure
that the drilling fluid column is exerting in the wellbore. The influx of fluid or gas into the
wellbore further reduces the hydrostatic pressure, which results in increased flow at the
surface and therefore further influx from the formation. The influx into the well bore shall
therefore be stopped as rapidly as possible by closing-in the well.
There are two normal reasons why the formation pressure can exceed the hydrostatic
pressure in the wellbore:
1.
Pore pressure or formation pressure increase more rapidly than drilling fluid weight
2.
The drilling fluid weight is sufficient to balance the formation when the well is full of
drilling fluid, but when the height of the drilling fluid column is reduced for some reason
hydrostatic pressure is reduced.
2.
3.
Swabbing
4.
Lost circulation
5.
6.
1.
This should seldom be the cause of a kick in development wells where formation pressures
are known. At a wildcat well where the pressures of the formation are partly unknown the
danger for insufficient drilling fluid weight is much greater.
In Normal Pressured Formations the pressure gradient is taken as 0.465 psi/ft. of depth. This
is the figure for salt water having a salinity of about 100,000 parts per million (ppm). The
drilling fluid density required to balance this pressure would be approx. 9 ppg.
It must be remembered that the overbalance increases with depth if the formation pressure
gradient remains constant. See Fig 37.
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Mud
Column
Pressure
10 ppg
Formation
Pressure
0.465psi/ft
Over
Balance
Pressure
5.000
ft
2600
psi
2325
psi
275
psi
10.000
ft
5200
psi
4650
psi
550
psi
15.000
ft
7800
psi
6975
psi
825
psi
Pf
CHAPTER
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DEPTH
Hole
Depth
ITEM
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Ph
PRESSURE
O/B
Fig 37
2.
This particular cause of well kicks is one, which should never happen today, but it still does.
When a stand of drill pipe is pulled from the well, the volume of the metal pulled must be
replaced with drilling fluid. If this is not done, the level of the drilling fluid in the well will drop.
Since the bottom hole hydrostatic pressure is the product of the drilling fluid density multiplied
by the height of the column, the bottom hole hydrostatic pressure will reduce if the height of
the column is reduced. If this reduction in height is appreciable, the bottom well hydrostatic
pressure may be reduced to such an extent that the safety margin may be taken away and
the well may kick.
Different measurements can indicate if the proper amount of drilling fluid is pumped into the
well. One possibility is a pit volume monitoring, but large pits will not show small changes;
these can best be seen in trip tanks. This is one or more high tanks with a little cross-section,
where a little change in volume is easy to see. It should be near the rig floor and calibrated so
the Driller can easily see and compare the volumes pumped into the well versus steel pulled
out.
Another possibility is that the Driller by help of a stroke counter can check the amount of
drilling fluid pumped into the well from the pits.
Fig 38
384 ft
500 ft
DEPTH
Example:
If, while pulling out of a well at 8000'
carrying 200 psi hydrostatic overbalance
with 10 ppg. drilling fluid, the drilling fluid
level was allowed to drop to 384 ft. below
the surface, the well would be just on balance.
Pf
Ph
PRESSURE
U/B
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Swabbing
Balled bit
b.
c.
d.
a.
b.
Pulling Pipe too fast - This piston action is enhanced when pipe is pulled too fast.
The rig supervisor should be sure that the pipe is pulled slowly of bottom for a
reasonable distance. However, the well should be watched closely at all times to be
sure it is taken the correct amount of fluid. Fig 39 show recommended pulling speed
w/16.9 ppg mud in the wellbore.
c.
Drilling fluid Properties - Swabbing problems are compounded by poor drilling fluid
proper-ties, such as high viscosity and gels. Drilling fluid in this condition tends to cling
to the drill pipe as it moves up or down the well, causing swabbing coming out and lost
circulation going in.
Fig 39
300
280
260
240
220
Sec. Pr Stand
200
180
160
140
120
100
80
60
40
20
0
1000
2000
3000
4000
BIT DEPTH
5000
6000
7000
8000
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Normal good practices to prevent or minimise swabbing are aimed at keeping the drilling fluid
in good condition, pulling the pipe at a reasonable speed, and using some type of effective
lubricant drilling fluid additive to reduce balling. Additives such as blown asphalt, gelsonite,
detergent, and EP additives are effective in many cases. Good hydraulics will often help
clean a balled-up bit or bottom well assembly.
If the well does swab, in spite of best practices, the pipe should be run back to bottom
immediately, the drilling fluid circulated out, and its weight increased before making the trip.
Sometimes a short trip is made to see if the well actually swabs when several stands of pipe
are pulled.
4.
Loss of Circulation
a.
High Drilling fluid Weight - If the hydrostatic head of the drilling fluid exceeds the
fracture gradient of the weakest exposed formation, circulation is lost and the fluid
level in the well drops. This reduces the effective hydrostatic head acting against the
formations that did not break down. If the drilling fluid level falls far enough to reduce
the bottom hole pressure below the formation pressure, the well will begin flowing.
Thus, it is important to avoid losing circulation. Should returns cease, loss of
hydrostatic head can be minimised by immediately pumping measured volumes of
water into the well. Measuring the volumes will enable the drilling supervisor to
calculate what density of drilling fluid the formation will support without fracturing.
b.
Going into well too fast - Loss of circulation can also result from too rapid lowering of
the drill string. This is similar to swabbing, only in reverse; the piston action forces the
drilling fluid into the weakest formation. This problem is compounded if the string has a
float in it and the pipe is large compared to the well. Particular discretion is required
when running pipe into a well having exposed weaker formations and heavy drilling
fluid to counter high formation pressure. Fig 40 show recommended running speed
w/16.9 ppg mud in the wellbore.
c.
Underground Blowouts - Loss of circulation due to any cause can create a condition
known as an underground blow out. This results when the hydrostatic head at a
permeable, exposed formations drops below the formation pressure. Fluids then
produce into the well and flow uncontrolled into the zone that has broken down. The
situation can be very difficult to control, and the well is usually lost below the formation
MTC
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300
280
260
240
220
Sec. Pr Stand
200
180
160
140
120
100
80
60
40
20
0
1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 11000 12000 13000 14000 15000 16000
BIT DEPTH
Fig 40
5.
a.
Drilling fluid cut by Gas: Gas cutting of the drilling fluid need not always indicate that
kick has occurred. When a porous gas zone is drilled the gas in the pores of the
cuttings will be released as the cuttings approach the surface. This will happen despite
the fact that a good 200 psi overbalance is carried in drilling fluid column density.
Provided the drilling fluid viscosity and gel strength is low, this is no problem and the
drilling fluid can easily be degassed at the surface and go back into circulation at full
density. If this gas is not released at the surface and is allowed to continually recycle,
problems will crop up. When in doubt stop the pump and observe the well for flow.
b.
Drilling fluid Cut by Water: If drilling fluid density is reduced by the addition of water
there must be a corresponding rise, equal to the amount influx, in the drilling fluid pits.
Therefore, this should seldom happen. If it does, the pit level and flow rate indicators
are not functioning.
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Abnormal Pressure
Usually a formation with such pressures gives enough warning that proper steps can be
taken. Once these zones are detected, it is normally possible to drill into them a reasonable
distance while raising the drilling fluid weight as necessary to control gas entry. However,
when pressure due to drilling fluid weight approaches the fracture gradient of the highest
exposed formation, it is good practice to set casing. Failure to do this has been the cause of
many underground blowouts and lost or junked wells.
02.07 Warning Signals
It is impossible for a blowout to occur under normal conditions without warning of its
development. The wellbore and the drilling fluid system is a closed circulation system, and
any influx from the formation into the system will show up in the form of increasing returns
from the annulus and an increase of total drilling fluid volume in the surface system (drilling
fluid tanks).
Often while drilling we can get indications at the surface that we are entering a transition
zone, that is to say a zone where pressure increases slowly because of the formations
relatively slow change of compaction, but sometimes such formations are difficult to interpret.
Normally we will have many clear indications of increasing formation pressure before a kick
occurs.
The following points show the indications that we can often receive at the surface before or
when a kick has occurred:
1.
While drilling:
a.
Drilling rate increase - drilling breaks
b.
Gas in return drilling fluid - gas-cut drilling fluid
c.
Chlorides in return drilling fluid - salt water cut drilling fluid
d.
Change in the density of cuttings
e.
Change in the size of cuttings
f.
Fall in circulation pressure
g.
Temperature increase in return drilling fluid
h.
Increase in R.P.M. (rotary speed)
i.
Increase in flow from the wellbore
j.
Increase in volume in drilling fluid pits (pit gain)
2.
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a.
An increase in penetration rate can often be a sign of drilling into a softer formation.
Pump pressure can also change because the drilling fluid is simply cleaning out the
cuttings under the bit better than previously. These two examples are not of course
signals that a kick is about to occur.
We discussed earlier also that penetration rate is also dependent upon differential
pressure. An increase in penetration rate can also indicate, therefore, that differential
pressure is known to be reduced and there is danger of taking a kick. An increase in
penetration rate must always be noted and acted upon.
The bit must be picked up off bottom, the
drilling fluid pumps must be stopped, and
6
8
10
12
2
4
the well must be checked for flow.
A drilling break is a sudden change in
penetration rate from a low to a higher
value. This sudden change in penetration
can vary considerably depending upon
the actual formation type. In some cases
a "break" can be from between 10 ft. to
50 ft./hour, in others maybe only 5 ft. to
10 ft./hour. In all cases where drilling is
conducted in areas that are unknown
or where high pressures are expected,
after a relatively long period of slow
drilling is followed by faster drilling, no
more than between 2 to 4 feet should
be drilled before the pumps are shut down
and the well checked for flow. See Fig 41
12:00
12:15
12:30
12:45
13:00
13:15
13:30
13:45
14:00
14:15
Fig 41
Background gas increases quite suddenly if the bit penetrates a zone of higher pore
pressure. This background gas is not gas that intrudes into the wellbore from the
formation but gas which is contained between the wellbore cuttings. If this gas has a
high pore pressure it will expand considerably on the way up to the surface and may
make up 50% of the drilling fluid volume. Such a situation is not so critical if it is
properly treated.
This gas is removed from the drilling fluid at the surface with the help of a Degasser.
If the drilling fluid is not properly degassed before it is pumped back down the well the
hydrostatic pressure in the well will be lowered and the chance for a kick to occur is
possibly. On the other hand, gas in the return drilling fluid could mean that there
actually exists an underbalance in the well and gas is intruding. In such a case this is
a real kick situation and the necessary steps to contain it must be made immediately.
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c.
The chloride content in drilling fluid, ( fresh-water based drilling fluid ) will normally
increase when high-pressure zones are penetrated. However, this increase is
impossible to notice when salt-water based drilling fluid, or drilling fluid with high
chloride content, is in use. This indication, therefore is not reliable enough on its own
to be of any use to us in indicating high pressure zones.
d.
The density of rock formation will nearly always be reduced if it is associated with a
high pressure zone. This is because it will have a greater porosity. This is a good
indicator if it is possible to examine different cuttings at the shale shaker, and with the
help of S.P.M. and annulus capacity decide from which depth they originate.
e.
The size of the cuttings often suddenly change when a high-pressure zone is
penetrated, they can become long and splintery in shape.
f.
Changes in pump pressure are a direct result of changing resistance (friction) in the
drilling fluid, if formation fluids or gas penetrate the wellbore and intermingle with the
drilling fluid. However, it will only be a small part of the drilling fluid in the annulus that
becomes affected in this way.
Pump pressure will normally fall if a kick occurs, as part of the drilling fluid in the
wellbore becomes lighter through reduction in weight and viscosity. If the kick is a gas
kick it is possible that the gas forces its way up the annulus of its own accord and
pushes the drilling fluid ahead of it. This will cause large pressure fluctuations.
STROKES
STROKES
110
PRESSURE
165.5
112
PRESSURE
162.5
Fig 42
A reduction in pump pressure can in some cases give an increase in pump speed.
This occurs because of the decreased load on the pump. However, some rigs have
drilling fluid pumps that are self-regulating, which is to say that regardless of what
loads are imposed on the pumps they will automatically use less or more energy and
maintain a constant pre-determined speed. See Fig 42
We should also be aware that pressure reductions can occur through reasons other
than kick situations, such as washouts in the drill string etc.
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g.
Flow line (return drilling fluid) temperature often increases when a high pressure zone
is penetrated, but although this has been observed in many places throughout the
world it is not a particularly trustworthy indication on its own. Drilling fluid temperature
can often increase when caustic soda and barite are added, well geometry can also
cause temperature increases (higher drilling fluid velocities). A clear and uniform
temperature increase that could possibly indicate a formation with a high pressure is
best seen when shown graphically in detail.
h.
Rotary table speed (R.P.M.) often increases when a high pressure zone is penetrated.
This is because the formation is breaking up easier and, therefore, offering less
resistance to the bit.
i.
Increasing flow at the flow-line is immediately the first signal that a kick is occurring.
This indication is called a positive kick indicator and require no flow check, but an
immediately shut in of the well to minimise the size of the influx. See Fig 43
Fig 43
j.
An increase in pit volume will always occur when fluid or gas enters the wellbore,
because a proportional amount of drilling fluid is displaced out of the well and into the
drilling fluid pits. Any unexplained pit gain is a sure sign of a kick and is also called a
positive kick indicator where the necessary precaution and steps must be carried
out immediately.
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a.
If drilling fluid returns are observed at the flow-line when the pumps are not running
this is a certain sign that formation fluids are flowing into the wellbore. Therefore, the
annulus becomes underbalanced and drilling fluid is displaced into the drilling fluid
pits. See Fig 43
Pf
PRESSURE
DEPTH
DEPTH
Ph
Pf
Ph+Pl
Pl annulus
Ph
PRESSURE
Fig 43
b.
Trip gas, which is gas that permeates into the wellbore during a trip, will normally
increase when a high-pressure zone is penetrated, and drilling fluid weight is not
increased to counter balance this. This trip gas is measured by a gas detector at the
flow-line that continuously monitors the drilling fluid and will be seen as a peek on the
chart during first circulation bottoms up after a trip. Trip gas alone is not a reliable kick
indicator.
c.
Connection gas is the name given to the gas which penetrates into the wellbore when
circulation is stopped and a new length of pipe added to the drill-string. This
connection gas will always increase as a rule when a high pressure zone is
penetrated. Connection gas is also monitored by the gas censor at the flow line and is
normally not a problem as long the gas is removed from the drilling fluid and not recirculated. To avoid reducing pressure hydrostatic in the annulus more that one slug of
connection gas should not be circulated out at any given time.
d.
Well-fill after a trip accompanied by an increase in trip gas can indicate high pressure,
but can also be caused by other factors such as poor drilling fluid qualities, swelling
formations and incorrect well-filling procedures so therefore it is unreliable in itself as
an indicator.
e.
"Tight" well, which is when the formation closes back in on the drill string, can occur
when connections are made and can indicate high pressure. This condition can also
warn us that there is a danger of the drill string becoming stuck ( sometimes
permanently ).
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When the drill string is pulled out of the well the volume of steel which it comprises
must be replaced by equivalent volume of drilling fluid, this is achieved by pumping
measured amounts of drilling fluid into the well as the drill string is removed. The well
shall at all times be kept full of drilling fluid. The amount of drilling fluid needed to fill
the well on a trip must be calculated before-hand and the amount used on the trip
must be identical, if the amount becomes dissimilar the reasons must immediately be
found. This quantity is usually checked every 5 stands. If the well is taking too small
an amount of drilling fluid, formation fluids are intruding into the wellbore, and if the
well is taking too much drilling fluid, drilling fluid is flowing into the formation, both
situations are highly dangerous and must be controlled.
If we are drilling ahead and for any reason we have cause to think that a kick may be
developing, the well must immediately be checked for flow. If there is no flow and everything
is in order we go back to drilling. If the well is flowing, we shut the well in either using a soft
shut-in or a hard shut-in procedure.
Soft Shut-in Procedure:
1.
Pick-up from bottom and position drill string, shut down mud pumps and rotation.
Flow check. Well flowing.
2.
1.
Pick-up from bottom and position drill string, shut down mud pumps and rotation.
Flow check. Well flowing.
2.
If it is a positive kick indication that is observed keep in mind that no flow check is
carried out, but the well is shut in instantly.
Remembering what has been said about MAASP, we must observe the casing pressure as it
begins to rise and ensure that it does not exceed the pre-determined MAASP value.
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Now that the well is shut-in, the pressure in bottom of the well will soon come into balance
with the formation pressure.
The different between the two existing methods to close the well in is that the Hard Shut-in
Procedure reduces the amount of influx into the wellbore with resulting lesser annulus
pressure and surface pressure when circulating out the kick.
The purposes of the shut-in procedure are to:
1.
2.
3.
The purpose of raising the bit from bottom of the well are to get:
a.
b.
c.
d.
Ram type preventer can be used when it is secured that there is not a tool joint
opposite this.
e.
f.
After killing drill pipe wire line tools can be run in.
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Fig. 44 and 45 show the situation just after the well is shut in. On account of the influx in the
bottom of the well there can now be read pressure on the standpipe (PSIDPP) and pressure on
the casing (PSICP). The cause for the kick is an increase in the formation pressure PF .
PSIDPP
NATIONAL
PSICP
PSICP
PSIDPP
BOP
Gradient
of mud
PSIDPP
PSICP
PHDP
PHA
D
E
P
T
H
PH
PH
Gradient
of influx
Annulus
Drill Pipe
PF
Pf
PRESSURE
PF
Fig 45
Fig 44
This new pressure will be the sum of the hydrostatic pressure from the column of drilling fluid
in the drill pipe PHDP and the pressure on standpipe ( PSIDPP ). The new pressure of the
formation will also be the sum of the hydrostatic pressure from the column of drilling fluid-gas
in annulus ( PHA ) and the pressure on the casing ( PSICP ).
PHDP + PSIDPP = PF = PHA + PSICP
The pressure reading on the standpipe PSIDPP alone will be determined by the pressure of the
formation ( PF ). The pressure reading on the casing ( PSICP ) will be determined by both the
pressure of the formation and the amount of gas, which is flowed into the wellbore. Gas has a
pressure gradient of @ 0,17 psi/ft. Drilling fluid with a weight of 10 ppg has a pressure
gradient of 0,52 psi/ft. From this is showed the more gas flowed into the wellbore, the lower
hydrostatic pressure PHA from the column of drilling fluid-gas, as PF = PHA + PSICP. Fig 45
shows this connection from 3 different quantities of influx.
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PSIDPP and PSICP are gauges connected to the bottom of the well via the drilling fluid. They
can be used to calculate the kill drilling fluid density for a kick or to see how much pressure a
formation can stand before losing circulation, such as with a leak off test.
For well control the PSIDPP is used to calculate the kill drilling fluid density required for
killing a well with a certain influx. The drill pipe is full of clean and homogeneous drilling fluid
newly treated from the pits. To know how much to increase the drilling fluid density to kill a
well, it is necessary to know how much the original drilling fluid density to begin with is so the
PSIDPP is used. The annulus or casing has cuttings and gas or salt water in it, so it is much
harder to determine an accurate drilling fluid weight increase from it.
The calculation of kill drilling fluid weight is made as follows:
Kill MW =
P sidpp
+ MW 1
TVD x 0,052
Where:
Kill MW =
the drilling fluid density required balancing the pressure in the formation.
PSIDPP =
the read back pressure on the standpipe after the well is shut in and the
pressure stabilised.
TVD
0,052 =
a constant which tells how much the hydrostatic pressure will be changed for
every feet fluid column at a fluid with a density equal to 1 PPG.
MW1
Fig. 46 shows how to figure the drilling fluid density increase from PSIDPP out from a Chart:
PSICP can together with PSIDPP be used to calculate the pressure gradient (density) for the
influx by using the following formulae:
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100
200
900
1000
1000
1.9
3.8
5.8
7.7
9.6
11.5
13.5
15.7
17.3
19.2
2000
1.0
1.9
2.9
3.8
4.8
5.8
6.7
7.7
8.6
9.6
3000
0.6
1.3
1.9
2.6
3.2
3.8
4.5
5.1
5.8
6.4
4000
0.5
1.0
1.4
1.9
2.4
2.9
3.4
3.8
4.3
4.8
5000
0.4
0.8
1.2
1.5
1.9
2.3
2.7
3.1
3.5
3.8
6000
0.3
0.6
1.0
1.3
1.6
1.9
2.3
2.6
2.9
3.2
7000
0.3
0.6
0.8
1.1
1.4
1.7
1.9
2.2
2.5
2.8
8000
D
E 9000
P 10000
T 11000
H
12000
0.2
0.5
0.7
1.0
1.2
1.4
1.7
1.9
2.2
2.4
0.2
0.4
0.6
0.9
1.1
1.3
1.5
1.7
1.9
2.1
0.2
0.4
0.6
0.8
1.0
1.2
1.3
1.5
1.7
1.9
0.2
0.4
0.5
0.7
0.9
1.1
1.2
1.4
1.6
1.8
0.2
0.3
0.5
0.6
0.8
1.0
1.1
1.3
1.4
1.6
13000
0.1
0.3
0.4
0.6
0.7
0.9
1.0
1.2
1.3
1.5
14000
0.1
0.3
0.4
0.6
0.7
0.8
1.0
1.1
1.2
1.4
15000
0.1
0.3
0.4
0.5
0.6
0.8
0.9
1.1
1.2
1.3
16000
0.1
0.2
0.4
0.5
0.6
0.7
0.8
1.0
1.1
1.2
Fig 46
Often the drill pipe and casing pressures do not stop, but continue to rise. This could be due
to:
1.
2.
Low permeability
Percolation of gas up through the drilling fluid
Low Permeability: If the permeability of the formation in the kick zone is low, then the influx
will come slowly. There will go some time before the influx can create a pressure in the top of
the drill string and the annulus respectively, which added to the hydrostatic pressure can
balance the pressure in the formation. You must therefore wait until the pressures have
stabilised before the accurate PSIDPP and PSICP can be read.
Percolation: If the slowly rising pressure is due to gas percolating up the well the pressure
does not represent reservoir pressure, but is due to the low density of the gas. On account of
this, the gas will raise up through the drilling fluid without expansion. If this situation is
handled properly it will cause no major problems. How the situation must be handled is
mentioned in section ????? in relation to the volumetric method.
Low or no Pressures on Standpipe (PSIDPP)
M:\IWCF Surface\3\1\Section 5.doc
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Low pressure: If there is no PSIDPP after the well is Shut-in following could be the reason:
1.
2.
3.
4.
If there is no float install in the drill string, check the gauges on the standpipe manifold to see
that this is not the problem. Change gauges as required after isolation to obtain SIDPP.
Float in the drill pipe:
Pump as slowly as possible (3 to 5 SPM) until the casing pressure starts to rise. Then
stop pumping. The pressure after the pump stops should be PSIDPP.
2.
Slowly bring the pump up to kill rate holding casing pressure constant. The circulating
drill pipe pressure is identical to the ICP (initial circulating pressure). The PSIDPP can
now be calculated using the formula below:
PSIDPP =
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It can be seen by the calculations in chapter 02 of this book, that the bottom hole pressure in
a well shut in will be balanced by the hydrostatic pressure (both annulus and drill string) and
pressure at the surface (casing and standpipe pressure). As long as this bottom hole
pressure is held constant no more formation fluid/gas can intrude into the wellbore. If the
bottom hole pressure is allowed to fall below the formation pressure, a fresh influx will enter
the wellbore and we will have to deal with a second kick. If the bottom hole pressure is
increased too much there is a possibility to break down the formation resulting in losses and
further complications to the well control problem.
To get the influx out of the well, drilling fluid is pumped down the drill string. This displaces
the influx higher and higher up the annulus until it reaches the surface where it is vented out
of the wellbore via the choke. This can be achieved by holding the bottom hole pressure
constant during circulation (i.e. the bottom hole pressure that was registered when the well
was shut in).
How can it be known at the surface that bottom well pressure is being held constant,
under circulation?
We can deduce that if there is no change in the height of the drilling fluid column or drilling
fluid properties and, furthermore, no change in the pressure at the surface acting on the
drilling fluid column there will not be any change in bottom hole pressure.
Therefore we have the possibility of observing changes in the bottom hole pressure by way of
the gauges installed respectively on the standpipe and casing.
If the bit is at the bottom of the well it is normal practice to use the standpipe (drill string)
pressure as a bottom hole pressure indicator. If the drilling fluid weight in the drill string
remains constant, a constant standpipe pressure will indicate a constant bottom hole
pressure.
Well Killing Methods:
There are several methods recognised within the industry to control formation pressure while
circulate out a kick and the primary object regardless of method is to keep constant bottom
hole pressure.
Drillers Method.
Wait and Weight Method.
Concurrent Method.
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This method is also called the "Constant Drill-Pipe Pressure Method" and consists of two
steps. First step is to circulate the kick out of the wellbore without changing the drilling fluid
density. Second step is to displace the original drilling fluid out of the well bore with heavier
drilling fluid (Kill Mud) which will exert enough hydrostatic pressure to balance the formation
pressure.
After taken an influx and shutting in the well pressure will build up on the standpipe and
casing gauges because of the hydrostatic underbalance (drilling fluid weight too low to
balance formation pressure).
This pressure is known as "Shut In Drill pipe Pressure" PSIDPP. As long as the drill string
contains drilling fluid of the original weight, PSIDPP will always exist as an extra pressure
registered at the surface required to balance formation pressure.
When the influx is circulated out, the pump will have to overcome the PSIDPP + the friction
losses in the circulating system at the desire pump rate. The friction losses in the circulating
system has been determined previously when checking the RRCP ( Reduced Rate
Circulating Pressure) and the only changes to the bottom hole pressure balance is the
increase due to friction losses in the annulus which is considered to be very small and
therefore not taking into consideration when circulating out the influx.
Where and when is the value for RRCP found?
RRCP is the friction loss in the system at a decided pump speed (reduced pump rate). These
pressures are noted at several different reduced pump rates, for example at 20, 30, and 40
SPM and the pressure is recorded on the remote choke panel and noted on the pre-recorded
kill sheet.
The RRCP is normally recorded at the beginning of each shift. Other factors could require the
RRCP to be recorded more frequently such as:
Change in drilling fluid properties.
Change in drill string configuration.
Very fast drilling.
The pump pressure is called Initial Circulation Pressure ICP and is registered on the
standpipe gauge on the remote choke panel. To reach the ICP while keeping constant
bottom hole pressure the pumps are slowly brought up to desired reduced rate while keeping
casing pressure constant by manipulating the choke. At the desire pump rate the drill pipe
pressure is identical to the ICP.
ICP = RRCP + SIDPP
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What happens to the casing pressure as an influx is circulated out of the wellbore?
If the influx is fluid (water or oil), the casing pressure will remain constant until the influx
begins to vent at the choke.
If the influx is gas, the gas must be allowed to expand as it rises up through the annulus, to
ensure that bottom hole pressure does not increase. In this situation more drilling fluid is
displaced out of the wellbore through the choke than pumped into the well. Therefore the
drilling fluid pit level will increase. This also means that when the height of the drilling fluid
column in the annulus is reduced and the column of gas increased loss of hydrostatic
pressure takes place, but increasing casing pressure compensates for this loss. The
expansion of gas depends of the drilling fluid properties and type. See Fig 47.
FLUID INFLUX
GAS IN WATER BASE DRILLING FLUID
GAS IN OIL BASE DRILLING FLUID
1500
1400
1300
1200
CASING PRESSURE
1100
1000
900
800
700
600
500
400
300
200
SICP
SIDPP
100
0
1000
2000
3000
4000
5000
STROKES - BIT TO SURFACE
6000
7000
8000
Fig 47
To ensure that bottom well pressure does not change as a kick is being circulated out
standpipe pressure must remain constant all the time.
When the influx is circulated out the pump can be stopped and the well closed.
Standpipe pressure and casing pressure will now be the same value (PSIDPP) due to that both
the drill pipe and the annulus is filled with a homogeneous column of original drilling fluid and
no further influx has taken place.
The next step consists of replacing the original drilling fluid with a heavier drilling fluid (KMW)
that will create sufficient hydrostatic pressure to balance the formation pressure.
M:\IWCF Surface\3\1\Section 5.doc
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The drill string is filled gradually with heavy drilling fluid and therefore its hydrostatic pressure
will change. The drill pipe pressure must be allowed to decrease and can for that reason not
be held constant, but as long as the heavy drilling fluid is confined inside the drill string there
will be no change of drilling fluid in the annulus and therefore no change in pressure either.
So casing pressure is held constant until the heavy drilling fluid has reached the bit. The new
standpipe pressure observed at this stage is the final circulating pressure (FCP) and held
constant until the annulus is full of heavy drilling fluid. If the new drilling fluid is the correct
weight the well should now be "killed" (dead) and standpipe and casing pressure should be
zero when pumps are stopped.
KMW
FCP = RRCP x -----------------OMW
Drillers Method 1st Circulation:
Well Kick Data:
Hole size
Hole depth TVD/MD
Casing (9 5/8 in) TVD/MD
Drill pipe 5 in capacity
Heavy Wall pipe 5 in
Capacity
Drill collars 6 in
Capacity
Drilling fluid density
Capacity open hole x collars
Capacity open hole x drill pipe/HWDP
Capacity casing x drill pipe
Fracture fluid density at the casing shoe
SIDPP
SICP
Mud pumps displacement
Slow Circulating Rate Pressure at 30 SPM
Pit gain
8
11536
9875
0.01741
600
0.00874
880
0.00492
14.0
0.03221
0.04470
0.04891
16.9
530
700
0.1019
650
10.0
in
ft
ft
bbl/ft
ft
bbl/ft
ft
bbl/ft
ppg
bbl/ft
bbl/ft
bbl/ft
ppg
psi
psi
bbl/strk.
psi
bbl
With the following date given the kill sheet can be filled out and the necessary information be
required to kill the well:
Internal strokes from surface to bit:
Total annulus from bit to surface:
Open hole from bit to shoe:
Kill fluid density:
Initial circulation pressure
Final circulation pressure:
Initial MAASP with drilling fluid density:
New MAASP with kill fluid density:
Influx gradient
Height of influx around DC
Height of influx around DP
1812
5360
620
14.9
1180
692
1489
1027
0.178
310
204
strokes
strokes
strokes
ppg
psi
psi
psi
psi
psi/ft
ft
ft
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PDP
Shoe
PA
ANNULUS
OMW
OMW
ANNULUS
CBI/NLN
08
DRILL STRING
PA
DRILL STRING
PDP
REVISION
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OMW
AUTHORISED BY
OMW
Shoe
GAS
BHP
BHP
GAS
Fig 48
Fig 49
Situation Fig 48 shows the start of circulation. The standpipe pressure is equal to PSIDPP
plus RRCP(Reduced Rate Circulating Pressure). The pressure at the casing head Pa is equal
to PSICP .
While keeping constant casing pressure the pumps are slowly brought up to slow
circulating rate, in this case 30 SPM. When the pumps are running at 30 SPM and
pressures have stabilized the ICP pressure on the drill pipe gauge is keep constant.
ICP
=
530 psi + 650 psi = 1180 psi
Shoe pressure
=
7189 psi + 700 psi = 7889 psi
MAASP
=
8678 psi - 7189 psi = 1489 psi
SIDPP + RRCP
Phshoe + SICP
Max Shoe Pressure - Phshoe
Drill Pipe Pressure is kept constant while gas is being pumped up through the open hole
section and the top of the gas bubble reach the shoe. The gas is expanding allowing the
pressure inside bubble to decrease.
Casing pressure increasing due to the expanding gas is displacing drilling fluid.
CSG P
=
BHP - (Phmud + Phgas)
775 psi
Shoe pressure is increasing with same value as the casing pressure.
Shoe P
=
Phshoe + Csg P
7964 psi
MAASP remains constant due to no change in Ph inside the casing.
MAASP
=
Max Shoe Pressure - Phshoe
1489 psi
M:\IWCF Surface\3\1\Section 5.doc
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PDP
PA
Shoe
BHP
Fig 50
ANNULUS
GAS
DRILL STRING
OMW
OMW
ANNULUS
DRILL STRING
OMW
GAS
OMW
Shoe
BHP
Fig 51
Drill Pipe Pressure is kept constant while gas is being pumped from the open hole section
until all the gas is inside the casing so the open hole section is displaced to original drilling
fluid. The gas is expanding allowing the pressure inside bubble to decrease.
Casing pressure increasing due to the expanding gas is displacing drilling fluid.
CSG P
=
BHP - (Phmud + Phgas)
785 psi
Shoe pressure is constantly decreasing from gas reach the shoe until all gas is inside
casing.
Shoe P
=
BHP - Phopen hole
7718 psi
MAASP start increasing from the first gas enters the casing due to change in Ph inside the
casing.
MAASP
=
Max Shoe Pressure - Phshoe
1685 psi
Situation Fig 51 shows the gas at the choke.
Drill Pipe Pressure is kept constant while gas is being pumped up inside the casing and
the top of the gas bubble reach the choke. The gas is expanding allowing the pressure
inside bubble to decrease.
Casing pressure increasing due to the expanding gas is displacing drilling fluid and when
top of the gas bubble reach the choke casing pressure is increased to max.
CSG P
=
BHP - (Phmud + Phgas)
1580 psi
Shoe pressure remains constant from the moment all gas is inside the casing.
Shoe P
=
BHP - Phopen hole
7718 psi
M:\IWCF Surface\3\1\Section 5.doc
MTC
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MAASP increasing with the same value as the Csg P due to change in Ph inside the
casing and will reach max value when gas at choke.
MAASP
=
Max Shoe Pressure - Phshoe
2480 psi
PA
ANNULUS
DRILL STRING
OMW
PDP
OMW
Shoe
BHP
Fig 52
Situation Fig 52 shows that all the gas is now circulated out.
Drill Pipe Pressure is kept constant while gas is being pumped out of the well through the
choke.
Casing pressure decreasing while drilling fluid is displacing gas in the well bore and will
reach SIDPP when all the gas is out of the well.
CSG P
=
BHP - Phmud
530 psi
Shoe pressure remains constant while the gas is displaced from the well bore due to no
change in Phopen hole.
Shoe P
=
BHP - Phopen hole
7718 psi
MAASP decreasing with same value as the Casing Pressure and will reach initial MAASP
when the annulus is displaced to original drilling fluid.
MAASP
=
Max Shoe Pressure - Phshoe
1489 psi
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Shoe
BHP
Fig 53
PA
ANNULUS
OMW
KMW
ANNULUS
PDP
DRILL STRING
PA
DRILL STRING
OMW
PDP
OMW
Shoe
BHP
Fig 54
Situation Fig 53 shows the kill fluid is being pumped to the rig floor.
Kill mud is being mixed to 14.9 ppg and 2nd circulation is started.
Casing pressure is kept constant while kill fluid fills the drill string.
CSG P
=
BHP - Phmud
530 psi
Drillpipe pressure decreasing while kill fluid fills the drill string.
DP P
=
RRCP + (BHP - Phmud)
Shoe pressure remains constant while kill mud fills the drill string due to no change in
Phopen hole.
Shoe P
=
BHP - Phopen hole
7718 psi
MAASP remains constant while kill mud fills the drill string.
MAASP
=
Max Shoe Pressure - Phshoe
1489 psi
Situation Fig 54 shows that kill fluid has reached the bit.
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Shoe pressure remains constant while kill mud fills the drill string due to no change in
Phopen hole.
Shoe P
=
BHP - Phopen hole
7718 psi
MAASP remains constant while kill mud fills the drill string.
MAASP
=
Max Shoe Pressure - Phshoe
1489 psi
Shoe
ANNULUS
KMW
ANNULUS
OMW
KMW
Shoe
BHP
BHP
Fig 55
PA
DRILL STRING
PDP
PA
DRILL STRING
KMW
PDP
Fig 56
Situation Fig 55 shows that kill fluid is on its way up the annulus.
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Casing pressure decreasing as kill fluid moves up the annulus and will reach 0 psi when
kill fluid reach the choke.
CSG P
=
BHP - Phmud
0 psi
Shoe pressure remains constant while kill fluid is displacing original mud inside the casing
due to no change in Ph open hole.
Shoe P
=
BHP - Phopen hole
7657 psi
MAASP decreasing as kill fluid is displacing original mud inside the casing with same
value as the drop in casing pressure.
MAASP
=
Max Shoe Pressure - Phshoe
1020 psi
CASING PRESSURE
900
800
700
600
500
400
300
200
100
0
2000
4000
6000
8000
10000
12000
14000
16000
STROKES
Fig 57
Fig 57 shows the pressure relationships between drill pipe and casing.
Drill Pipe Pressure 1st circulation:
Drill Pipe Pressure constant while displacing annulus to original drilling fluid and
removing gas from well bore.
Drill Pipe Pressure 2nd circulation:
Drill Pipe Pressure decreasing to FCP will kill fluid fills the drill string and then
constant while kill fluid displaces original mud in annulus.
Casing Pressure 1st circulation:
Casing Pressure constantly increasing until gas reach choke.
Casing pressure decreasing to SIDPP while gas is displaced from the well bore.
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This method is also called the "balance method" and is described below.
The well is shut in and pressure values are observed. The drilling fluid is increased to the
weight necessary to kill the well. While keeping constant casing pressure the pumps are
slowly brought up to slow circulating rate and when running at the desire rate the drill pipe
pressure is the ICP.
The primary objective while killing the well is to keep constant BHP, but as the heavy drilling
fluid fills the drill string the ICP cannot be held constant due to the change in hydrostatic
head. In the annulus the gas expands as it rises, so therefore casing pressure cannot be held
constant either.
However, the choke can be manipulated in such a way that standpipe pressure can be
gradually decreased as the heavy drilling fluid is pumped down the drill string. How much and
how often it is decreased can be decided in the following way.
Like the Driller's Method we begin to circulate with a standpipe pressure equal to PSIDPP +
RRCP and when the drill string is full of heavy drilling fluid the pressure will be equal to the
new RRCP with heavy drilling fluid inside the string or FCP. This change in standpipe
pressure occurs over a certain period of time that depends on the total number of strokes it
takes to pump the drill string full of heavy drilling fluid. (Surface-to-bit).
The easiest way is to represent this graphically. The following graph will show standpipe
pressure changes in relation to pump strokes combined with a table that shows the new
standpipe pressure for every 100 strokes. See Fig 58
The figures used for the graph and table apply to example in Drillers Method and W&W
Method.
Pressure change per 100 strokes is calculated in the following way:
P/100 strk =
P/100 strk =
27psi/100 strk
Circulation of the heavy drilling fluid from surface-to-bit can now proceed by regulating the
choke after the table, so the bottom-hole pressure will remain constant.
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As soon as the drill string is full of heavy drilling fluid (after 1812 strokes) no change will occur
of drilling fluid density and drilling fluid column in the drill string, which means that standpipe
pressure (692 psi) can be held constant for the rest of circulation.
PRESSURE
0
100
200
300
400
500
600
700
800
900
1000
1100
1200
1300
1400
1500
1600
1700
1800
1812
1180
1153
1126
1099
1072
1045
1018
991
964
937
910
883
856
829
802
775
748
721
694
692
1100
900
700
500
300
100
500
1000
1500
2000
STROKES
Fig 58
When killing a kick by the Weight and Wait Method, there are four phases that are described
below.
Phase 1.
Mix the required kill fluid immediately. When the kill fluid is ready, start pumping
and open choke slowly while the pump is brought up to speed holding casing
pressure constant at this initial start-up. As the drill string is gradually filled with
kill fluid, circulation pressure is regulated with the choke to follow the values of
the curve, until the calculated FCP with kill fluid at the bit is reached. (At this
stage the drill pipe should be dead).
Phase 2.
Continue pumping until the gas is at the choke keeping constant drill pipe
pressure.
Phase 3.
Continue pumping until all the gas is out. At this stage the annulus will be full of
kill fluid, minus the capacity of the drill string which is light drilling fluid.
Phase 4.
Continue pumping until the annulus is full of heavy drilling fluid. At this stage
the well should be dead.
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8
11536
9875
0.01741
600
0.00874
880
0.00492
14.0
0.03221
0.04470
0.04891
16.9
530
700
0.1019
650
10.0
in
ft
ft
bbl/ft
ft
bbl/ft
ft
bbl/ft
ppg
bbl/ft
bbl/ft
bbl/ft
ppg
psi
psi
bbl/strk.
psi
bbl
With the following date given the kill sheet can be filled out and the necessary information be
required to kill the well:
Internal strokes from surface to bit:
Total annulus from bit to surface:
Open hole from bit to shoe:
Kill fluid density:
Initial circulation pressure
Final circulation pressure:
Initial MAASP with drilling fluid density:
New MAASP with kill fluid density:
Pressure drop/100 strk
Influx gradient
Height of influx around DC
Height of influx around DP
1812
5360
620
14.9
1180
692
1489
1027
27
0.178
310
204
strokes
strokes
strokes
ppg
psi
psi
psi
psi
psi/100 strk
psi/ft
ft
ft
Situation Fig 59 shows the start of circulation. The standpipe pressure is equal to PSIDPP
plus RRCP (Reduced Rate Circulation Pressure). The pressure at the casing head Pa is
equal to PSICp.
While keeping constant casing pressure the pumps are slowly brought up to slow
circulating rate, in this case 30 SPM. When the pumps are running at 30 SPM and
pressures have stabilized change to ICP and then keep DP pressure on schedule.
ICP
=
530 psi + 650 psi = 1180 psi
Shoe pressure
=
7189 psi + 700 psi = 7889 psi
MAASP
=
8678 psi - 7189 psi = 1489 psi
SIDPP + RRCP
Phshoe + SICP
Max Shoe Pressure - Phshoe
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83
PDP
PA
ANNULUS
Shoe
DRILL STRING
OMW
OMW
ANNULUS
DRILL STRING
OMW
KMW
PDP
ITEM
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OMW
Shoe
GAS
BHP
Fig 59
BHP
GAS
Fig 60
Situation Fig 60 shows kill fluid fills the drill string while gas is circulated a way up the
annulus.
Drill Pipe Pressure is kept on schedule while gas is being pumped up through the open
hole section and the top of the gas bubble reach the shoe. The gas is expanding allowing
the pressure inside bubble to decrease.
Drill Pipe Pressure is kept on schedule with 27 psi drop per 100 strokes pumped.
DP P
=
ICP - (470 x 27)
1053 psi
100
Casing pressure increasing due to the expanding gas is displacing drilling fluid.
CSG P
=
BHP - (Phmud + Phgas)
775 psi
Shoe pressure is increasing with same value as the casing pressure and reach max. value
when gas reaches the shoe.
Shoe P
=
Phshoe + Csg P
7964 psi
MAASP remains constant due to no change in Ph inside the casing.
MAASP
=
Max Shoe Pressure - Phshoe
1489 psi
Situation Fig 61 shows kill fluid fills the drill string while gas is circulated inside the casing.
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PA
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84
PDP
PA
GAS
Shoe
ANNULUS
OMW
KMW
ANNULUS
DRILL STRING
OMW
DRILL STRING
OMW
CHAPTER
KMW
PDP
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GAS
Shoe
OMW
BHP
Fig 61
BHP
Fig 62
Shoe pressure is decreasing while gas moves from below the shoe until all gas inside the
casing.
Shoe P
=
BHP - Phopen hole
7718 psi
MAASP start increasing from the first gas enters the casing due to change in Ph inside the
casing.
MAASP
=
Max Shoe Pressure - Phshoe
1685 psi
Situation Fig 62 shows kill fluid has filled the drill string.
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Drill Pipe Pressure constant at FCP after kill fluid reach the bit.
DP P
=
FCP
85
692 psi
Casing pressure increasing due to the expanding gas is displacing drilling fluid, but slower
due to kill fluid is displacing original mud.
CSG P
=
BHP - (Phmud + Phgas + Phkill mud) 1278 psi
Shoe pressure remains constant after kill fluid enter casing due to no change in Phopen hole.
Shoe P
=
BHP - Phopen hole
7641 psi
MAASP increasing with the same value as the Csg P due to change in Ph inside the
casing.
MAASP
=
Max Shoe Pressure - Phshoe
2178 psi
PDP
PA
PDP
PA
OMW
ANNULUS
KMW
ANNULUS
Shoe
DRILL STRING
OMW
DRILL STRING
KMW
GAS
KMW
Shoe
KMW
BHP
BHP
Fig 63
Fig 64
Situation Fig 64 shows kill fluid has displaced all the gas out of the well bore.
Drill Pipe Pressure constant at FCP after kill fluid reaches the bit.
DP P
=
FCP
692 psi
Casing pressure decreasing while gas is displaced out of the well bore.
CSG P
=
BHP - (Phmud + Phkill mud)
180 psi
Shoe pressure remains constant after kill fluid enter casing due to no change in Phopen hole.
Shoe P
=
BHP - Phopen hole
7641 psi
MAASP decreasing while gas is displaced out of the well bore.
MAASP
=
Max Shoe Pressure - Phshoe
1204 psi
Situation Fig 65 shows kill fluid has displaced the remaining original drilling fluid out of the
wellbore.
Drill Pipe Pressure constant at FCP after kill fluid reaches the bit.
M:\IWCF Surface\3\1\Section 5.doc
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CHAPTER
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86
692 psi
Casing pressure decreasing to 0 psi while kill fluid displaces original mud out of the well
bore.
CSG P
=
BHP - Phkill mud
0 psi
Shoe pressure remains constant after kill fluid enter casing due to no change in Phopen hole.
Shoe P
=
BHP - Phopen hole
7641 psi
MAASP decreasing while kill fluid displace original mud out of the well bore.
MAASP
=
Max Shoe Pressure - Phshoe
1027 psi
PA
ANNULUS
DRILL STRING
KMW
PDP
KMW
Shoe
BHP
Fig 65
Fig 66 shows the pressure relationships between drill pipe and casing.
Drill Pipe Pressure:
Drill Pipe Pressure decreasing from ICP to FCP while kill fluid fills the drill string.
Drill Pipe Pressure constant at FCP the remaining circulating time.
Casing Pressure:
Casing pressure constantly increasing until gas reach the choke.
Casing pressure decrease rapidly while gas is displaced from the well bore.
Casing pressure decreasing to 0 psi while original mud is displaced with kill fluid.
Shoe Pressure:
Increase while gas is moving up in the open hole section.
Decrease while gas enters the casing.
Constant until kill fluid reaches the bit.
Decrease while kill fluid is moving up the open hole section.
Constant after open hole has been displaced to kill fluid.
MAASP Pressure:
Constant while gas is moving up in the open hole section.
Increase rapidly while gas enters the casing.
Increase until gas reaches the choke.
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CASING PRESSURE
900
800
700
600
500
400
300
200
100
0
1000
2000
3000
4000
5000
6000
7000
8000
STROKES
Fig 66
Annular pressure will fall to 0 PSI as soon as heavy drilling fluid appears at the choke.
When this is observed the well should be dead. A flow check can now be made.
If no flow is observed the blow-out preventer can be opened, and the drilling fluid can be
circulated and conditioned as necessary, a trip margin can be added if it was not added to
the kill drilling fluid at the start of the operation. Tripping or drilling can now take place again.
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This is the most complicated of the three methods and its main value lies in the fact that the
killing operation can be started as soon as the closed in pressures etc. have been recorded.
Instead of waiting until the surface drilling fluid has all been weighted up to the kill drilling fluid
weight, circulation at the reduced rate is started and the drilling fluid weight is increased while
circulating.
The rate of increase will depend on the mixing facilities available on the rig. The complication
here is that the drill pipe can be filled with fluids of different densities, making calculation of
the bottom well hydrostatic pressure difficult. However, provided adequate supervision is
available on the rig this could be the most effective way of killing a kick.
Procedure for Concurrent Method
When all the kick information has been recorded, open up the pump slowly while adjusting
the choke until the initial circulating pressure has been reached at the reduced circulating
rate. The drilling fluid should he weighted up at the maximum rate available with the rig
equipment and, as the drilling fluid weight changes in the suction tank the choke operator is
informed. He checks the pump strokes gone when the new drilling fluid weight starts on his
chart, similarly with each change of drilling fluid weight, adjusting his choke pressure to suit
the new drill pipe conditions as pre-recorded on his surface to bit graph.
When the final kill drilling fluid reaches the bit the final circulating pressure will be reached
and from this point onwards the pressure should be kept constant until the operation is
completed.
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Fig. 66 shows a comparison of casing pressures under killing according to the used method.
DRILLERs METHOD
CONCURRENT METHOD
1500
1400
1300
1200
1100
1000
PRESSURE
900
800
700
600
500
400
300
200
100
0
1000
2000
3000
4000
5000
6000
7000
8000
STROKES
Fig 66
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ADVANTAGES
Simplest to teach and
understand.
Very few calculations.
In case of saltwater the
contaminant is moved out
quickly to prevent sand settling
around drilling assembly
CONCURRENT
METHOD
Minimum of non-circulating
time.
Excellent for large increases in
mud weight (underbalanced
drilling)
Mud condition (viscosity and
gels) can be maintained along
with mud weight.
DISADVANTAGES
Higher casing shoe pressure if
long open hole section (gas
kick).
Higher annular pressure (gas
kick).
Takes two circulations.
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When a kick occurs there are a lot of facts to record and analyse. These facts are recorded in
a so-called work sheet, a pre-planned scheme. These work sheets, when completed will give
us a complete picture of the conditions and calculations in a kick situation. These work sheets
can differ greatly from company to company but they all have the same basic content.
Contents of Work Sheets
A work sheet will contain, in one way or another the following facts:
Information that is Previously Known
Equipment:
Drill string:
Drill collars:
Bit diameter:
Casing:
Open Hole:
Pumps:
By using the previous mentioned work sheet (Kill Sheet) all required calculations to circulate
out a kick on a safe manner is easily done. See Fig 67
Surface to bit strokes.
Bit to surface strokes.
Bit to shoe strokes.
Kill mud weight.
Initial Circulating Pressure.
Final Circulating Pressure.
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Fig 67
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Fig 67a
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95
01.09 General
It is always important to analyse what the influx actually is when a kick is taken into the
wellbore. It can be decided what the influx is (gas, oil or water) by making a calculation with
height and pressure.
The height of the influx is easy enough to find by the measured pit gain at the surface (bbl)
and the annulus capacity that is already known in bbl/ft.
hi =
If we call the depth of the well H, drilling fluid weight MWm, we can work out the different
pressures in the annulus and drill string and furthermore bottom hole pressure (formation
pressure). See Fig 68.
SIDPP
SICP
OMW
ANNULUS
DRILL STRING
OMW
H - Hi
BHP
Hi
Shoe
INFLUX
Fig 68
Formation Pressure
Hi
Height of influx
Wi
Density of influx
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P sidp - P sia
+ MW m
hi x 0,052
As the influx is either gas, oil, water or a mixture of same the density of the influx is
lower than the drilling fluid with result that SICP is greater than SIDPP the formula can
be expressed as follow:
W i = MW m -
P sia - P sidp
(ppg)
hi x 0,052
When knowing the density of the influx pressure gradient can then be calculated as follows:
Gi = Wi x 0,052 psi/ft
P sia - P sidp
psi / ft
hi
02.09 Examples
Example #1:
Influx
OH DC capacity
Drilling fluid density
TVD
SIDPP
SICP
25 bbl.
0.042 bbl/ft
15 ppg
7600 ft
265 psi
660 psi
Height of Influx:
hi =
25 (bbl)
= 595 ft.
0.042 (bbl / ft)
Gradient of Influx:
G i = 15 x0.052 -
660 - 265
psi / ft = 0.116 psi/ft
595
Comparing the pressure gradient with table Fig 06 it can be seen that the influx is gas
or a mixture of gas/oil.
Example #2:
Same as example #1 except that SICP is 450 psi.
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97
Gradient of influx:
G i = 15 x0.052 -
450 - 265
psi / ft = 0.469 psi/ft
595
Comparing the pressure gradient with table Fig 06 it can be seen that the influx is
water.
We should be aware that there could be margin in these calculations of error. The accurate
annular or DC-OH capacity is not known due to wash out etc. and the results are therefore
quite unsure and shall not be used for anything else than to get a rough index of what the
influx is. The circulation of a kick is also not dependent on what the influx is. Therefore this
particular calculation is not relied upon to any great extent. At the same time it can be
advantageous to know whether it is a gas kick or oil/water kick that we have to deal with.
If it is a gas kick we can be prepared for the high casing pressure and pit volume increase
towards the last stage of circulation, which will not occur if the influx is a fluid.
The pressure gradients for influx are as noted below.
Between 0.47 to 0.52 psi/ft. the influx is saltwater. if the influx is less than 0.16 psi/ft. the influx
is gas. Between 0.31 and 0.42 psi/ft. the influx should be oil, but it could also be a mixture.
See Fig 06.
If we are in doubt about the result, treat the kick as a gas kick, and in this way the most
dangerous situation will be expected.
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98
Lost circulation
01.10 General
Lost circulation is one of the most serious problems that occur in rotary drilling. Lost
circulation is defined as loss of drilling fluid into the formation, which can be total. As most
wells are drilled there is experienced a lesser or greater loss of drilling fluid to the formation.
Lost circulation is both expensive and time-consuming (price of drilling fluid and lost rig time).
In connection with well killing operations lost circulation is extremely dangerous. See Fig 69.
Losses can best be described as unintentional transfer of fluid from the borehole
into the formation.
When a kick occurs and the well is shut in, the drill pipe pressure informs us of the extra
pressure required balancing the formation. The problem is that when the well is shut in it is
difficult to decide if in fact lost circulation has, or is occurring. The biggest problem is therefore
the uncertainties.
02.10 Causes of lost circulation
The three most common causes that lost circulation arise in connection with a kick.
l.
2.
3.
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99
One of the most common causes of lost circulation in a kick situation is a bad cement job at
the base of the last casing string. Most operators insist that the cement is pressure tested
after drilling the shoe, to test its strength and bond to the casing. The test pressure shall take
into account the highest drilling fluid weight that is to be used in the next phase of drilling or
shall follow legal requirements. A bad cement job is dangerous because it can allow gas to
escape up the side of the casing to the surface. Large gas blowouts have occurred in oilfields
because of this.
Formation breakdown
This cause of lost circulation is most common. The breakdown can be caused by large
pressure fluctuations, the use of drilling fluid that is too heavy or from blowout conditions. In
most cases after the pressure falls the breakdown in the formation will close itself up in a
relatively short time. Such a formation breakdown often occurs around the casing shoe and in
effect is exactly the same as a bad cement job.
Fractured and fissured formations
In hard formations fractures and fissures can be the cause of serious lost circulation
problems. It can be difficult to stop these formations taking drilling fluid. In many cases these
kind of formations are the actual reservoir beds, and the pressure which is used to balance
the reservoir is often very close to the pressure that will cause breakdown and resultant lost
circulation.
03.10 Well control with partly lost circulation
In most cases the first sign that lost circulation is occurring is a fall in the drilling fluid pit level.
Fig 70 and Fig 71 shows the relationships in such a situation.
PIT LEVEL
PDP
NATIONAL
1100
PA
BOP
900
700
500
LOST CIRCULATION
300
WEAK
FORMATION
100
TIME
Fig 70
Fig 71
LOST
CIRCULATION
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Fig. 70 shows a graph of pit. The solid line shows how the pit level changes during a gas kick,
from when the kick is taken to when it is killed. The dotted line could show how the pit level
will change if part-lost circulation occurs while killing a gas kick.
Fig. 71 shows the situation in the well. The gas is circulated a way up the annulus and breaks
out of the wellbore into a relatively weak zone. This zone cannot withstand the pressure of the
choke combined with the hydrostatic pressure, and therefore drilling fluid will flow into the
formation. If the fluid column falls under circulation, there are several methods that can be
used to combat this problem, and are as follows:
l.
If the lost volume is not too great and the drilling fluid volume can be made up by
mixing new drilling fluid, go ahead. The pressure on the weak zone will decrease as
the gas bubble passes upwards. The problem solves itself.
When circulating with part-lost circulation the pressure at the choke will be the highest
casing pressure that the formation can withstand. Every 30 minutes the choke is
closed partly so the pressure in the well bore increases 100 psi. If the annular pressure
does not increase, open the choke to the same setting as before and continue
circulating out the influx. If the well bore pressure increases check for similar increase
on the drill pipe pressure. If the drill pipe pressure does not increase, open the choke
to the same setting as before and continue circulating out the influx. If both the drill
pipe and annulus pressure increases the losses are decreasing and the formation is
healing itself. If so shut the well in and record the new SIDPP:
2.
Stop the pump and close in the well. Give the well from 30 minutes to 4 hours to heal
itself up. Hold SIDPP constant by regulating the choke. If the casing pressure rises by
more that 100 psi continue to circulate out the influx.
3.
By manipulating the choke keep casing pressure constant while the pumps are
brought up to the new lower circulating rate.
b.
Adjust the choke until the annular pressure is the same as when the well was
shut in (this method not good for sub-sea wellheads). Proceed accordingly now
that a new initial circulation pressure of drill pipe is known.
4.
Mix a pill of lost-circulation material of a type, which will be effective on the formation in
question. Normally lost circulation material is more effective in hard formations and
less effective in softer plastic formations.
5.
If the losses continue after the above-mentioned solution has been tried a barite or
barite/diesel plug can be pumped in attempt to seal off the weak zone.
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Standard blowout control procedure cannot be used if the well cannot be circulated. With total
lost-circulation gas can rise up to the surface, but there is also the danger of an underground
blowout. The only way to solve the problem is first to stop loss of drilling fluid to the formation
so the well can be killed with the help of standard procedure.
l.
Barite Plug:
The best solution with a gas kick is to try and plug the gas zone with a barite
plug and proceed to seal the lost circulation zone. In the meantime it is possible
that there can occur a high speed underground flow of formation fluid/gas into
the weak zone. This flow could possibly wash away the barite plug, so to try to
prevent this a plug as large as 300 ft in height should be used. See Fig 72.
BARITE PLUG MIXTURE for 300 ft.
180
15
100
0s
xB
160
Water in bbl.
140
- 15
0 lb
12-1/4
120
For a
100
9-7/8
80
60
40
20
arit
e
700
sx
17-1
/2
8-3/4
7-7/8
335 sx B
ari
15
sph
ate
Bari
te - 1
00 lb
Pho
ho
sph
le us
ate
e tw
ice t
he m
ix fo
ra
425 sx
Barite
- 50 lb
270 sx B
ari
6-1/2
P ho
te - 50 lb
te - 35 lb
185 sx Barite
-
ole
Phosp
hate
Phospha
te
Phospha
te
25 lb Phosph
ate
17
16
12-1
/4 h
19
18
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Gunk Plug:
A gunk plug is a plug consisting of bentonite mixed with diesel fuel and is a
very fast solidifying plug that is especially effective for water flows. The plug will
not start to become stiff until it comes into contact with water, so there is no
danger of premature setting. When the plug is pumped down in the bottom of
the well the diesel is washed away from the solids, which begin to set as they
come into contact with the water. A large plug shall be used, about 300 ft. in
height. An oil plug shall be pumped before and after the gunk plug to prevent
contamination of the plug with drilling fluid to avoid premature swelling of the
bentonite. For gunk plugs in Oil Based drilling fluid Geltone II (MI product
name) or similar is used. See Fig 73.
Prior to pumping gunk plugs all lines must be flush and cleaned.
DIESEL OIL
bbl
BENTONITE
sacks
TOTAL VOLUME
bbl
6-1/2
7-7/8
8-3/4
9-7/8
12-1/4
15
17-1/2
9
13
14
20
33
50
66
27
40
49
62
98
150
200
12
18
22
28
44
66
89
Fig 73
PA
BOP
KILL LINE
Lost
Circulation
Material
WEAK
FORMATION
PLUG
Fig 74
M:\IWCF Surface\3\1\Section 5.doc
INFLUX
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01.11 General
Volumetric Method is used, if gas or gaseous influxes for one or another reason cannot be
circulated out.
Examples of such a situation can be:
- Prior to pumping kill fluid with conventional method.
- Pipe off bottom.
- Drill string or bit plugged.
- Drill string out of hole.
- Wash out in the drill string.
- If drill string have been cut and left in hole.
- Repairs to pumps or other equipment failure such that normal kill procedure cannot be
exercised.
When the gas bubble is down hole, the Volumetric Method can be used to allow the
bubble to expand while it migrates up the hole, keeping bottom hole pressure constant.
The basic of this method is the knowledge that every bbl of fluid gives a certain bottom
hole pressure. This pressure can be measured in psi/bbl by dividing the fluid gradient psi/ft
with annular volume in bbl/ft or the volume of the well bore in bbl/ft if there is no drill string
in the hole.
As the gas migrates up the annulus, the annular capacity usually changes. It is therefore
necessary to estimate the location of the gas, calculate the correct annular volume and
control the casing pressure accordingly. In general with pipe in the hole casing/drill pipe
capacity is used due to this is the longest section the gas has to migrate.
The amounts of fluid which are to be bled off or pumped (lubricated) into the well, must be
measured precisely enabling us to have exact control of pressure in the well bore.
A migration rate exceeding 1000 ft/h (300 m/h) makes the Volumetric Method a fair
alternative, but keep in mind that recent research has show that gas is able to migrate as
fast as 10.000 ft an hour under ideal condition even in highly deviated wells.
02.11
1.
Closing the well
When the well is shut-in, take accurate readings of the shut-in casing pressure (SICP) and
pit gain. Make note of the time when readings are taken.
An increase in closed-in pressures confirms that the influx is gas and migration is taking
place.
2.
Estimating the migration rate
When a gas influx is taken, the large density difference between gas and drilling fluid will
cause the gas bubble to migrate up the hole. As gas migrates, without expansion being
permitted, pressure throughout the wellbore increases.
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The velocity of gas-migration depends on hole size, gas and fluid densities, fluid viscosity
and whether gas influx is one big bubble, or distributed as many smaller bubbles. A
common rule of thumb is to assume a gas migration velocity of between 500 ft to 1000 ft
per hour. If oil base drilling fluid is in use, gas migration may be limited by solubility or
gas/oil miscibility effect. The following discussion of gas migration applies to water base
drilling fluid only.
The distance that gas has migrated and the rate of migration may be estimated as follows
See Fig 75:
300 psi
PA
12.5 ppg
10000 ft
GMD
P2 - P1
= -------------------------MWG
GMR
GMD
= -------------------------T 2 - T1
Where:
GAS
6500 psi
Fig 75
03.11
1. Shut the well in and record the initial shut-in casing pressure SICP, Pit Gain and Initial
Shut-in Time.
2. Allow the casing pressure to increase by approx. 100 psi (P1) above the original shut-in
pressure for safety factor. The safety factor is used because the pressure will always
fluctuate a little depending on the man at the choke, so by using a safety factor we
make certain that the bottom hole pressure does not drop below the formation pressure
so further influx is taken into the wellbore.
P2 = SICP + P1
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3. Allow a new pressure increase 50-100 psi (P3), but do not exceed the fracture pressure
at the casing shoe. This pressure is called working range and will determine the
amount of fluid in the well bore that represents this pressure.
P4 = SICPP + P1 + P3 = P2 + P3
5. Calculate the volume of fluid corresponding to the pressure increase, i.e. volume to
bleed off (Vm).
P3 x Cap
Vm = Cap x h = -------------MWG
Cap = Hole capacity refers to the capacity directly above the bubble. In practice it is
usually acceptable to use capacity of the casing below BOPs for the following
reasons:
Open hole capacity is generally close to casing capacity.
Only small volumes of fluid are bleed from the well, when the bubble is in open
hole. Most of the increase in surface pressure and associated fluid occurs as
gas approaches surface, where hole capacity is known accurately.
6. As the annulus pressure increases above P4 bleed of the calculated volume (Vm)
gradually maintaining the pressure P4 at the choke.
7. After having bleed off the calculated volume (Vm), let the pressure build up to P5:
P5 = P4 + P3
8. Repeat points 6 and 7 until casing pressure stabilises as the gas reaches the surface.
9. As gas is bled out of the hole the bottom hole pressure will decrease. Additional fluid
should be pumped (lubricated) back into the well bore to maintain a constant bottom hole
pressure to prevent an additional kick.
04.11 Lubrication Technique
This method is used to reduce the casing pressure when gas is at the surface so that
another operation such as stripping or snubbing can be performed.
1. Calculate the hydrostatic pressure, which will be exerted by a certain volume of drilling
fluid in the annulus. If we use the same working range as before the volume will be the
same.
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2. Slowly pump the given volume of fluid into annulus through the kill line. Allow the fluid
to fall through the gas (by gravity). Low yield point fluids are preferable. A small
pressure increase (P) may occur due to compression of the gas bubble.
3. Bleed gas from annulus until the surface pressure is reduced by an amount equal to
the hydrostatic pressure of the fluid pumped in.
Do not bleed off drilling fluid.
If the annulus pressure increases during pumping in procedure, the amount of this
increase (P) should be bled off in addition to the pressure bled for hydrostatic
pressure increase. If drilling fluid starts coming back shut-in the choke and wait for the
gas to percolate to the surface before continuing to bleed off.
4. Repeat this procedure until all gas has been bled off or the desired surface pressure
reached.
Lubrication
During the pumping and gas bleeding, it will usually be necessary to decrease the
volume of fluid to be pumped before the gas is bled of completely.
This is because the annular volume occupied by the gas decreases with each
pumping and bleeding sequence.
If the Volumetric Method is going to be used it is important that we have the right
equipment and drills have been carried out with all the crews. See Fig 76.
5
BOP
HALLIBURTON
PA
2
KILL LINE
PUMP
GAS
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Casing:
Hole:
EFD/Leak off:
1.
Shut in data:
SICP:
2.
243 psi
P2 = SICP + P1
3.
P2 = 243 + 100 =
P4 = P2 +P3
2.
P4 = 343 + 50 =
393 psi
P3
H = -----------MWG
5.
343 psi
50
H = ----------- =
10x0.052
96 ft
Vm = 0.07 x 96 =
6.73 bbl
Vm = Cap x H
Fig 77
BOP
HALLIBURTON
Vm
PA
Vm
KILL LINE
GAS
3
P3
P3
Vm
5
P3
Vm
4
Pa
P3
6
P1
1
5
GAS
GAS
S
I
C
P
BLEED OFF
3
2
GAS
GAS
GAS
LUBRICATE
P3
P1
BHP
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1.
2.
The gas bubble is allowed to percolate without expansion increasing the annulus and
BHP with the safety factor (P1)100 psi to P2.
3.
The gas bubble is allowed to percolate further without expansion increasing the
annulus and BHP with the working range (P3) 50 psi to P4.
P4 = 243 + 100 + 50 = 393 psi
4.
While keeping 393 psi on the annulus 6.73 bbl of drilling fluid is bleed off allowing the
gas bubble to percolate and expand. While bleeding off the 6.73 bbl the BHP pressure
will decrease 50 psi (P3).
5.
After first bleed off, the well is shut in and the gas bubble is allowed to percolate
further without expansion increasing the annulus pressure and BHP with the working
range (P3) 50 psi to P5.
P5 = 243 + 100 + 50 + 50 = 443 psi
While keeping 443 psi on the annulus 6.73 bbl of drilling fluid is bleed off allowing the
gas bubble to percolate and expand. While bleeding off the 6.73 bbl the BHP pressure
will decrease 50 psi (P3).
6.
After second bleed off, the well is shut in and the gas bubble is allowed to percolate
further without expansion increasing the annulus pressure and BHP with the working
range (P3) 50 psi to P6.
P6 = 243 + 100 + 50 + 50 + 50 = 493 psi
While keeping 493 psi on the annulus 6.73 bbl of drilling fluid is bleed off allowing the
gas bubble to percolate and expand. While bleeding off the 6.73 bbl the BHP pressure
will decrease 50 psi (P3).
By continue this procedure the gas is brought to surface and the operation is reversed so
6.73 bbl of drilling fluid is lubricated into the well bore after witch (P3) 50 psi + P is bleed off.
See Fig 77.
Fig 78 shows a work sheet to be used to keep control when using the Volumetric Method
and Fig 79 illustrate the pressures in the wellbore while using the Volumetric Method.
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Psi/bbl
Pressure inc.
P3
Original pressure
P4
New pressure
Total pit
volume
Fig 78
PRESSURE
BLEED OFF
LUBRICATE
TIME
Fig 79
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This method of well control is occasionally proposed for handling shallow gas kicks. If it is
anticipated that shutting-in a kick will result in surface pressure above the maximum
allowable, the well is allowed to flow through the choke (and kill) line and surface pressure
is maintained slightly below the maximum allowable value. In this way the rate of influx
may be sufficiently slowed to allow well control to be regained by circulating kill fluid down
the drill string.
There may be circumstances under which this technique can be implemented
successfully, however there are inherent dangers. Initially bottom hole pressure is
maintained at a value below the kicking formation pressure and inflow will therefore
continue. The continued influx will reduce bottom hole pressure further as the annulus is
unloaded. Only if kill fluid can be circulated into the annulus at a sufficient rate to
overcome this unloading effect and increase the bottom hole pressure will well control be
regained.
The low choke method is an attempt to out run a kicking well, and should not be
attempted except for handling shallow gas kicks.
07.11 Bullheading
1. Stabilised SIDPP and SICP Do the pressures stabilise very quickly, indicating a kick
from a high permeability formation? Is gas migration evident?
2. Influx volume and fluid type.
3. What are the estimated fracture pressure gradients for the shales and any exposed
sand(s) in the open hole? How do they relate to the shoe strength (LOT)? How are
shales and sands distributed in the open hole? Is fracturing the hole (with potentially
charged formations) an acceptable consequence?
M:\IWCF Surface\3\1\Section 5.doc
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SICP
HALLIBURTON
SICP
SICP
BOP
KILL LINE
GAS
INFLUX
HALLIBURTON
KILL LINE
SIDPP
SICP
BOP
BULL
HEADING
INFLUX
Fig 80
5. If a gas influx is suspected (shut in pressure continues to rise indicating migrating gas
in water base system), pumping rate for bullheading must be fast enough to exceed
the rate of gas migration. If pump pressures increase instead of decreasing, this is an
indication that the pumping (injection) rate is too slow to be successful. This can be a
problem in a large diameter hole.
6. The possibility of breaking down the formation of long open hole sections beyond the
last casing shoe rather than the producing formation. This could provoke the
development of an underground blowout.
Bullheading Procedure
1.
2.
3.
4.
Ensure that sufficient fluid of the current weight is available for the operation and
that the line to the kill pump suction is clear.
Line up BOP and choke manifold to pump down lower kill line. Pressure test the
surface equipment to above the maximum injection pressure.
Start the bullheading operation at a sufficiently slow rate such that the volume
versus rate relationship can be monitored. Attempt to keep the rate constant during
the operation and plot up volume versus rate as per leak off graph. Allow for the
compressibility of the drilling fluid as the pressure is brought up to the injection
pressure.
As bullheading continues, the surface pressures should theoretically decrease as
lower density influx is displaced by higher density fluid. Surface pressures should
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be monitored and plotted at regular intervals to check that the influx is being
bullheaded away. If the injection pressure does not fall it may be as a result of fluid
being injected into a formation above the influx. See Fig 81
The injection pressure may increase during the operation as the permeability of the
reservoir is damaged. If the injection pressure approaches the maximum allowable
surface pressure, stop the pumps and allow the pressure to stabilise. Recommence
at a slower rate keeping within the maximum pressure limitations.
If it becomes impossible to bullhead without exceeding maximum pressure
limitations i.e. fracture pressure, the decision to continue bullheading operations in
excess of this pressure will depend upon the volume of the remaining influx and the
position of the bit in the hole.
Once the calculated volume of influx has been bullheaded back to the formation,
bleed off trapped pressure and shut in the well to monitor drill pipe and casing
pressures.
If the shut-in pressures have fallen, then it is a fair assumption that the operation
has been partially successful. It should be remembered that if the kick was taken
whilst drilling. It is unlikely that the drill pipe and casing pressures will read the same
due to the dissemination of the influx in the fluid.
If bullheading was seen to be successful, then it should be continued until the drill
pipe and casing pressure are similar. The subsequent well kill operation to secure
the well will depend on how the kick was taken.
If the influx was taken whilst drilling, then the well can be killed using the wait
and weight method utilising the original shut in pressure information.
If the pipe is off-bottom, then it will be necessary to strip back to bottom using
standard stripping procedures. A circulation should then be performed,
maintaining constant bottom hole pressure, to clear the hole of disseminated
gas.
If the procedure is not seen to be successful, then consideration will have to be
given to:
Stripping back to bottom if necessary and circulating out the influx at a rate
dependent on its size and the limitations of the surface equipment.
Beginning operations leading to the suspension of the well.
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1300
Formation Strength
1100
900
Pump Pressure
700
500
3
300
100
Volume pumped
Fig 81
1:
Bullheading taking place over the influx with plugging of the formation taking place.
2:
3:
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01.12
Introduction
During drilling, completion and work-over operations it sometimes becomes
necessary to trip tubular through the BOPs under pressure. The procedures
used are called Stripping and Snubbing.
Stripping: This procedure is used when the pipe weight is sufficient to overcome the
upward force created by well pressure acting on the cross-sectional area of
the pipe.
Snubbing: This procedure is used when the pipe weight is not sufficient to overcome the
upward force created by well pressure on the cross-sectional area of the
pipe. In this case an external force must be applied to move the pipe through
the BOPs.
02.12
Stripping
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the BOP. Pressure from the well must not be used to equalise the pressure across
the rams.
The objective in all stripping operations is to maintain a constant bottom hole
pressure, slightly greater than the formation pressure, throughout the entire
operation.
03.12 Closing Procedures
Stripping procedures must be adjusted to suit the well conditions and the equipment,
which is available. A specific procedure should be developed for each situation.
The following guidelines provide a basis for the design of detailed procedures closing in
the well on a kick, with pipe off bottom and stripping back to bottom:
To avoid excessive surface pressures, the correct closing in procedure as outlined should
be adopted, i.e. Close in the well at the first indication of flow.
1.
2.
3.
4.
5.
6.
7.
8.
In general, the annular preventer is used for stripping pipe into or out of the hole. The annular
preventer allows the use of one preventer and permits the tool joints to pass through the
packing
ACCUMULATOR
BOTTLE
PRECHARGE @ 400 PSI
OPEN
ANNULAR
PREVENTER
BALL VALVE
CLOSE
Fig 82
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element without creating excessive pressure surge in the well bore. To minimise the wear,
the pipe should be well lubricated with grease and closing pressure applied to the annular
preventer kept to a minimum. A surge bottle should be installed as close to the annular
preventer as possible. See Fig 82.
Regardless of the method used to strip pipe into the hole and enable effective pressure
control, it is very important to measure all of the fluid that comes out of the well bore.
Formation fluid that has entered the well bore may be gas and during stripping operation
migration may take place, so it is essential that rigs are suitably rigged-up to immediately
implement the volumetric method. See Fig 83.
1.
2.
3.
Adjustable choke.
4.
5.
6.
Fig 83
05.12
Procedure
1:
After closing in the well, determine the influx volume and record pressures at two
minute intervals. After closed in pressures have stabilised; further record pressures
at five minute intervals.
2:
3:
Convert the working pressure Pw of say 50 psi into an equivalent working volume V
in the OH/DC annulus (the volume of fluid to be used for volumetric control steps).
See Fig 84.
PW x Cap
V = Cap x h = -------------MWG
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Fig 84
117
Fig 85
V
H2
Expansion
of gas influx
V
4:
H1
Determine the extra back pressure Ps to compensate for the loss of hydrostatic
pressure as the bit and drill collars are run into the influx. If the influx is assumed to
be in the open hole beneath the bit, an increase in surface pressure will be required
to maintain BHP above Pf when this event occurs. It is unknown when the extra
back pressure will be required since the exact position of the influx is unknown; it is
therefore advisable to adopt a suitable safety factor from the very start of the
stripping operation.
Since overbalance (trip margin) will exist in nearly all wells which kick during round
tripping, it is not possible to use closed in annulus pressure SICP to make an
accurate estimate of the magnitude of the influx and thus the additional back
pressure required to compensate for the previous mentioned loss of hydrostatic
head. It is therefore essential to accurately measure the influx volume gained at
surface, and by application of a factor based on the ratio open hole to DC/OH
annulus, calculate the expected loss of hydrostatic head as the DCs enter the
influx. See Fig 85.
(Mud Gradient - Influx Gradient) x Influx Volume
Ps = ---------------------------------------------------------------------DC/OH Capacity
5:
Adjust the closing pressure on the annular preventer to a minimum, but avoid
leakage. Whilst reducing closing pressure check continuously for flow.
6:
Allow annulus pressure to build up to PCHOKE whilst stripping the first stand.
PCHOKE = SICP + PS + PW
Where
SICP =
Initial closed in annulus pressure before second build
up.
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8:
Avoid excessive surge pressures by adjusting the pipe lowering rate to allow
chokeman to maintain PCHOKE constant.
9:
10:
PCHOKE1 = PCHOKE + PW
See Fig 86
11:
Pw
Expansion
of gas influx
Fig 86
12:
By repeating this cycle, as often as necessary gas is able to percolate upwards and
expand while a nearby constant BHP is maintained.
13:
Values of pressure and volume should be recorded in table throughout the stripping
exercise.
With the bit on bottom the well can be killed using the Drillers Method first circulation, but
first ensure that the entire string is full of mud.
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Note 1:
A length of the first stand will be stripped against the closed in well until the required
stripping choke pressure, PCHOKE, has been reached. Only the remainder of the stand,
which is stripped at constant choke pressure, should be considered when bleeding off the
closed end displacement volume.
For example, if the required PCHOKE is reached after stripping two singles of the first stand,
only one third of the closed end displacement volume should be bled off into the stripping
tank. The same principle will of course apply when PW increment are added.
Note 2:
Should, during the stripping operation, bottom hole pressure inadvertantly drop below
formation pressure (BHP < PF), a second influx will take place. The method makes
allowance for this eventuality and re-established the required PCHOKE by overcompensating
for the loss of hydrostatic pressure caused by the new influx. This is achieved
automatically due to the manner in which PW has been calculated. PW compensates for
loss of hydrostatic pressure assumed opposite the DCs. A second influx will enter in the
open hole section resulting in a volume gain at surface, where it will be interpreted as a
volumetric step. The well will be closed in and PCHOKE allowed to increase by PW. The
effect, of course, will be to overcompensate the underbalance that existed in the well. In
other words it is impossible to loose hydrostatic control of the well since the method is self
correcting.
06.12 Snubbing
Snubbing involves moving pipe in and out of a well under pressure, while maintaining
constant bottom hole pressure. The operation is very similar to stripping except that the
pipe will not move into the well under its own weight and must be forced in through
application of external force at the surface. Snubbing operations are much more
dangerous than stripping operations and always involve the use of specialised equipment
and personnel.
Two types of snubbing system are generally employed namely mechanical snubbing units
and hydraulic snubbing units. Mechanical snubbing units require the use of the drilling rigs
hoisting system, while hydraulic snubbing units are self contained.
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01.13 General
Gas cut drilling fluid is the term used when the drilling fluid contains a percentage of gas in the
form of small bubbles, when it returns to the surface. Generally gas cut drilling fluid does not
decrease the hydrostatic pressure so much as to cause underbalance/kick situations. This is
because the gas content in the drilling fluid is mostly compressed, except very close to the
surface. Every atmosphere (14.7 psi) reduces the gas volume by half. Therefore the drilling
fluid weight considerably reduces the volume of the gas.
If the volume of the gas in the drilling fluid is very small the reduction in bottom well pressure
will also be very small. Fig. 87 shows a typical example of pressure reduction bottom well
caused by gas cutting of drilling fluid.
20
-9
50% cut
pg
-5
10 p
pg
ppg
ppg
33.3% cut
18
p
ppg
18 ppg - 13
.5 ppg
10 ppg
- 6.66
ppg
18 ppg
- 12 pp
g
25% cut
10 ppg - 7.5
7
6
10% cut
10 ppg - 9 ppg
DEPTH in 1000ft
10
9
8
1
0
20
40
60
80
100
120
Fig 87
It is very important to understand that the gas expanding as it nears the immediate surface
causes almost all the bottom well pressure reduction. Therefore flow line drilling fluid weight
can be very low in some cases.
02.13 Causes of gas cut drilling fluid
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1.
When a gas bearing formation is penetrated the cuttings will always release an amount
of gas into the drilling fluid. This will be the first gas to register at the surface, and is a
positive indication that a gas bearing formation has been penetrated. This type of gas
will not cause a drilling fluid weight reduction, but if there is any doubt, pick up the drill
string, shut down the drilling fluid pumps and check for flow.
2.
Another cause of gas cut drilling fluid is that some formations with a very low
permeability have a pore pressure, which is bigger than the hydrostatic pressure from
the drilling fluid column.
So long as the drilling fluid is circulated there is a small overbalance in the well
because of pressure loss in the annulus. When circulation is stopped a small
underbalance will occur, ant this causes varying amounts of gas to intrude into the
wellbore. This often occurs when the pumps are shut down during a connection or
during a trip and these conditions are respectively called Trip Gas and Connection
Gas.
3.
The third cause of gas cut drilling fluid can be a washout in the wellbore. This washout
or cavity acts as a trap for old gas cut drilling fluid which is picked up by the drilling fluid
at a later period in time and transported to the surface.
Calculations to estimate the change in hydrostatic pressure caused by gas cut drilling
fluid
Reduction of bottom well pressure caused by gas cut drilling fluid can be calculated by using
the following formula:
P = 2.3 x N x Log BHP
P
Original MW Gascut MW
Gascut MW
BHP =
Example:
Well depth
OMW
GMW
12.000 ft
14 ppg
7 ppg
94 psi
The pressure in the well (bottom well) is therefore reduced by 94 PSI which answers to a
change in drilling fluid weight of 0.15 ppg.
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A more practical and precise method for calculating bottom hole pressure reduction is
reached by using the volumetric method. The volumetric method is used in the following way.
The volume increase in the drilling fluid tanks that has flowed back due to gas cut drilling fluid
is measured.
This figure can be used to calculate the change in hydrostatic pressure in psi/bbl units by the
following formula:
P=
Fig 87 shows that even with a flow line weight reduction of 50% through gas cutting, bottom
hole pressure is not seriously affected, as the reduction is less than the change that is caused
through pressure loss in the annulus.
Although pressure reductions from gas cut seldom cause underbalance, there are other
factors that can lead to dangerous situations. Foremost gas cut drilling fluid is an indication of
(possible) low drilling fluid weights, and pump effectiveness can be seriously reduced by gas
cut drilling fluid.
If drilling fluid becomes seriously gas cut the pump output is seriously decreased, that can
lead to a following fall in annulus pressure loss, fall in bottom hole pressure and therefore risk
of influx and blowout.
It is therefore most important that gas cut drilling fluid is de-gassed (gas content extracted)
before it is pumped down hole again.
It may be that he most common fault in connection with gas cut drilling fluid is the tendency to
maintain the original drilling fluid weight with barite without removing all the gas from the
drilling fluid. When a moderate gas cutting gives a relatively small change in hydrostatic
pressure, it is possible that addition of barite to increase drilling fluid weight can lead, in
extreme cases, to lost circulation.
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Early detection of gas kicks in oil based mud is of particular importance. The
behaviour of hydrocarbon gases in an oil based drilling fluid is fundamentally different from
their behaviour in a water based drilling fluid. These differences must be understood to
allow safe handling procedures to be followed.
The solubility of methane in diesel oil is approximately 100 times greater than in
water, and therefore comparatively large gas flows (10 MMSCFD) can be taken into
solution when circulating an oil based drilling fluid. The volume of the resulting solution is
approximately equal to the sum of the gas and oil components, and therefore an influx will
result in both a pit gain and an increase in return flow rate, as for a water based fluid.
As shown in Fig 88 the expansion of a gas in oil solution, with decreasing pressure, is
different from the expansion of the gas that occurs when a water based fluid is in use.
Diesel alone
0
2.000
PRESSURE (PSI)
PRESSURE (PSI)
2.000
Methane alone
4.000
6.000
4.000
6.000
8.000
8.000
10.000
10.000
1
10
RELATIVE VOLUME
100
4% Methane in diesel
10
100
RELATIVE VOLUME
Fig 88
When a water-based fluid is in use, gas expansion occurs continuously, and the kick is
therefore comparatively easy to detect. With an oil based mud there is negligible
expansion until the solution reaches the bubble point, but at pressures below the
bubble point the expansion is very rapid.
The bubble point can be very difficult to determine due to a lot of unknown factors, but Fig
89 shows a typical phase equilibrium.
Zone A:
Zone B:
Zone C:
Zone D:
For pressure above the bubble point line and below the critical temperature
the material in the reservoir is a liquid.
For pressure above the dew point line the material in the reservoir is gas.
For material outside the dew line the material is always gas.
For material within the phase envelope the material is a 2 phase equilibrium
mixture of free gas and its associated liquid.
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Zone C
3
LIQUID
7000
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FREE GAS
1
Critical
Point
6000
Lin
e
Bu
bb
le P
oin
t
10%
25%
e
t Lin
Poin
PRESSURE PSI
Dew
2-Phase Zone D
40%
0
- 200
400
TEMPERATURE F
800
Fig 89
If a hydrocarbon liquid at point 1 is expanded down line from 1 to 2, the pressure reach the
bubble point line and the liquid starts to evaporate (boil) and bubbles of gas appear within
the liquid. As the expansion proceeds more gas is produced at the expense of liquid.
If hydrocarbon gas at point 3 is expanded down a line to point 4, the pressure is reduced
to the dew point line and droplets of liquid starts to appear in the gas (the gas condenses).
As the expansion proceeds, more liquid is produced at the expense of gas.
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In all previous calculations in well control we have presumed that the measured pit gain
after shutting in the well was equal to the size of influx in the well bore. This prediction is
due to that liquid is incompressible, witch is in fact not quit right.
When performing a leak off test a certain amount of fluid is required to obtain pressure in
the well bore. The greater the annular capacity is and the higher pressure applied the
more volume has to be pumped into the well bore.
This pressure/volume effect will also be applicable when looking on the size of an influx
into the wellbore. As we drill deeper and longer the annular capacity is greatly increased
and compression of the fluid has to be taking into consideration to determine if the
handling capacity of our surface equipment is sufficient.
Fig 90 shows the compressibility of a water base drilling fluid system:
Applied
pressure
500
600
500
1000
1500
2000
2500
3000
3500
4000
0.75
1.50
2.25
3.00
3.75
4.50
5.25
6.00
0.90
1.80
2.70
3.60
4.50
5.40
6.30
7.20
1.05
2.10
3.15
4.20
5.25
6.30
7.35
8.40
1.20
2.40
3.60
4.80
6.00
7.20
8.40
9.60
1400
1500
1.35
1.50
1.65
1.80
1.95
2.10
2.70
3.00
3.30
3.60
3.90
4.20
4.05
4.50
4.95
5.40
5.85
6.30
5.40
6.00
6.60
7.20
7.80
8.40
6.75
7.50
8.25
9.00
9.75 10.50
8.10
9.00
9.90 10.80 11.90 12.60
9.45 10.50 11.55 12.60 13.65 14.70
10.80 12.00 13.20 14.40 15.60 16.80
2.25
4.50
6.75
9.00
11.25
13.50
15.75
18.00
Fig 90
Example:
A 10 bbl measured influx in a water base drilling fluid system of 1400 bbl and a
SIDPP of 1000 psi.
Influx to handle on surface:
10 bbl + 4.20 bbl = 14.20 bbl
This means that the 10 bbl influx measured as pit level increase is actual a 14.20 bbl
influx, witch means that the volume of gas we have to handle on surface is 42% higher
than expected.
When drilling with oil base drilling fluid the problem increases considerably and especially
in the HPHT wells we are drilling to day we have to take this fluid compression seriously
when evaluating handling method of an influx into the well bore. See Fig 91.
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Example:
A 10 bbl measured influx in an oil base drilling fluid system of 1400 bbl and a SIDPP
of 1000 psi.
Influx to handle on surface:
10 bbl + 7.00 bbl = 17.00 bbl
Applied
pressure
500
1000
1500
2000
2500
3000
3500
4000
500
600
1.25
1.50
1.75
2.50
3.00
3.50
3.75
4.50
5.25
5.00
6.00
7.00
6.25
7.50
8.75
7.50
9.00 10.50
8.75 10.50 12.25
10.00 12.00 14.00
2.00
4.00
6.00
8.00
10.00
12.00
14.00
16.00
2.25
4.50
6.75
9.00
11.25
13.50
15.75
18.00
2.50
5.00
7.50
10.00
12.50
15.00
17.50
20.00
2.75
5.50
8.25
11.00
13.75
16.50
19.25
22.00
3.00
6.00
9.00
12.00
15.00
18.00
21.00
24.00
3.25
6.50
9.75
13.00
16.25
19.50
22.75
26.00
1400
1500
3.50
7.00
10.50
14.00
17.50
21.00
24.50
28.00
3.75
7.50
11.25
15.00
18.75
22.50
26.25
30.00
Fig 91
This means that the 10 bbl influx measured as pit level increase is actual a 17.00 bbl
influx, witch means that the volume of gas we have to handle on surface is 70% higher
than expected.
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01.14 Introduction
From its early beginnings in the 1920s when it was regarded as a black art, directional
and horizontal drilling has evolved to the point where it can truly be regarded as a science,
although not always an exact science. The offshore and onshore drilling industry is
founded on directional and horizontal drilling. Without the use of directional drilling
techniques, it would not be economical to produce oil from most offshore fields.
Improvements in directional drilling tools and techniques coupled with advances in
production techniques have led to a steady increase in the production of wells drilled
directionally and horizontal rather than vertically. As the search for oil and gas extends into
ever more hostile and demanding environments, this trend will continue.
This also means that normal well control practice used in vertical wells have to altered to
meet the new demand for deviated/horizontal well control. The true vertical depth of the
wells drilled to day is getting less while the measured depth is increasing making it harder
to control bottom hole pressure and ensure that the influx is circulated out.
The normal preferred method in circulating out an influx is the Wait and Weight witch
means that the increasing hydrostatic pressure causes the drill pipe pressure to fall when
circulating kill fluid from surface to bit. Pump strokes represent a certain measured length
of fluid in the drill pipe. In a vertical well, the measured length of the fluid is the same as
the vertical length of the fluid. In a deviated well, the vertical length of the fluid is less than
the measured length of the fluid. This means that the pressure will drop less in a deviated
well than in a vertical well per stroke. By calculating an average pressure drop across both
the vertical and deviated sections of the well, the pressure will drop too slowly in the
vertical section of the well. This means that by using our regular kill sheet in a deviated or
horizontal well we tend to overpressure the well, which can lead to stuck pipe and lost
circulation. These problems not only exist in deviated wells, but can also be created in
vertical wells.
We will have a look on a few pressure developments while circulating out an influx using
the Wait and Weight method.
5 bbl
Ph
5 bbl
Ph
Fig 92
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ICP
Fig 93
ICP
FCP
Fig 94
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ICP
FCP
Fig 95
ICP
FCP
Fig 96
In a horizontal well with a uniform string using the Wait and Weight method the red
dotted line represent the theoretical pressure graph when circulating kill fluid to the bit from
ICP to FCP.
The blue line represents the true pressure graph to follow using the Wait and Weight
method.
By using the theoretical pressure graph it can be seen that while kill fluid is circulated to
the bit the well is in extreme overbalance witch can lead to serious additional well control
problems. See Fig 96.
By using the deviated well control sheet the true pressure graph can be calculated.
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02.14 Complications
When taking a gas influx into a horizontal well bore some associated problems might be
encountered and have to be taking into consideration.
The density of the gas is lower than the density of
the drilling fluid with the result that the gas will
accumulate in the top of the well bore in the
horizontal section. See Fig 97.
Fig 97
Fig 99
A gas kick taking in a horizontal well section is most likely due to drilling through a fault
with the result that there is a great chance for losses at the same time due to the
difference in formation pressure.
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KOP
TVD/MD 4200 ft
SHOE
Hole size
Hole TVD
Hole MD
KOP MD/TVD
EOB TVD
EOB MD
Csg 10-3/4 TVD
Csg 10-3/4 MD
BHA
DP cap.
DC cap
OH/DC cap
OH/DP cap
Csg/DP cap
SIDPP
SICP
Influx volume
RRCP
8-3/4
6130 ft
16330 ft
4200 ft
5470 ft
6178 ft
6200 ft
8200 ft
80 ft
0.01755bbl/ft
0.0066 bbl/ft
0.03014 bbl/ft
0.04896 bbl/ft
0.07373 bbl/ft
410 psi
450 psi
8.2 bbl
450 psi
TD
TVD 6130 ft
MD 16330 ft
EOB
TVD 5470 ft
MD 6178 ft
Fig 101
By using the example in Fig 101 the kill sheet can be filled
capacity/stroke data be obtained:
Internal
Surface to KOP
73.7 bbl
KOP to EOB
34.7 bbl
EOB to BHA
176,8 bbl
BHA
0.5 bbl
External
BHA/OH
2.4 bbl
DP/OH
394.1 bbl
DP/Csg
604.6 bbl
Calculations:
Calculate the required kill fluid density:
(A)
SIDPP
410
KMW = OMW + ----------------= 14.3 + -----------------= 15.6 ppg
TVD x 0.052
6130 x 0.052
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(B)
(C)
(D)
(E)
SIDPP at KOP = SIDPP - (KMW - OMW) x 0.052 x KOPtvd = 410 - (15.6 - 14.3) x 0.052 x 4200 = 126 psi
(F)
(G)
(H)
SIDPP at EOB = SIDPP - (KMW - OMW) x 0.052 x EOBtvd = 410 - (15.6 - 14.3) x 0.052 x 5470 = 40 psi
(I)
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The Wait and Weight method is also called the balance method witch means that the
kill fluid is pumped to the bit holding BHP constant by adjusting the choke to keep the precalculated drill pipe pressure on schedule according to the graph. To use Wait and
Weight method in horizontal wells is not recommended due to that it requires a lot of
calculations and the kill fluid has to be pumped to the bit at reduced rate to control the drill
pipe pressure, with the result that the influx will stay trapped in the horizontal section.
The following graph shows the drill pipe and casing pressure while circulating out the influx
at the previous example using Wait and Weight method. See Fig 101.
1200
1100
1000
900
ICP
800
KOP
700
500
EOB
PRESSURE
600
FCP
400
Csg. Pressure
300
Gas at EOB
200
100
000
0
1500
3000
4500
STROKES
6000
7500
9000
10500 12000
Fig 101
This method is also called the constant drill-pipe pressure method and consist of two
steps. First step to circulate out the influx without changing drilling fluid density and second
to displace OMW with the KMW. This method does not require the same calculations as
the Wait and Weight method and are therefore more simple, but not recommended due
to using reduced rate for circulating the result could be that the influx will stay trapped in
the horizontal section.
The following graph shows the drill pipe and casing pressure while circulating out the influx
at the previous example using Drillers Method. See Fig 102.
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1200
1100
1000
DP Pressure
900
700
600
500
PRESSURE
800
400
KMW at EOB
Csg. Pressure
300
Gas at EOB
200
100
000
STROKES
3000
6000
9000
12000
Fig 102
To circulate out a influx in a horizontal well bore the annular flow must be so high that the
flow becomes turbulent and test have showed that a annular velocity of at least 100 ft/min
is required. The industry recommendation is to use the Drillers Method with modification
to handle an influx in a horizontal well and the following is only guidelines.
Prepare calculations for using Drillers Method.
Calculate open hole strokes from bit to end of horizontal section.
Keep constant casing pressure while bringing pumps to required SPM to give
minimum 100 ft/min annular velocity.
Keep constant drill pipe pressure while flushing influx out of horizontal section.
Keep constant casing pressure while bringing pumps down to reduced circulating
rate.
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Continue circulating influx out of the well bore using Drillers Method
With influx out of well bore keep constant casing pressure while pumping kill fluid to
bit using reduced circulating rate.
With kill fluid at bit keep constant casing pressure while bringing pumps to required
SPM to give minimum 100 ft/min annular velocity.
Keep constant drill pipe pressure while flushing light drilling fluid out of the
horizontal section.
Keep constant casing pressure while bringing pumps down to reduced circulating
rate.
Continue circulating light drilling fluid out of the well bore using Drillers Method.
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Running/Pulling Pipe.
01.15 Introduction
Most well control incidents take place during tripping pipe for different reasons, but in
general they can all be considered to be negligence from the drilling team. The negligence
could be due to a single circumstance or a combination of several circumstances. The
reasons for well control incidents during tripping could for the following reasons:
1.
2.
3.
4.
02.15
Pumping Slug
Pumping a slug prior to pulling out of hole is a well-known procedure in the drilling
industry. The slug is a heavy pill of drilling fluid with a density higher than the drilling fluid
used during drilling. The slug is pumped into the drill pipe prior to start pulling the drill
string out of hole and due to its higher density will create a U-tube effect allowing the fluid
level inside the drill string to drop. The drill string can then be pulled dry avoiding any
pollution on the rig floor, so the roughnecks do not get in contact with the drilling fluid.
Prior to pumping a slug it is important that calculation are made to determine the amount
of fluid that will be drained back into the trip tank due to the U-tube effect as this will be
indicating if the well is in balance. Tripping should not start before the U-tube effect is
finished and the correct amount of this effect has been measured in the trip tank.
As the amount of slug pumped is known together with the internal capacity of the drill pipe
in use the following formulas can be used to determine the level drop inside the drill pipe
and the volume to be drained back into the trip tank:
MTC
DOCUMENT ID
03-13-01
ORIGINAL DATE
DRILLING SECTION
AUTHORISED BY
CBI/NLN
REVIEWED BY
1/8/02
SUBJECT:
PREPARED BY
01
ITEM
JNO/HES
CHAPTER
JOA
REVISION
PAGE
15
140
Example:
12.6
14.5
22
0.01776
ppg
ppg
bbl
bbl/ft
The slug is pumped and the surface lines displaced by original drilling fluid. The Topdrive
is disconnected and the slug allowed to drop. See Fig 103
Calculate:
Length of slug.
Level drop.
Trip tank return
22 bbl
Length of slug = ----------------------- =
0.01776 (bbl/ft)
1239 ft
14.5 (ppg)
Level Drop = 1239 (ft) x ------------------- 1239 (ft) = 187 ft
12.6 (ppg)
Trip tank return = 187 (ft) x 0.01776 (bbl/ft) = 3.32 bbl
PDP
NATIONAL
PDP
NATIONAL
Level drop
Length of slug
Length of slug
Trip tank increase
Fig 103
MTC
DOCUMENT ID
03-13-01
ORIGINAL DATE
DRILLING SECTION
1/8/02
SUBJECT:
PREPARED BY
JOA
AUTHORISED BY
REVISION
CBI/NLN
REVIEWED BY
01
ITEM
JNO/HES
CHAPTER
PAGE
15
141
= 1239 ft
= 1549 ft
= 4.4 bbl
or
Ph of slug in 5 DP =
= 934 psi
= 1168 psi
MTC
DOCUMENT ID
03-13-01
ORIGINAL DATE
REVISION
CBI/NLN
REVIEWED BY
1/8/02
PREPARED BY
AUTHORISED BY
01
ITEM
JNO/HES
CHAPTER
JOA
PAGE
15
142
As can be seen on the calculation an expected extra return into the trip of 4.4 bbl must be
expected when slug enter the 4-1/2 drill pipe and this volume needs to be calculated prior
to tripping to avoid any misunderstandings when pulling pipe out of hole.
03.15
When pulling pipe out of hole it is important that the hole is kept full all the time to maintain
the pressure hydrostatic in the well bore. If the pipe is pulled without adequate hole fill the
level will drop in the well bore with the result of a decrease in the bottom hole pressure. If
the decrease in the bottom hole pressure gets severe the well might get in underbalance
resulting in an influx into the well bore. As all displacement and capacity figures is known
for the pipe in use on a drilling rig the pressure drop for tripping pipe can easily be
calculated using the following formulas:
Pulling dry Drill Pipe:
Drilling fluid density(ppg) x 0.052 x DP metal displacement(bbl/ft)
Pressure drop per ft. pulling dry pipe = ------------------------------------------------------------------------------------------Casing capacity (bbl/ft) - DP metal displacement (bbl/ft)
Example:
12.6
0.01776
0.00852
0.00768
0.03658
450
0.07287
ppg
bbl/ft
bbl/ft
bbl/ft
bbl/ft
ft
bbl/ft
Calculate the pressure drop per ft. pulling dry Drill pipe:
12.6 x 0.052 x 0.00852
----------------------------------- = 0.0867 psi/ft
0.07287 - 0.00852
M:\IWCF Surface\3\1\Section 5.doc
MTC
DOCUMENT ID
AUTHORISED BY
03-13-01
ORIGINAL DATE
CBI/NLN
REVIEWED BY
1/8/02
PREPARED BY
REVISION
01
ITEM
JNO/HES
CHAPTER
JOA
PAGE
15
143
Calculate the pressure drop per ft. pulling wet Drill pipe:
12.6 x 0.052 x (0.01776 + 0.00852)
------------------------------------------------ = 0.3696 psi/ft
0.07287 - (0.01776 + 0.00852)
For different reasons it could be necessary drop the level in the annulus, but by doing so
the bottom hole pressure will be reduced. If pulling pipe without filling the hole the amount
of pipe that can be pulled before the well loses its overbalance can be calculated by using
the following formulae:
Pulling dry Drill Pipe:
Overbalance (psi) x (Casing Capacity - DP metal displacement)
Pipe to pull before well starts to flow (ft) = ------------------------------------------------------------------------------------------Drilling fluid density x 0.052 x DP metal displacement
Example:
12.6
0.01776
0.00852
0.00768
0.03658
450
0.07287
10000
0.6995
ppg
bbl/ft
bbl/ft
bbl/ft
bbl/ft
ft
bbl/ft
ft
psi/ft
MTC
DOCUMENT ID
03-13-01
ORIGINAL DATE
1/8/02
PREPARED BY
AUTHORISED BY
REVISION
CBI/NLN
REVIEWED BY
01
ITEM
JNO/HES
CHAPTER
JOA
PAGE
15
144
04.15
As mentioned before then all displacement and capacity of the tubular used on a drilling rig
should be known so the correct calculated amount of fluid can be measured filling the hole
as the pipe is pulled out of the hole. This measurement is carried out by the use of the Trip
tank where the fluid volume can be measured either visual or by an electronic measuring
devise. Any deviation in the correct calculated amount of fluid means that some
abnormalities is taking place down hole and tripping must be stopped and the problem
evaluated and rectified.
If the hole is taking more fluid than calculated per stand tripped out of hole either wet or
dry some dynamic losses is taking place and the situation needs to be evaluated. Minor
dynamic losses when pulling out of hole could turn into severe losses when running back
into the hole due to surge pressure created. Consideration should be made to run back to
bottom and cure losses prior to comments tripping.
If the hole is taking less fluid than the calculated per stand tripped out of hole either wet or
dry indicates that the hole could be swabbing. The reason for swabbing could be due to
balled bit/ BHA or due to very high viscosity combined with a low BHA annulus capacity.
The less amount of fluid that the hole has taken could be formation fluid that has been
swabbed into the well bore and depending on the amount of swabbed fluid the bit should
be run or strip back to bottom and the well circulated clean prior to commence tripping or
alternative pumping out of hole. If the formation is tight the swabbed fluid could come from
the drill pipe with the result that the fluid level inside the drill pipe has been lowered and
thereby the pressure hydrostatic. If the level drop inside the drill pipe becomes severe the
hydrostatic pressure inside the drill pipe might drop below formation pressure. This result
could be that the formation starts producing and formation fluid could enter the drill string
creating complications. Prior to tripping it is of extreme importance that swab pressure is
calculated and the correct pulling speed found to avoid swabbing tendency.
05.15
When running the drill string into the well bore it is of equal importance that the fluid
coming back for the pipe run is measured as any deviation from the calculated amount
MTC
DOCUMENT ID
03-13-01
ORIGINAL DATE
1/8/02
PREPARED BY
JOA
AUTHORISED BY
REVISION
CBI/NLN
REVIEWED BY
01
ITEM
JNO/HES
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PAGE
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means that some abnormalities is taking place down hole. The tripping has to stopped and
the problem rectified prior to continue running in.
If the volume coming back is higher than the calculated volume this could indicate that the
bit or drill string is plugged and that the pipe is not filled as running in. Circulation has to be
established and the bit/string unplugged before continue tripping. If a drill pipe float is
installed in the drill string circulation should be broken every 1500 ft to avoid excessive
collapse pressure on the drill string.
If the volume coming back is less than the calculated volume the reason could be that the
tripping speed is to high and excess surge pressure is created on the formation with result
in losses. Prior to tripping it is of extreme importance that surge pressure is calculated and
the correct running speed found to avoid breaking down the formation.
MTC