Well Control Course

Well Control Equipment

Shallow Gas

Introduction
Since years, shallow gas blowouts have jeopardized the oil industry
drilling operations, killed many people, and destroyed many rigs.
An analysis of well control statistics done by Veritec has revealed that:
• 33% of all gas blow outs: results from shallow gas kicks.
• 54% of shallow gas blowouts cause severe damage or total loss
of the drilling support, due to the failure of the diverter system.

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Shallow Gas

DIVERTERS,
is not the answer for shallow gas.
If any, move the rig off location.

Shallow Gas

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Shallow Gas

Shallow Gas

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Shallow Gas

Shallow Gas

Definition

• SHALLOW GAS is considered to be any gas accumulation encountered

during drilling at depth above the setting point of the first string of casing
intended for, or capable of pressure containment.

• SHALLOW GAS generally occurs as normally pressured accumulations

in shallow sedimentary formations with high porosity and high permeability

• Drilling through such gas bearing formation requires extreme caution.

Because of the difficulty in early detection of an influx while drilling top
hole sections , the gas, upon entering the wellbore expands and reaches
the surface very rapidly and with little warning.

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Shallow Gas

Evaluation & Planning

• SHALLOW SEISMIC SURVEY

• SHALLOW GAS PLAN SPECIFIC TO THE RIG / WELL

• DRILL A PILOTE HOLE, NORMALLY 9 7/8” OR LESS

Shallow Gas
Preparation
• RESERVE OF HEAVY MUD
- WILL BE 1 TO 2 ppg HEAVIER THAN THE MUD WEIGHT BEING USED.
-THE MINIMUM VOLUME WILL BE THE CALCULATED ANNULAR VOLUME
FOR THE SECTION TD.

• ALL MEASURING INSTRUMENTS

- MUST BE CALIBRATED AND IN GOOD CONDITION
- THE MOST RELIABLE INDICATOR REMAINS THE FLOW OUT SENSOR.

• CLEAR DRILLING OR TRIPPING PROCEDURE

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Shallow Gas
Prevention
• FLOW-CHECKS WILL BE MADE EVERY TIME A PROBLEM IS
SUSPECTED, AND EACH CONNECTION WILL BE SYSTEMATICALLY
FLOW-CHECKED WHILE DRILLING IN POTENTIAL SHALLOW GAS
ZONES.

• DRILLING RATE SHOULD BE CONTROLLED TO PREVENT EXCESSIVE

BUILD UP OF SOLIDS WHICH COULD CAUSE FRACTURING OF THE
FORMATION AND RESULT IN LOST CIRCULATION.

• SWABBING MUST BE PREVENTED WHILE TRIPPING OUT OF HOLE

IF NECESSARY THE DRILLSTRING SHOULD BE PUMPED OUT

Schlumberger Policies: I.14

A float (solid or ported) will be run while drilling and opening hole prior to
setting surface casing or any time the posted well control plan is to divert.

Shallow Gas

IF THE WELL START TO FLOW WHILE DRILLING

– DO NOT STOP PUMPING

– OPEN DIVERTER LINE AND CLOSE DIVERTER
– INCREASE PUMP SPEED
– SWITCH TO HEAVY MUD (MONITOR VOLUME)
– RAISE THE ALARM
– START EVACUATION PROCEDURE

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Diverter with Annular Packing Element

Flow line
Annular packing
to Shakers
element

Head
Piston
Diverter
open port

Diverter Body
close port

Functions should
Vent line to
be interlocked over board

Diverter with Insert Type Packer

Functions should Drill pipe

be interlocked Insert packer

lockdown dogs

Diverter close port

Diverter
lockdown dogs

Standard packer
Flow- Line Seal
Insert packer

Flow / Vent line

Support
housing
Flow- Line Seal

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Diverter
Wind

What is the position of the valves while drilling?

If the diverter needs to be operated, what will be the sequence?

Minimum Diverter Requirements

• CLOSING TIME SHOULD NOT EXCEED 30 SECONDS FOR

DIVERTERS SMALLERS THAN 18 3/4’’ AND 45 SECONDS FOR
DIVERTERS OF 18 ¾’’ NMINAL BORE AND LARGER
• A DIVERTER HEAD THAT IS CAPABLE OF PACKING OFF
AROUND THE KELLY, DRILL PIPE OR CASIND WILL BE USED
• AT LEAST TWO RELIEF LINES SHALL BE INSTALLED TO
PERMIT VENTING OF THE WELL-BORE RETURNS AT OPPOSITE
ENDS OR SIDES OF THE RIG.
• ON LAND RIGS A SINGLE LINE IS ACCEPTABLE
• THE DIVERTER RELIEF LINE(S) SHALL BE AT LEAST 8 INCH
DIAMETER.

Schlumberger Policies: I.19

THE DRILLER WILL CHECK ALL DIVERTER AND OVERBOARD
VALVES FOR PROPER SETTING AT THE BEGINNING OF EACH TOUR.

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API RP 53 - Installation

Remember !!!
A diverter is not intended to be a well control device:
it just allows for the flow to be diverted in a safe manner,
to contain the hazard for as long as possible, so as to
leave enough time for proper and safe evacuation of
personnel and/or move off from the location.

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Shallow Gas
It has been widely
demonstrated that the
original design concepts
underestimated the fact that,
most of the time, surface gas
blowout produce a huge
amount of gas and abrasive
solids, flowing at very high
velocity, quickly eroding and
destroying most of the
existing diverter
components, and causing
fire and/or explosion.

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Accumulator Unit

Accumulator Unit

3000

1500

1500

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Accumulator Systems

THE ACCUMULATOR BOTTLES ARE CONTAINERS THAT STORE

HYDRAULIC FLUID UNDER PRESSURE TO:

- DECREASE BOP FONCTIONS RESPONSE TIME.

- BE ABBLE TO SHUT IN THE WELL, IN CASE OF POWER FAILURE.

- VOLUME OF ACCUMULATOR BOTTLE: 10 gal

- WORKING PRESURE: 3000 psi

- NITROGEN GAS IS USED TO PRE-CHARGE ACCUMULATOR BOTTLES.

- MINIMUM PRECHARGE PRESSURE: 1000 psi

- MINIMUM OPERATING PRESSURE: 200 psi ABOVE PRE-CHARGE

Bladder Type

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Floating Type
P X V = CST

1000 psi X 10 gal = 10,000

VOL gas = CST / PRESS

CST 10,000
PRESS.

V. gas
BOTTLE

V. oil

USABLE FLUID =

API RP 53 - Accumulator

Usable Hydraulic fluid is:

The fluid recoverable from the accumulator system between
the maximum accumulator pressure and 200 psi above pre-
charge pressure.

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API RP 53 – Accumulator Capacity

The BOP control system should have sufficient usable
hydraulic fluid volume, with pumps inoperative, to:
- Close one annular
- Close all rams
- Open one HCR
The remaining pressure will be 200 psi or more above the
minimum pre-charge pressure.

Accumulator Capacity
Schlumberger Standard

The accumulator volume of the BOP systems will be sized to keep

a remaining stored accumulator pressure of 200 psi or more
above the minimum recommended pre-charge pressure after
conducting the following operations (with pumps inoperative):
• Close all ram and annular functions and open all HCR valves.
• Open all ram and annular functions and close all HCR valves.
• Close the annular.
• Open the remotely operated choke line valve.

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API RP 53 – Reservoir Capacity

Each closing unit should have a fluid reservoir
with a capacity equal to at least twice the
usable fluid capacity of the accumulator system

Accumulator Capacity
Schlumberger Standard
EXAMPLE:

BOP Equipment: 1 Annular + 3 Rams + HCR Valve

Closing Volume (CV): 20 + (3 x 10) + 1 = 51 Gal

Opening Volume (OV): 20 + (3 x 10) + 1 = 51 Gal
Closing Volume (CV): 20 = 20 Gal
Open Choke Line Valve (OV): 1 = 1 Gal

Usable Volume (UV): = 123 Gal

Nominal Volume (NV): 2 x UV = 246 Gal

25 accumulator bottles

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API RP 53 - Minimum Calculated Operating Pressure:

Is the minimum pressure to effectively close and seal a ram

BOP against a well bore pressure equal to the maximum rated
working pressure of the BOP.
This pressure is equal to the maximum working pressure of the
BOP divided by the closing ratio specified for that BOP.

API RP 53 – Pumps Systems

With the accumulator isolated from service:
The pump system should be capable of closing the annular on
the minimum size drill pipe being used, open the remote
operated choke valve and provide the operating pressure level
recommended by the annular BOP manufacturer to effect a
seal on the annulus within 2 minutes.

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API RP 53 – Pumps Systems

Each surface BOP control system should have a

minimum of 2 pump system having independent
power sources, such as electric or air.

API RP 53 – Pumps Systems

•Each pump should provide a discharge pressure at least
equivalent to the BOP control system pressure.
•Air pumps should be capable of charging the
accumulators to the system working pressure with 75 psi.

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API RP 53 – Pumps Systems

Each pump should be protected from over pressurization by
a minimum of 2 devices.
•One device (pressure limit switch) should limit the discharge pressure so
that it will not exceed the working pressure of the BOP control system.

•The second device (relief valve) should be size to relieve at a flow rate at
least equal to the design flow rate of the pump and should be set to relieve
at not more than 10 % over the control unit pressure.

API RP 53 – Pumps Systems

Electric, and or, air supply should be

available at all times such that the
pumps will automatically start when the
system pressure has decreased to
approximately 90 % of the system
working pressure and automatically
stop within +0 to - 100 psi of the
control system working pressure.

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API RP 53 – BOP Response Time

Response time between activation and complete operation of a
function is based on BOP closure and seal off.

SURFACE
18 3/4” 18 3/4”

30 sec. 45 sec.

30 sec.

Remote valves should not exceed the minimum observed ram BOP

Choke Manifold
At least three flow paths must be provided that are
capable of flowing well returns through conduits that are
76.14 mm (3”) nominal diameter or larger.

At least one flow path:

• Shall be equipped with a remotely controlled, pressure operated
adjustable choke. Simplified choke manifolds without remote control
choke may be acceptable on light rigs with 2 – 3K psi stacks

• Shall be equipped with a manually operated adjustable choke

• Must permit returns to flow directly to the pit, discharge manifold or

other downstream piping without passing through a choke.
Two gate valves with full rated working pressure must be provided in
this unchoked path

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API RP 53 – Initial Pressure Test

The initial pressure test on components that

could be exposed to well pressure should be
to the rated working pressure of the ram
BOP or to the rated working pressure of the
well head ( whichever is lower).

Annular may be tested to a minimum of 70%

of the annular preventer working pressure.

API RP 53 – Initial Pressure Test

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Packing Unit

Pressure Test Schlumberger

Low Pressure Test

. 200 – 300 psi for 5 minutes prior to each high pressure test.

High Pressure Test

. Rams-type BOPs and related control equipment including
the choke manifold shall be tested at the anticipated surface
pressure.
. Annular will be tested to 50 % of the rated working pressure
of the components.
. All high pressure tests will be conducted for 10 minutes.

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API RP 53 – Choke Manifolds & Kill Lines

• Manifold equipment subject to well

pressure (up-stream including the choke)
should have a minimum working
pressure at least equal to the rated
working pressure of the ram BOP in use.
• All choke manifold valves should be full
bore.
• Function Tests: at least once a week.

Shell Test
The body of new BOP’s are subjected to a
hydrostatic proof testing or shell test prior shipment:
Rated Working API Size Designation API Size Designation
Pressure (psi) 13 5/8 and Smaller 16 3/4 and Larger
2,000 4,000 3,000
3,000 6,000 4,500
5,000 10,000 10,000
10,000 15,000 15,000
15,000 22,500 22,500
20,000 30,000 ---

The hydraulic operating chamber shall be tested at a minimum test pressure equal
to 1.5 times the operating chamber’s rated working pressure.

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Tester Cup & Tester Plug

Ring Gaskets

Type “R”

“X” type are

pressure energized
Type “RX” meaning that well
pressure helps to
effect the seal

Type “BX”

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Ring Grooves

The most common ring grooves are:

• API 6B - 2,000 / 5,000 psi
• API 6BX - 2,000 / 20,000 psi
---------------------------------------------------

Ring gaskets to be used for specific grooves are:

• API 6B - use API type “R” or type “RX”
• API 6BX - use API type “BX”

Exercise

Which pressure energized ring gasket can match with a

ring groove API 6B ?

- BX
-R
- RX

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Flange Types

Stand-off Closed Face

gives gives
instability stability

BX
R or RX Ring Gaskets
Ring Gaskets

API 6B Flange API 6BX Flange

Nominal Size

What does this mean ?

a 3-1/16 , 10 000 flange

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Connection

Studded

Clamp Hub

Flanged

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Annular BOP’s
They are design to:

- Be closed on an open well (should be avoided)

- Reciprocate or rotate the string while maintaining a seal
against the well bore.(need approval during WC situation)
- Seal around a square or hexagonal Kelly.
- Pass the tool joints through while stripping.

They can be operated with a variable Operating Hydraulic Pressure.

Hydril GX

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Hydril GL

1- Latched Head
2 - Opening Chamber Head
3 - Opening Chamber
4 - Closing Chamber
5 - Secondary Chamber
6 - Piston Seals
7 - Piston
8 - Packing Unit

Cameron DL

Quick-Release Top

Donut
Packer
Access Flaps
Outer Cylinder
Locking Grooves Lock Down
Packer Insert Vent Port
Operating Piston
Pusher Plate
Closing Hydraulic Port
Opening Hydraulic Port

Vent Port

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State the Rating Operating Pressure
Manufacturer’s Data

Hydril GL: Secondary Chamber

Standard Surface Hookup Optional Surface Hookup

Connects the secondary chamber to the Connects the secondary chamber to the
opening chamber closing chamber
- Least amount of fluid - Least amount of closing pressure for
optimum closing force
- Fastest closing time

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Safety Valves

Schlumberger Policies: I.22

Any time a trip is interrupted the hand tight installation of a safety
valve is required.

Schlumberger Policies: I.23

A minimum of one safety valve and one inside BOP with
appropriate cross-overs will be available on the rig floor at all times,
including a circulating head when running casing. A proper means
of handling will be provided to assist with its installation.

Full Opening Safety Valve

Upper seat

Ball

Crank
Lower Seat

Body

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Inside BOP’s
Release Rod
Locking Screw Release tool

Valve Release rod

Upper Body

Seat
Valve

Valve Spring
Lower Body

Float Valves

USED TO:
• Prevent sudden influx entry into the drill string.
• Prevent back flow of annular cuttings from
plugging bit nozzles.

Schlumberger Policies: I.14

A float (solid or ported) will be run while drilling and
opening hole prior to setting surface casing or any
time the posted well control plan is to divert.

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Cameron Type - U
Operating
Piston Operating
Bonnet Cylinder

Ram change
cylinder
Ram change piston

Seal Rings Assy.

Bonnet

Ram Assy.

Body
Intermediate
Flange

Shaffer Rams - NL

Block Retaining screw

Rubber Holder

Retaining screw

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Cameron Variable Bore Ram Assy.

Top Seal
Packer

Body

Shearing Blind Rams

Upper Shear Ram Top Seal

Blade
Side Packer
Lower Shear
Ram assembly

Face Seal

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Cameron Manual Lock

Cameron Wedge Lock

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Hydril MPL (Multiple Position Lock)

Hydraulically-actuated mechanical clutch mechanism

Shaffer Ultralock

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Shaffer POSLOCK (One Position Locking Mechanism)

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Mud Gas Separator

Circulating through
Circulating through MGS, above design
MGS, no gas no capacity, unloading
pressure gas to shakers

Circulating gas Possible

through MGS, within improvement of
design capacity mud seal height

Typical Offshore Set-up Typical Land Rig Set-up Typical Offshore Set-up Typical Land Rig Set-up

The mud gas separator is a low pressure vessel

Mud Gas Separator

1 - Diameter and length of the vent line
GAS

controls the amount of back pressure in

Baffle Plate MGS

From Choke
Manifold 2 - Diameter, height and internal design
controls the separation efficiency in MGS

Siphon Breaker

Mud
To Shakers
3 - Height of the “U” tube control the
working pressure and the fluid level
to stop the gas going out of the MGS

Drain Line with valve

The function of the MGS is to mechanically separate gas from the mud.

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Mud Gas Separator
Vent Line
650 psi

0 psi

• A gas kick is being circulated

out of a well.
• The slow circulating rate is
40 spm.
• The pump output is .119
bbls/stk.
• That means 4.76 Barrels of
mud are passing through the
Mud Gas Separator (MGS)
every minute.
Mud Seal : 20 ft

Mud Gas Separator

Vent Line
650 psi
0 psi

• The mud weight is 10 ppg and

has a pressure gradient of 0.52
psi/ft.
• The MGS shown here has a
Mud Seal that is 20 feet high.
• So once it is full of our 10 ppg
mud it would take a gas
pressure of 10.4 psi from
within the separator to
evacuate the mud seal.
Mud Seal : 20 ft

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MGS – Gas at Surface
1000 psi Vent Line • We now have gas at
surface, and the annulus
8 psi pressure has risen to 1000
psi.
• Because we are still
pumping at 40 spm which
is 4.76 bbls/min. To keep
bottom hole pressure
constant we must bleed off
the same amount of gas.
• Because the gas up
stream of the choke is at
1000 psi and we are
bleeding it down to
atmospheric pressure
(14.72 psi) ,the volume, as
Mud Seal we know from Boyles law
does not remain the same.

MGS – Gas at Surface

1000 psi Vent Line • We now have gas at
surface, and the annulus
8 psi pressure has risen to 1000
psi.
• Because we are still
pumping at 40 spm which
is 4.76 bbls/min. To keep
bottom hole pressure
constant we must bleed off
the same amount of gas.
• Because the gas up
stream of the choke is at
1000 psi and we are
bleeding it down to
atmospheric pressure
(14.72 psi) ,the volume, as
Mud Seal we know from Boyles law
does not remain the same.

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Gas Expansion Through Choke
1000 psi Vent Line
• Using boyles law we can find
8 psi how much gas per minute we
would have down stream of the
choke.
• Boyles laws states;
P1 V1 = P2 V2
• We know our pressure up
stream of the choke whitch is
Gas expansion through 1000 psi, so this is our P1.
the choke.
• At 40 spm our volume of flow is
P1 = 1000 psi 4.76 bbls/min so this is our V1.
V1 = 4.76 bbl/min
P2 = 14.72 psi • And our pressure down stream
of the choke is atmospheric at
14.72 psi.

Mud Seal

Gas Expansion Through Choke

1000 psi Vent Line • At 40 spm the amount of gas
escaping up the vent line is 323
8 psi bbls/min.
• This large volume of gas
causes a back pressure due to
friction losses that is
proportional to the Inside
Gas expansion through Diameter (ID) and length of the
the choke.
Vent line.
P1 = 1000 psi • The larger the ID and shorter
V1 = 4.76 bbl/min the length of the vent line the
P2 = 14.72 psi
less the back pressure in the
1000 x 4.76 = 4760 MGS.
4760 • As long as this back pressure
14.72 = 323 bbl/min
does not exceed the hydrostatic
pressure of the mud seal. Gas
Mud Seal should not travel down to the
shakers.

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Blow Down Line
1000 psi • The easiest and safest way of
preventing the loss of the mud
8 psi seal is to reduce the pump
speed, if the pressure in the
MGS approaches 85% of the
mud seal hydrostatic pressure.
• A blow down line can also be
fitted. This is an overboard line
that is fitted with a pilot
operated valve controlled by
Blow Down computer.
line • This system sounds an audible
alarm when the MGS safe
pressure is exceeded. If the
pressure in the MGS is not
reduced within a given time
Mud Seal period the blow down valve is
opened.

Mud Gas Separator

Vent line

What is the maximum operating pressure

From Choke
of this MGS with 11.3 ppg mud ?
Manifold
MGS

22’

To Shale
Shakers

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Vacuum Degasser

The Vacuum De-gasser is designed to remove the

small bubbles of gas in mud:
• Left after passing through the MGS
• In case of gas cut mud
• When circulating any trip gas

The Vacuum De-gasser will be line up at all times during the Well
Control operation and should be tested every tour.

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