Lecture 10: Well Control Causes of Kicks, Kick Detection Techniques & Well Control Equipments

Arun S Chandel
Assistant Professor aschandel@ddn.upes.ac.in 09997200339

Kicks
A kick is the term used to describe the inflow of formation fluid into the wellbore during drilling operation. This s arises a ses due to o the e formation o a o pressure p essu e being be g greater g ea e than the hydrostatic pressure imposed by the mud column. This can happen in a normal or abnormally pressured formations. A kick may be primarily composed of salt water, oil, natural gas or a combination of the fluids. The influx of formation fluid may arise for a variety of reasons These include: incl de

Causes of Kicks

Major j Causes
Insufficient mud weight; Swabbing; Not keeping the hole full; Loss of circulation (partial and full);

Kicks occurring during drilling operations most often occur due to insufficient mud weight. weight Kicks generally occur during trips with the influx occurring from a combination of swabbing and failure to keep the hole full. Swabbing is the result of the piston effect of the drillpipe due to excessive trip speed resulting in instantaneous vacuum being created below the bit. bit
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Insufficient mud weight

.may occur due to: Penetration e e a o of o an a abnormally ab o a y pressured p essu ed zone; o e; Accidental dilution of the mud by fluid addition at surface Dilution of mud by y influx from an aquifer q exposed p to open hole; Gradual mud density reduction due to gas cut and failure to degas the mud at surface; Improper mud mixing and poor quality control in measurement.

Low o Level of o Drilling g Fluid u d Column ou Not keeping the hole full

Two conditions may lower the fluid column in the annulus. These are: Failure to fill the hole during a trip; Lost circulation during drilling

Hole Fill During Trips

In pulling out the drillstring, the driller must refill the hole with mud of equivalent volume. Monitoring of the volume of mud filling the hole is done with the use of the Trip tank or Possum Belly Tank. The trip tank is a small mud pit (Approx. 50bbls) separate from the active pits. This trip tank is fully equipped with a volume l gauge that th t can be b monitored it d from f rig i floor fl or mud d loggers l console. l In I monitoring the trip, the driller must calculate the theoretical mud volume displaced by one or five stands of drillpipe. During the trip, the driller then measures the actual mud volume p pumped p into the hole for each stand of p pipe p pulled.

Lost Circulation
Lost circulation is the loss of substantial quantity or whole mud into the formation. It may occur as a result of: Mud loss to cavernous or vugular formation; Penetration of depleted or subnormal zones; Mud loss to fractures opened by excessive annulus pressure. This may be due to annular blockage, surge pressures, excessive hydraulics, pressures imposed to break mud gel strength. Lost circulation will result in insufficient mud column and thus reduction in bottom hole pressure. Kick due to lost circulation can be a major well control problem. If the well cannot be shut in, an underground blow out can occur. 7

Swabbing
Swabbing is the reduction of bottom hole pressure caused by upward pipe movement - result is reduced bottom hole pressure. pressure High trip speed can lead to instantaneous vacuum below the bit. The swab pressure depends on: Pipe velocity; Bit and/or BHA balling; Clearance between pipe and hole - the smaller the annular cross section, the greater the swabbing action; Mud rheology - the higher the viscosity, viscosity the greater the swabbing action.

Pre Recorded Kick Data

M i Maximum W Working ki Casing C i P Pressure

The casing and blowout preventer (BOP) are d designed i d for f th the different diff t expected t d pressures during each drilling phase. This is determined during well planning. planning The pressure requirements are based on the maximum anticipated pressures caused by a gas kick.

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(Maximum Allowable Annular Surface Pressure)

MAASP

This is the annular pressure at the surface that corresponds to the pressure at the weakest point of the hole. The fracture gradient at the last casing shoe traditionally defines the weakest point. The MAASP represents the annulus pressure which may be expected to result in loss of circulation while controlling a kick. kick MAASP = 0.052 x (Frac ) x Dw
Frac = Fracture pressure at shoe equivalent mud wt in ppg

= current mud weight in ppg / Dw = TVD of weakest point

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Ri C Rig Capacity it f for W Weighting i hti M Mud d

Although this data does not appear in the worksheet, , it is important p as it defines the number of circulation cycles necessary to regain primary control with given change of mud. The rig capacity depends on total reserves of weighting materials (Barites, (Barites etc) and the maximum rate of addition to system. The maximum rate of addition is measured in Ib/min or kg/min kg/min. Backup supply MUST always be available on rig.

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System y Pressure u Losses o at a Slow o Pump Rate

To control circulating a kick out of the hole without the risk of causing a second influx or losses from breaking down the f formation ti with ith excessive i annular l pressures slow l a circulating i l ti rate t (SCR) is used. of the well. This is is dependent on the rig, but this is usually about 20 or 30 strokes per minute. This slow rate must be taken: At the start of each tour; If the mud weight changes; If bit arrangement changes; After bit changes; Every 500 ft drilled.

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Example 1: Current Mud weight = 7 7.2 2 ppg Casing shoe TVD = 4000 ft Estimated fracture pressure = 6200 psi Annular pressure losses = 350 psi Bottom hole pressure = 2000 psi Calculate MAASP.
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Solution:
BHCP= BHP+pann. = 2000+350 = 2350 psi Equivalent mud wt.= 2350/(0.052x4000) = 11.3 ppg Fracture press. Gradient = 6200/(0.052x4000)= 29.8 ppg Frac = 29.8 11.3= 18.5 ppg

MAASP= 0.052 x (18.5 7.2) x 4000 = 2350.4 psi MAASP

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Height of Influx
Height of influx, ft = pit gain, bbl annular capacity, bbl/ft

Example 1 Determine the height, ft, of the influx using the following data: Pit gain = 20 bbl (Dh = 8.5 in. Dp = 6.5) Solution Height of influx, ft = 20 bbl 0.029 14 bbl/ft Height of influx = 686 ft

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B Barrels l of f influx i fl opposite it DP=Pit DP Pit Gain G i Barrels B l opposite it DC Height g of influx opposite pp DP, , ft= Barrels opp. pp DP/Annular / Capacity p y

Example 2 D t Determine i th height the h i ht in i ft of ft, f the th influx i fl using i th the following data: Pit gain = 20 bbl Hole size = 8.5 in. Drill collar OD = 6.5 in. ; Drill collar length = 450 ft Drill pipe OD = 5.0 in.
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Solution 2

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Estimated Type of Influx

Influx weight= mud wt ((SICP SIDPP)/height of influx X 0.052) then: 1 3 ppg = gas kick 4 6 ppg = oil kick or combination 7 9 ppg = saltwater kick

Question 3 Determine the type of the influx using the following data: Shut in casing pressure = 1044 psi Shut-in Shut-in drill pipe pressure = 780 psi Mud weight = 15.0 ppg
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Pit gain = 25 bbl Hole size = 8.5 in. Drill collar OD = 7 in. ; Drill collar length = 250 ft Drill pipe OD = 5.5 in.

Solution 3

The influx is saltwater kick (influx weight ( g = 8 ppg)

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Kick Detection Techniques

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Kick Detection
The single most important step to blowout prevention is closing the blowout preventers when the well kicks. The decision to do so may well be the most important of your working life. It ranks with keeping the hole full of fluid as a matter of extreme importance in drilling operations. (Chevron Well Control Manual) Be prepared and maintain a kick control Work Sheet at all times.
A kick can occur at any time during the drilling of a well. To prevent any major catastrophe therefore, early detection of a kick is essential to primary well control. As a primary precaution, it is important for all personnel including the mud logger to be always in a state of readiness. Certain pre-kick information must be collected and available for use in case a kick occurs. occurs These include volumes and pressures data. A kick control Work Sheet (see Appendix) must be maintained for this purpose.
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There are a number of indicators that provide early warning of kick occurrence - positive kick indicators are: Mud pit level/flow Increase; Incorrect hole fill up during trip; Decrease in standpipe pressure/Increase in pump rate; Inc ease/dec ease in drillstring Increase/decrease d illst ing weight eight Potential indicators are: Increase in penetration rate; Lost circulation; Changes in gas levels, mud density and conductivity

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P i i Positive Kick Ki k Indicators I di

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1 Mud 1. M d Pit L Level l / Flow Fl Increase I

These parameters are major positive indicators indicators. As the influx of formation fluid displaces the mud in the annulus, the pit level would increase in the active mud tanks. There would also be evidence of increase in return t fl flow rate t if logged. l d The Th effectiveness ff ti of f pit it gain/flow increase depends on: Initial size and type of kick; Mud fluid base and rheology; Minimum sensitivity of the measuring systems But remember Gas kicks are more difficult to detect than oil /water due to its compressibility ...

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2 Incorrect 2. I t Fill-up Fill During D i Trips T i

If the hole does not take the correct volume of mud for the volume of pipe pulled from the hole then an influx has probably been swabbed into the well bore The driller and mud loggers should be maintaining independent records of volume taken to fill the hole for every 5 stands If the hole fill is not correct go back to bottom and circulate bottoms up to check what is at the bottom of the hole
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The U-Tube Analogy gy

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3. Decrease 3 a in Standpipe a dp p Pressure/Increase u / a in Pump Rate

The circulation system is a U U-tube tube. An influx of fluid into the annulus creates an imbalance resulting in a decrease in hydrostatic pressure in the annulus. annulus In such an unbalanced system system, gravity helps move drilling fluid down the hole, requiring less energy from the pump. This will result in a decrease in the standpipe pressure

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4 Increase/Decrease 4. I /D in i Drillstring D ill t i Weight W i ht

Any influx into the wellbore from the formation reduces the buoyancy of the annular drilling fluid. A sensitive weight indicator will register this change in weight as an increase in drill string weight. For very large kicks, fluid may enter the annulus with enough g force to cause a decrease in indicated string weight.

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P Potential i l Ki Kick k Indicators I di

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1. Increase in Penetration Rate (Drilling Break)

A marked increase in rate of penetration (ROP) may indicate either changes in the type of formation being drilled or a reduction in the differential between the mud pressure and pore pressure. Generally, p y the following g parameters p affect the ROP: Rock type; Formation bulk density/porosity; Differential pressure; Bit type/wear; Drilling breaks are generally evidence of Hydraulics; porosity change. Drilling rate tends to Weight on bit; decrease with depth. Thus when a Rotary speed; drilling break occurs, it may be an Personnel/equipment. evidence of transition to an abnormal zone. It is crucial at this point to stop drilling and check for flows.
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2 Lost 2. L t Circulation Ci l ti

Loss of substantial quantity of mud into th formation the f ti will ill result lt i in reduction d ti i in hydrostatic column height in the annulus. If not checked, checked this can result in a kick kick.

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3. Changes 3 a g in Gas a Levels/Mud / ud Density/Conductivity

Gas extracted from the mud comes from one or more of the following sources: -

Liberated gas which is the measured gas from the return mud flow, released from the pore spaces of the drilled cuttings. It is th so-called the ll d background b k d gas during d i circulation. i l ti If there th is i overbalance, and the ROP is constant with flow rate, this liberated gas; Produced Gas enters the wellbore from adjacent permeable formations when underbalance exists. exists A background gas increase when ROP is constant is evidence of produced gas; Recycled gas is the gas recirculated into the hole. It appears on detection equipment as an increase in background levels; Contamination Gas results from chemical breakdown of mud additives; Connection gas and trip gas are short duration gas peaks caused by swabbing action.

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3. Changes 3 a g in Gas a Levels/Mud / ud Density/Conductivity

Depending on sensitivity level surface monitors should detect a relatively steady level of gas extracted from mud during normal drilling. This background gas level may show occasional variations i ti d depending di on penetration t ti rate, t mud d pumping i rate, t hydrocarbon content of section drilled. Under normal conditions, the background gas should remain within about 50% of local average It is crucial that all gas values must be reported whether average. they are significant or not. Thorough inspection of gas monitoring systems and calibration as part or routine maintenance exercise is essential to preventing potential disasters

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Connection and trip gas are most common while drilling. The connection gas peaks are a clear sign that pressures are near balance, making for optimum ROP. Swabbing is the main cause of connection/trip gas as it creates negative diff differential ti l pressure. . Effects Eff t of f gas expansion i at t surface are varied. Evidence includes: Rapid fall in flow line mud density; Increase in return flow; Mud pit level increase; Rapid increase in total gas or hydrocarbon levels.

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Well Control Equipments

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Well Kill Circulating System

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Blowout Prevention (BOP) System

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BOP Stack in Various Operation al Modes

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Annular Preventer
... consists of an annular rubber sealing element which, when pressure is applied, closes l around d th the drillpipe d ill i or kelly Since pressure can be applied progressively, p g y, the annular preventer can be made to close on any size or type of drillpipe A slight relaxation of pressure may allow a small leakage of fluid and permit the pipe to be rotated within the annular preventer or pulled (stripped) through, - slowly!
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Ram Preventer
Ram preventers use pairs of hydraulic rams and solid ram blocks to close around a o nd the pipe or shut off the hole. Ram preventers may be classified into three types depending on the blocks used internally:
Pipe Rams Blind Rams Shear Rams

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Ram Preventers
diameter of the pipe being used. A drillstring comprising different pipe sizes, sizes such as 3-inch 3 inch and 5-inch 5 inch drill pipe, pipe would require two sets of pipe rams to accommodate both sizes of pipe. These are also operated hydraulically, and close around the tubing portion of drill pipe when used.

Pipe rams: These have semi-circular openings that match the

is in the hole. If they are shut on drill pipe, they will flatten the pipe, but not necessarily stem the flow. flow

Blind rams: These are designed to close off the hole when no pipe

Shear rams: These are a form of blind rams that are designed to
cut drill p pipe p when closed. This will result in the dropping pp g of the drillstring below the BOP stack unless the stack is designed in such a way as to have a set of pipe rams below the shear rams on which a tool joint can be supported. They will stop the flow from the well. Shear rams are usually only used as a last resort when all other rams and the annular preventer have failed.
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Choke and Kill Lines

After the BOP is closed, high-pressure fluid can be released at carefully controlled rates by use of a hydraulically controlled valve (choke valve). The choke line carries these high pressure fluids to the choke. choke From here the flow goes through the poor-boy de-gasser which removes the free gas. It then returns to the pits for treatment and further de-gassing with the vacuum de-gasser The kill line is used to introduce heavy drilling fluid to the well through a check-valve on the BOP in order to control high formation pressures. It fills the borehole from the top (instead i t d of f using i th the drillpipe d ill i to t fill the th borehole b h l f from th the bottom). It is also used to fill the annulus when pipe is being tripped out

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Other Components
Diverter System
In certain cases, it may be necessary to allow the well to blowout in a controlled manner rather than be shut-in. This is common in shallow sections due to insufficient casing to contain a kick. In these circumstances, a diverter system will be used. This is a relatively low pressure system, often using the annular preventer to seal off the annulus below the flow line. The diverter line will then be opened below the annular preventer to allow the flow to be directed away from the rig.

Kelly y Cocks
The BOP stack can only be used to stop the flow of fluids from the annulus. Additional valves are used to stop the flow within the drillstring. These valves include kelly cock valves and internal blowout preventers. Kelly cocks are generally placed at the top and bottom of the kelly. kelly These valves may be installed as a permanent part of the drillstring or just when a kick occurs. They can be automatic or manually controlled and they consist of subs with valves that may be of a spring loaded ball type, a flapper valve type, or dart type. The drawback of these valves is that while preventing a blowout up the string 45 they prevent the shut-in drillpipe pressure from being monitored.

Choke Manifold
Control of the kick and kill fluids during kill operations is accomplished using a choke manifold. This manifold must be able to work under a variety of conditions, such as high pressure, with oil, gas, mud and water, and be capable of withstanding the effects of abrasive solids (sand and shale) in the ki k fluids. kick fl id The Th manifold if ld should h ld be b capable bl of f controlling t lli the th well ll using i one of f several chokes and be able to divert flow to one of several areas, such as reserve pits, burn pits, or degassers. Since vibrations occur during kill operations, p , the manifold must be securely y anchored down, , with as few bends as possible to prevent washouts under high pressure flow conditions.

Accumulator
The system used for closing the BOP's is a high pressure hydraulic fluid accumulator. Hydraulic fluid is stored under pressure, the pressure being provided by stored nitrogen. When hydraulic oil is forced into the accumulator by a small volume, volume high pressure pump, pump the nitrogen is compressed, compressed storing potential energy. When the BOP's are activated the pressured oil is released, either opening or closing the BOP's. Hydraulic pumps replenish the accumulator with the same amount of fluid that was used to operate the BOP. A Accumulators l t commonly l have h minimum i i working ki pressures of f 1200 psi i and d maximum working pressures of between 1500 and 3000 psi.
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Closing the Well In

The Blowout Preventer (BOP) Stack Closes the annulus Has multiple redundancies
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Protecting the Drill Pipe Side

The top valve is a FULL OPENING SAFETY VALVE. Installed on the drill pipe when a kick is taken while tripping. The lower valve is an INSIDE BOP - it is potentially DANGEROUS and its use should be avoided!
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Protecting the Drill Pipe Side

continued

To provide permanent protection in the d ill pipe drill i when h handling h dli a kick ki k a drilling d illi float valve should be used. This is a non-return non return valve installed immediately above the bit.

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