INTRODUCTORY WELL CONTROL
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MODULE 1 :
INTRODUCTION
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In the oil and gas industry, an ‘out of control’
well is the biggest threat to life, equipment
and the environment.
When a well is ‘out of control’, it is called a
BLOWOUT.
Drilling Contractors are in the frontline for
preventing such incidents because they:
i)Drill the hole
ii)Open up the formation for the first time
since it was deposited 10s or 100s of millions
of years ago
iii)If hydrocarbons exist, they are the first to 1
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In the oil and gas industry, an ‘out of control’
well is the biggest threat to life, equipment
and the environment.
When a well is ‘out of control’, it is called a
BLOWOUT.
Drilling Contractors are in the frontline for
preventing such incidents because they:
i)Drill the hole
ii)Open up the formation for the first time
since it was deposited 10s or 100s of millions
of years ago
iii)If hydrocarbons exist, they are the first to 1
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If the formations which are drilled have
high pressures and are not able to
control, then a Blowout is likely to occur. A
Blowout means we have lost control; it
means the fluids in the formation(gas, oil
or water) are escaping the wellbore all the
way to the surface. If these formation
fluids are flammable and/or toxic, the rig
is likely to burn down; people would be
killed and damage to the environment
would occur.
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Drilling Contractors greatest exposure
to risk is with Blowouts. Preventing
Blowouts is, therefore, an essential part
of day to day operation.
First line of defense against a Blowout
is pressure exerted by the drilling mud,
called HYDROSTATIC PRESSURE. It is
this pressure that acts against the
fluids in formation, preventing them
from entering the
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wellbore. This is known as PRIMARY
Well Control.
If we underestimate the formation fluid
pressure, the mud hydrostatic will not
be enough to control the well. In this
case, it is very likely that formation
fluids will force their way into the
wellbore causing mud to be pushed out
of the hole at the surface.
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If this happens, the well is said to be
‘kicking’. In other words, we have taken a
KICK.
Because the Kick is displacing(pushing)
mud out at the surface, we should be able
to detect this by watching the mud flow
rate from the well and the level of mud in
the mud pits. If either increases, then it is a
sign(indication) that a kick could be
occurring downhole.
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We therefore have to continuously
monitor Flow Rate and Pit Level and set
alarms to tell us of any changes.
Having recognized something may be
going wrong downhole; we prepare to
shut in the well. If we did nothing at this
stage, all the mud would eventually be
pushed out of the hole meaning that
there would be a Blowout.
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To shut in the well, we stop drilling,
raise the bit at selected distance off
bottom, shut off the mud pump and
check to see if the well is flowing on its
own(that is without the pumps running).
If it is flowing, then we assume there is
a kick. The next thing to do is shut in
the well by operating the Blowout
Preventers(BOP)
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The Blowout Preventer equipment seals
off the Annulus and inside the drill
string, preventing any further flow from
the well. These Blowout
Preventers(BOPs) are our second line of
defense; hence, they give us
SECONDARY control
Primary Control = Mud Hydrostatic
Secondary Control = BOPs
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We therefore start with two lines of
defense. If we take a kick, then we
have to rely on the BOPs; if they fail,
then a Blowout will soon follow
Both lines of defense are vital; we must
make every effort to prevent a kick by
having the correct mud in the hole, and
preventing a kick becoming a Blowout
by keeping the BOPs in first class
condition.
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Therefore, care of the mud and care of
the BOPs must have the highest
operational priority on the rig. If we do
take a kick and shut the well in, the
next step is to ‘kill the well’. This
means raising the mud weight to a
value that will restore PRIMARY control
and pumping it around the well so that
it replaces the old mud.
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If the Kill is carried out correctly, then
the well would be dead; we can open
up the BOPs and mud hydrostatic
would hold back formation fluids.
Primary Control is restored.
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WELL CONTROL CYCLE
PRIMARY (Mud)
PREVENTION
KILL WELL TAKE KICK
SHUT IN WELL
SECONDARY (BOP)
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MODULE 2 :
CAUSES OF KICK
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TOPICS:
Definitions
Primary Control
Hydrostatic Pressure and Gradient
Pressure Balance
Causes of Kicks
-Reduction in Hydrostatic Pressure
-Increase in Formation Pressure
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BLOWOUT: An uncontrolled exit at the
surface of formation fluids from the
borehole.
The warning that a Blowout could occur
is called a Kick
KICK: An influx of formation fluids into a
borehole that causes an equal volume
of drilling fluid to be displaced out of
the hole.
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There are 3 stages of control to stop
Blowouts.
1)PRIMARY CONTROL: Pressure exerted by
drilling fluid to hold back the formation
2)SECONDARY CONTROL: Surface
equipment that is closed to stop any
further entry of formation fluids
3)TERTIARY CONTROL: Techniques to
control a Blowout once it is taking place
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PRIMARY CONTROL
Drilling fluid has weight. A column of
drilling fluid exerts a pressure on the
walls of the hole and on the bottom.
When the mud is not being
circulated(static), this pressure exerted
is called the Mud Hydrostatic Pressure
Hydrostatic Pressure is a function of :
DEPTH and MUD DENSITY(WEIGHT)
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Mud Weight
The Mud weight is the density ( mass per unit volume ) of a
drilling fluid.
Mud Weigth can be expressed in:
Pound per Gallon ( ppg )
Pound per Cubic Feet ( pcf )
Specific Gravity ( sg )
Pounds per gallon ( ppg ) is generally used for mud weight.
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Pressure
The pressure is a force or weight per
unit area exerted by a gas or liquid
against the walls of a vessel, hole, or
object inserted into said gas or liquid.
Pressure can be expressed in:
Pounds per square inches ( psi )
Kilograms per square centimeters ( kg / cm²)
Transocean usually use pounds per square inches ( psi ) for
the pressure.
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Derivation of
0.052
A cubic foot contain 7.48 US gallons.
If the fluid used to fill the cube weights 1
ppg, then the cube would weight 7.48
pounds.
The base of the cube has: 12x12=144
square inches.
7.48/144=0.05194
A 1 foot column of 1ppg fluid
exerts a pressure of 0.052 psi
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Pressure or Mud
Gradient
Since the pressure is measured in psi and depth is measured in
feet, it is convenient to convert mud weights from ppg to a
pressure gradient in psi/ft.
The conversion factor is 0.052
Pressure gradient (psi/ft) = Fluid Density (ppg) x 0.052
Example:
A fluid having a mud weight of 10 ppg will have:
10 x 0.052 = 0.52 psi ft as a pressure gradient.
A 1 foot column of 10 ppg mud will have a pressure of 0.52 psi
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Practical Exercise # 27
Calculate the pressure gradient for the following mud weight:
1- MW = 12 ppg PG = psi / ft
2- MW = 14 ppg PG = psi / ft
3- MW = 9.4 ppg PG = psi / ft
4- MW = 17 ppg PG = psi / ft
5- MW = 12.5 ppg PG = psi / ft
6- MW = 11.3 ppg PG = psi / ft
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Practical Exercise # 28
Calculate the mud weight for the following mud gradient:
1- PG = 0.478 psi / ft MW = ppg
2- PG = 0.754 psi / ft MW = ppg
3- PG = 0.684 psi / ft MW = ppg
4- PG = 0.465 psi / ft MW = ppg
5- PG = 0.445 psi / ft MW = ppg
6- PG = 0.455 psi / ft MW = ppg
7- PG = 0.623 psi / ft MW = ppg
8- PG = 0.587 psi / ft MW = ppg
9- PG = 0.52 psi / ft MW = ppg
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Hydrostatic Pressure
Hydrostatic Pressure is the pressure exerted by a column of
fluid ( at rest )and is calculated by multiplying the gradient
of the fluid by the True Vertical Depth at which the pressure
is being measured:
Hyd Pressure(psi) = Fluid gradient (psi/ft) x TVD
Example:
What is the hydrostatic pressure at 10,000 ft for a mud
gradient of 0.52 psi /ft ?
Hyd Pressure(psi) = 0.52 x 10,000
Hyd Pressure = 5,200 psi
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Hydrostatic Pressure
It is the vertical height/depth of the fluid column that matters, its
shape is unimportant !!!!!!
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• The essential properties of reservoir rocks are:
• - Their porosity and permeability.
• The porosity provides the storage space for fluids and gases and
is
• the ratio of the pore spaces in the rock to the bulk volume of the
rock.
• This is expressed as a percentage. Reservoir rocks commonly have
• porosity’s ranging from 5% to 30%.
• Formation permeability is a measure of how easy the fluid
will flow
• through the rock. Permeability is expressed in Darcys, from a few
• milliDarcys to several Darcys.
• These properties will determine how much and how quick a kick
will enter into the well. Kicks will enter a wellbore faster from rocks
having high permeability. 12
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Practical Exercise # 29
Calculate the hydrostatic pressure:
1- PG = 0.478 psi / ft TVD = 8,000’ HP = psi
2- PG = 0.754 psi / ft TVD = 8,000’ HP = psi
3- PG = 0.684 psi / ft TVD = 8,000’ HP = psi
4- PG = 0.465 psi / ft TVD = 8,000’ HP = psi
5- PG = 0.445 psi / ft TVD = 8,000’ HP = psi
6- PG = 0.455 psi / ft TVD = 8,000’ HP = psi
7- PG = 0.623 psi / ft TVD = 8,000’ HP = psi
8- PG = 0.587 psi / ft TVD = 8,000’ HP = psi
9- PG = 0.52 psi / ft TVD = 8,000’ HP = psi
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Hydrostatic Pressure
Using the formula for the pressure gradient and for the hydrostatic pressure:
Pressure gradient (psi/ft) = Fluid Density (ppg) x 0.052
Hyd Pressure(psi) = Fluid gradient (psi/ft) x TVD
We can write:
Hyd Pressure(psi) = Fluid Density (ppg) x 0.052 x
TVD
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Hydrostatic Pressure
It is usefull to visualize the well as a U-tube.
One column is for the pipe in the well and the other column is for the
annulus.
If the same fluid is used is both columns, hydrostatic would be equal and
the fluid would be static on both sides of the tube.
Mud Hydrostatic Mud Hydrostatic
in the string in the annulus
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Hydrostatic Pressure
If the pipe or the annulus are not kept full, then the hydrostatic pressure
in reduced.
Pipe is not full Annulus is not full
HP is reduced HP is reduced
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Practical Exercise
Calculate the HP:
1- Hydrostatic pressure of a column of mud 3,000 feet high filled with 9
ppg mud is psi.
2- Hydrostatic pressure exerted by a column of mud 2,000 feet high is
1,500 psi. The mud weight is ppg.
3- The hydrostatic pressure exerted by 12 ppg mud in a well is 1,700
psi. The true vertical depth of the well is ft.
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Practical Exercise
4- The pressure gradient of 13.5 ppg mud in 1,000 feet of hole is
psi/ft.
5- The hydrostatic pressure of one barrel of 13.5 ppg mud in an
annulus of capacity 0.112 bbl/ft is psi.
6- The mud gradient is 0.780 psi/ft at 11000 feet MD/10000 feet
TVD. What is the Hydrostatic pressure on bottom?
psi
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Practical Exercise
7- What is the mud weight if the hydrostatic pressure is 3000 psi at 4675
feet?
8- What is the equivalent mud weight for 4000 psi at 8000 feet?
9-
The TVD is 4500 feet, and the pressure is 3300 psi. What is the
equivalent mud weight?
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Practical Exercise # 32
10- What is the equivalent mud weight at 8500 feet TVD, 9500
TD with 4900 psi?
11- Change the pressure of 8500 psi into an equivalent mud
weight for a depth of 12000 feet MD/11000 feet TVD.
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Balanced
Balanced when Hydrostatic Pressure = Formation Pressure
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Under Balanced
Under Balanced when HP < FP
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Over Balanced
Over Balanced when HP > FP
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STUCK PIPE
The portion of the drillstring that cannot be rotated or
moved vertically.
Differential sticking.
Differential sticking typically occurs when high-contact
forces caused by low reservoir pressures, high wellbore
pressures, or both, are exerted over a sufficiently large
area of the drillstring
Formation Fracturing.
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To hold formation fluids back, the Mud
Hydrostatic Pressure must at least
equal the Formation Fluid Pressure
Kicks occur when UNDERBALANCED
Common drilling practice is to drill
slightly OVERBALANCED in the region
of 0.3 to 0.5ppg
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Causes of UNDERBALANCE are:
1)REDUCTION IN MUD HYDROSTATIC
PRESSURE
This can be caused by:
a) Drop in level of mud in hole
b) Drop in mud weight
c) Swabbing
d) Problems during cementing
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2) INCREASE IN FORMATION FLUID
PRESSURE
This can be caused by:
a) Trapped formation fluids
b) Salt Domes
c) Artesian Effect
d) Faults
e) Gas Cap
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CAUSES OF MUD HYDROSTATIC
REDUCTION
a) Drop in Mud Level
This is due to failure to fill hole when
pulling out
A 400ft drop in the level of 10ppg mud
will reduce Mud Hydrostatic by : 10ppg
X 0.052 X 400ft = 208psi
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Mud Hydrostatic with full Hole:
=10 X 0.052 X 10000 =5200psi
Mud Hydrostatic with drop of 400ft :
=5200 – 208 = 4992psi
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One cause of a KICK due to mud level
drop is LOST CIRCULATION
If a formation cracks or fractures, the
drilling mud can be lost. This causes
the mud level to drop. Mud level drop
means reduced Hydrostatic load.
A Kick can occur because Formation
Fluid Pressure may now be higher.
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The CAUSE OF LOST CIRCULATION is:
HIGH MUD WEIGHTS or HIGH SHUT IN
PRESSURES or SURGING
If the pressures on a formation are too
high, then Lost Circulation will occur.
This is why only a SLIGHT Overbalance
pressure is recommended drilling
practice.
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b) Drop in Mud Weight: This is due to
failure to hold mud weight constant.
Mud Hydrostatic shown previously was
5,200 psi with 10,000ft and hole full of
10ppg mud
If Mud weight dropped to 9.5ppg, then
the Hydrostatic Pressure would be:
=9.5 x 0.052 x 10000 = 4940psi
A drop of 260psi
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Failure to keep the hole full during trips
and failure to hold mud weight at
desired level is NEGLIGENCE
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c) Swabbing
When pulling out of the hole, the bit
acts like a piston. The sucking action
causes a temporary reduction in Mud
Hydrostatic Pressure. This short period
of UNDERBALANCE can allow Formation
fluids to enter the well bore. It occurs
only when the pipe is being pulled.
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FACTORS THAT CONTRIBUTE TO
SWABBING:
a) Pulling pipe too fast
b) High Viscosity mud
c) Small collar to hole wall clearance
d) ‘’Balled up’’ bit
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TO DETECT SWABBING:
Fill the hole with mud when pulling out
It should take a volume of mud EQUAL
to the volume of STEEL removed
Filling the hole during a trip is called
TRIP MONITORING
The Driller keeps a check to see if the
hole is taking the CORRECT
CALCULATED quantity of mud
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IF THE HOLE IS NOT TAKING CORRECT
VOLUME:
Run back to bottom, condition and
circulate bottoms up
HOLE TAKING TOO MUCH:
Possible lost circulation
HOLE TAKING TOO LITTLE:
Possible swabbing of Formation Fluids
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Running in the Hole can cause
SURGING
Surging can cause formation fracture
and lost circulation
To prevent of Swabbing when pulling
out, the mud weight is kept about 0.3
to 0.5ppg above Formation Pressure.
This extra margin is called TRIP
MARGIN
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d) Problems During Cementing
When Cementing, there is always a risk
that hydrostatic pressure could be
affected. Four possible causes of this
are:
1. Drop in Hydrostatic as Cement
Starts to Harden
When cement begins to change from a
liquid to a solid, it loses some of its
hydrostatic pressure before setting.
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This loss may be enough to go
underbalance and allow a kick to enter
the wellbore. Always monitor the well
as cement is setting.
2. Cement Channeling
If the cement does not form a good
bond against the hole wall or the
casing, then a Channel may form(may
be called a micro-annulus). Water
within the cement can fill this channel.
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If the channel occurs along the length of
the cement column and hydrostatic is
reduced, then it is possible for fluids to flow
from the formation and up the channel. The
Casing annulus must always be monitored
to check for pressure communication.
3. Lightweight Spacers
If you are using a low density scavenger
spacer, think how it will affect hydrostatic
pressure.
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Will it cause the well to flow? The effect
should be calculated before pumping
and you may need to consider a
weighted spacer.
4. Losses
Cement is normally heavier than the
mud, therefore, it is possible that losses
may occur. If the losses cause a drop in
the annulusfluid level, then it may
allow a kick to enter the wellbore.
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Correct planning of cement weights will
help minimize the risk of losses, but
always monitor fluid levels and be
prepared to keep the annulus full in the
event of losses.
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4)INCREASE IN FORMATION FLUID
PRESSURE
Kicks can also be caused by an increase
in the formation fluid pressure. Formation
pressure is the pressure of the fluids in
the pore spaces of the formation. These
fluids are mostly water, but can be
hydrocarbons such as gas or oil.
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When Formations are laid
down(deposited) in the sea, the space
between the grains of sediments(pore
spaces) is full of water. This water is
under ‘normal’ pressure. This means
the pressure is hydrostatic. On
average, formation water has a
pressure gradient of 0.465psi/ft. This is
equivalent to a mud weight of 8.95ppg.
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Abnormal Pressure can occur when the
fluid in the formation is trapped.
If Pressure were applied to a formation
either by more sediment being
deposited or by earth movements, then
the fluid in the pore spaces should
normally escape(much like squeezing a
wet sponge).
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If for some reason, the water is unable to
escape(trapped), it will pressure up. When
we drill an abnormally pressured formation
like this, the well may kick if we do not
have the correct mud weight. If we are
aware of a pressured formation, then the
mud weight can be raised before drilling
the section.
Abnormal Pressures are found all over the
world. Any formation drilled with a mud
weight in excess of 9.5ppg is abnormal.
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The causes of abnormal pressure
include:
Trapped fluids in thick shale sections
Pressure caused by salt domes
Artesian effects
Faulting
Gas Caps
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Primary Control is performed by the
Mud Hydrostatic Pressure
Primary Control is lost if:
a) Mud Hydrostatic Pressure drops
b) Formation Fluid Pressure rises
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Common Causes of Hydrostatic
Pressure drops are:
Failure to keep hole full during trips
Swabbing
Drop in mud weight
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Common Causes of Formation Fluid
pressure increase:
Trapped Formation Fluids
Proximity to Salt Domes
Artesian Well Effects
To help detect that Primary Control may
soon be lost, there are a number of KICK
WARNING SIGNS. This will be covered in
Module 2.
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MODULE 3 :
KICK WARNING SIGNS
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Many kicks give you warning before
they occur. But some kicks give no
warning at all.
If you can recognize the warning signs,
then remedial action can be taken to
re-establish SAFE Primary Control
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The most common warning signs are:
1. Improper fill up or displacement during
trips
2. Connection Gas
3. Increased Drilling Rate (ROP)
4. Increased Drill string Torque and Drag
5. Increased number and size of cuttings
6. Decreasing Shale Density
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IMPROPER FILL UP WHEN PULLING OUT
If the hole takes less than the correct
amount of mud to replace the steel
volume removed, then the hole is filling
up with formation fluids. That means
Swabbing is taking place.
Continued Swabbing will reduce the
Hydrostatic and Bottom Hole Pressure to
a level that will produce Underbalance
conditions. A kick will then occur.
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With improper fill up, you should return
to bottom, circulate and condition the
mud to obtain safe Primary Control.
Typical 5’’ OD Drill pipe has a steel
volume of 0.5 and 0.7 barrels per stand
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IMPROPER DISPLACEMENT WHEN
RUNNING IN
As steel is run into the hole, the drilling
fluid will be displaced and overflow. The
amount of overflow should be equal to
the steel volume run in. Overflow occurs
when lowering pipe and should stop
soon after slips are set. If overflow does
not cease, then the well may be flowing.
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If no overflow is noticed, then the
drilling mud may be leaking into the
formation indicating a fracture.
Correct procedure is to use proper Trip
Monitoring equipment when running in;
the same as should be done when
pulling out.
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GAS IN THE MUD
When gas enters the well bore, at the bottom
of the hole, it is under a pressure equal to the
Bottom Hole Pressure(Mud hydrostatic). This
is normal as any gas in the drilled formation
is released into the mud stream.
As it is circulated to the surface, the pressure
reduces causing the gas to expand. This
expansion can cause the mud weight to be
reduced or cut.
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As a general rule, something like 95%
of gas expansion takes place in the top
5% of the well.
The reduction in mud weight caused by
gas bubbles is called GAS-CUT MUD
and is an indicator of gas getting into
the well bore. It can reduce hydrostatic
on bottom, especially when the gas is
close to surface(maximum expansion.
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TRIP GAS – During trips, it is possible to
swab allowing some gas to enter the
wellbore. When bottoms up is circulated
after a kick, there is often a peak of gas
recorded by the Logger. This is called Trip
Gas.
CONNECTION GAS – Gas seen at the
surface bottoms up time after a
connection. It indicates mud hydrostatic is
low, but when circulating the BHP is
sufficient.
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Circulating the drilling fluid causes extra
pressure on the bottom. This extra
pressure is due to circulating friction in
the Annulus. When circulating is
stopped, this extra pressure is lost thus
reducing the Bottom Hole Pressure to
Mud Hydrostatic Pressure.
The presence of connection gas is a
sign to raise the mud weight a little.
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INCREASED DRILLING RATE
This is a gradual increase in Drill Rate(ROP).
This is common in Shale formation.
Trapped water cannot escape; therefore,
compaction is slowed down or halted.
Such formations with trapped water,
therefore, have greater pore spaces to hold
the water(POROSITY). This means there is a
lesser amount of Rock per unit volume of
Formation.
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Because the Drill Bit cuts rock not water,
the drilling rate will be faster than
expected(less rock to cut)
As we drill from normally pressured
formations(0.465psi/ft pressure gradient)
into abnormally pressured formations, the
amount of trapped water increases
gradually. Through the transition zone, the
Porosity increases and rock percentage
decreases. This causes a gradual increase
in Drill Rate.
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INCREASED DRILL STRING TORQUE
Torque is measured on the Rotary Table
and is displayed at the Driller’s Console.
Abnormally pressured or unstable
formations may have a tendency to close
up the hole and grip the string.
This effect will make the Drill string
harder to rotate and the Torque reading
will increase.
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INCREASED DRILL STRING DRAG
The tendency for the formations to creep
into the wellbore can be noticed when
raising the drill string during connections
and trips.
Drag is noticed by OVERPULL on the
WEIGHT INDICATOR.
This means that the Hook Load increases
above the normal load when pulling pipe.
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INCREASED NUMBER AND SIZE OF
CUTTINGS
As explained above, the reduced hole
diameter or unstable hole wall may give
rise to torque and drag. Also the rotating
pipe, collars, stabilizers etc. will knock
against the wall causing formation chips
to be released into the mud stream. This
will show up as an increase in the amount
of cuttings coming across the Shakers.
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Again, the rock chips released would
not have been ground by the bit. These
rock chips would, therefore, be larger in
size and often ‘Silver-like’ in shape.
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DECREASING SHALE DENSITY
Well site Geologists take cuttings of Shale
and measure their Density. The deeper you
drill, the more compact and more dense the
Shale.
Therefore, abnormally Pressure zones
exhibit a Decreasing shale density with
depth.
Geologists can detect these changes and
report these findings to Petroleum/Drilling
Engineers.
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Many of the Kick Warning Signs are
measured by changes in the mud or from
materials carried by the mud. A basic
understanding of what it does, key
properties and constituents is important
for the rig crew.
Drilling fluid or mud is very vital for well
control. It gives the primary control needed
to allow drilling to be carried out safely.
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The weight or density of the mud creates
the pressure necessary to prevent the
formation fluid entering the wellbore.
Other key functions are:
Cleaning cuttings from the well
Lining the hole wall with a filter cake
Suspending cuttings when pumps are
stopped
Minimizing reaction between mud and
formation
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The key Properties of mud are
therefore:
Density – for well control
Viscosity – for carrying cuttings
Filtration – to build filter cake
Gel strength – to suspend cuttings
Inhibition – to reduce reaction between
hole and mud
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To mix the mud that gives the required
properties, many different chemicals
are used. The main types are:
Water or Oil – for the base fluid
Polymer or Bentonite – Viscosity/Filter
cake/Gel strength
Barite – for density
Salts – for inhibition
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Maintenance of the mud properties is
the responsibility of the Mud Engineer.
As the mud plays such a vital role, it is
the responsibility of drilling contractors
to check the two key properties on a
regular basis, usually every 15 minutes.
These properties are Density and Funnel
Viscosity, both being checked at the
Shale Shakers and the mud suction pit.
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Changes to the mud density going in or
coming out of the hole are of great
concern. The Driller must be informed
of any changes immediately.
The Mud Balance must be calibrated
by the Mud Engineer on a regular basis
to ensure accuracy
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MODULE 4 :
KICK INDICATORS
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Secondary Control comes into play
once the well is kicking. That means
the formation fluids are entering the
wellbore, and if not controlled will lead
to a BLOWOUT.
Secondary Control is performed by the
Blowout Preventer and the chosen Well
Kill Method.
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FIRST – use Blowout Preventers to close
in the Well
SECOND – choose and use a Kill Method
to restore the Mud Hydrostatic Pressure
to a level that re-establishes Primary
Control
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As discussed earlier, the warning signs
are to help you take corrective action
before a kick takes place, for instance,
increase mud weight.
But the warning signs are not always
there. Some kicks just occur.
When a kick starts, it must be controlled
quickly. Failure leads to BLOWOUTS.
Fortunately, a Kick will indicate itself at
the surface.
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SURFACE INDICATORS OF A KICK ARE:
a) Excess flow from well when tripping
b) Return flow rate increase when pumping
c) Pit gain
d) Drilling break
e) Decreased pump pressure/increased
SPM
f) Flow from well with pumps off
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Once an indicator is confirmed, it is
vital to shut the well in quickly. Failure
to do so will lead to:
Large kick
Higher shut in pressures
Greater potential for lost circulation
More difficult kill operation
Potential blowout
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EXCESS FLOW FROM WELL WHEN
TRIPPING
Trip Monitoring will indicate if the well is
taking or returning the correct quantity
of mud.
When Running in, there is a flow from
the wellbore as the steel displaces
Mud.
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The flow will start soon after the pipe is
being lowered and continue for a short
period after the stand is set in the slips.
If flow does not stop between stands,
then the well may be kicking.
An indicator for this is the Flow gauge.
NO FLOW when Running in may
indicate possible Formation Fracture
and Lost Circulation.
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RETURN FLOW RATE INCREASE WHEN
PUMPING
The Circulation system is a CLOSED
SYSTEM.
This means that the volume of mud
pumped down the hole will be the same
as the volume returning.
Flow Paddle Indicators will show any
increase or decrease.
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INCREASES mean the well may be
kicking
DECREASES mean possible lost or
partial returns.
Flow Rate Increases are the FIRST good
indication that a Kick is happening.
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PIT GAIN: Formation fluids that enter the
wellbore will displace mud out of the hole.
This causes a PIT GAIN. The Volume of influx
will be equal to the Pit Volume gain.
Unaccountable gains in Pit Volume must be
checked by ‘’Stopping the Pumps and
checking for flow’’. Pit Gains will be noticed
very soon after the flow rate increase.
Quite often, they are the first sign if the flow
indicator is not reliable ie. Floating rig.
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DRILLING BREAKS
A sudden increase or decrease in Drill
Rate is a Drilling Break.
Many kicks have occurred immediately
after a Drilling Break.
The most common cause of a Drilling
Break is a change in Formation. But,
when the mud column goes
underbalanced, there is usually a sharp
rise in Drill rate.
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The Formation fluids are coming in and
this assists the Drill Bit, causing faster
Drill Rates.
Faster drilling formations are usually
more permeable. If the formation has a
pressure greater than the mud pressure,
then the kick will come in quicker than a
low permeability formation.
Any time a drilling break occurs, ‘’Stop
the Pumps and check for flow’’
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FLOW FROM THE WELL WITH PUMPS
OFF
This is the main solid evidence that the
well is actually kicking.
Whatever operation is being performed
at the time an Indication occurs, ‘’SHUT
DOWN THE PUMPS and CHECK FOR
FLOW’’
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Time wasted increases the dangers. If you
are not certain whether the well is flowing,
then line up the Trip Tank and monitor for a
level change. This will help detect any slow
flows.
Flow checks are carried out by the driller.
When drilling, the Driller will raise the string
off bottom and switch off bottom.
The well will then be observed to see if it is
flowing by observing the bell
nipple/flowline.
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PERMEABILITY EFFECTS ON KICK SPEED
Formation Permeability is the ability of a
formation to allow fluids to migrate from
high to low pressure.
Kicks occur when Formation Fluid
Pressure is higher than Mud Hydrostatic
Pressure.
If Permeability is high, then the kick will
enter the wellbore at a much faster rate
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MODULE 5 :
SHUT IN PROCEDURES
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Having seen the well is kicking, it is
now essential to Shut in the well as
quickly as possible.
On shallow wells, it is possible that the
pressures built up after Shut In will
fracture the formation causing the
influx to enter the formation just below
the Shoe.
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The influx may even force its way up
around the outside of the casing to the
surface. If this happens, a Blowout is on
the cards and the rig may be lost. If
doubts occur, the well must be
[Link], if a kick occurs there
are 3 choices of control:
[Link]
2. Soft Shut In
3. Hard Shut In
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Shut In Procedure does differ between
floating rigs and stable rigs. Company
Policy dictates what method to use and
when. We will cover each method of
control plus procedure when Tripping.
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SOFT AND HARD SHUT IN
When Shutting in the well that is
flowing it is possible, in some shallower
wells, to create a ‘Hydraulic Shock’ that
will momentarily increase pressure
downhole, enough perhaps to fracture
the formation. The SOFT Method is
said to reduce this risk although the
occurrence of this is very rare.
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To achieve a SOFT Shut In, there must
be an open Choke Line and open
Adjustable Choke.
Close the BOP, thus allowing the Well to
discharge along the choke line and
through the Choke(This helps check if
the choke is blocked). Then close the
choke.
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The HARD Method does not allow fluid to
discharge through the choke once the BOP
is closed. Essentially the BOP is just closed.
This may create ‘Hydraulic Shock’ if flow is
heavy.
If the SOFT Shut in is used, then the remote
choke is left in the OPEN position when
drilling.
If the HARD Shut in is used, then the
remote choke is left in the CLOSED position
when drilling
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In both methods, the Choke Line Valve
is left closed during drilling. This valve
is commonly called the HCR on stable
rigs and FAILSAFE on floating rigs.
No matter what Shut In Procedure to
use, the most important thing to do
once the BOP has been operated is to
check it has worked and there are no
leaks. Check all the possible parts of
the system for leaks.
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STABLE RIG SHUT IN WITH BIT ON
BOTTOM
Stable rigs are Land, Jack Up and
Production Platform Installations.
The following procedure is for a SOFT
Shut In
PROCEDURE:
1. Raise Kelly/Top Drive until tool joint is
above rotary table
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2. Shut down mud pumps
3. Open Choke Line Valve(HCR) at stack
4. Check that adjustable choke is open
5. Close annular preventer
6. Close adjustable choke
7. Check for leaks
8. Record Shut In Pressures and Pit Gain
The HARD shut in omits 4 and 6
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STABLE RIG SHUT IN WHEN TRIPPING
1. Install and make up the Fully Opened
Safety Valve in the Drill
String
2. Close the Safety Valve
3. Open Choke Line Valve(HCR) at stack
4. Check Adjustable choke is open
5. Close Annular Preventer
6. Close Adjustable Choke
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7. Pick up and make up Kelly/Top Drive
8. Open Safety Valve
9. Check for leaks
10. Record Shut in Pressures and Pit Gain
The HARD Shut in omits 4 and 6
This Procedure may differ slightly from
the policy on your rig. Always follow the
policy laid down for your rig.
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FLOATING RIG SHUT IN
This procedure is used to minimize
movement of the drill string through
the BOP’s due to heave.
PROCEDURE:
1. Pick up Kelly/Top Drive until tool joint
is clear of rotary table
2. Stop mud pumps
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3. Open inner and outer
valves(Failsafe) on riser choke line
4. Check adjustable choke is open
5. Close annular preventer
6. Close adjustable choke
7. Check for leaks
8. Record Pressures and Pit Gain
The HARD Shut In omits 4 and 6 above
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At this stage, you would decide whether
or not to break off the Kelly/Top Drive
and install a Kick Joint.
Following this, you would then hang off
with a tool joint on the Pipe Ram.
Procedure when Tripping would involve
making up and closing the Safety Valve
first.
Again, follow the company policy.
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When an insufficient amount of casing is
set in the hole, it is more than likely that
the formation will fracture if the well is
shut in. Because, surface formation are
relatively weak, a fracture up the side of
the casing may occur causing a blowout
around the Wellhead.
This will inevitably lead to a lost rig. By
diverting the kick, you direct the formation
fluids a safe distance from the rig.
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A proper Diverter is used, coupled with a
large internal Diameter Vent Line that
discharges well fluid a safe distance from
the rig or overboard in the case of
offshore rigs. Due to the danger of the
well fluids being gas there are normally
two vent lines that point in opposite
directions. The Driller would ensure that
fluid was discharged in the same direction
as the wind.
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PROCEDURE:
1. Raise Kelly/Top Drive above rotary
2. Open Overboard Line Valves
3. Close Diverter
4. Start pumping as fast as you can with a
fluid char in plentiful supply ie. Sea Water
No 1 may waste time and endanger life. In
serious conditions, you may decide to
close diverter before raising Kelly/ Top
Drive.
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The reason for shutting in the well is to
A) Stop any further influx of formation fluids
B) To help determine the pressure of the
formation fluids so that the well can be
killed with heavier mud.
There are 2 main methods of killing the well
1. Drillers method
2. Wait and Weight method
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Both Kill Methods require knowledge of
shut in Pressures
On initial shut in, the pressures are
recorded at regular intervals eg. Every
minute to monitor the build up of
pressure
In time, the well will pressure up and the
shut in pressures will stabilize.
The Pit Gain is also recorded at this time
to know the size of the kick.
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SHUT IN DRILL PIPE PRESSURE(SIDPP)
When a Kick occurs, it will usually enter and
contaminate the Annulus, therefore, the
drill string is full of drilling mud.
The Pressure that reads on the drill pipe
gauge after shut in is the SIDPP.
At Shut in,
Formation Pressure = Hyd Pressure + SIDPP
SIDPP is used to calculate Kill Mud
Weight(KMW)
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SHUT IN CASING PRESSURE
SICP is read at the Adjustable Choke
Pressure Gauge
It represents the difference between
Formation Fluid Pressure and the
Hydrostatic Pressure of fluids in the Annulus.
Because the kick fluid has entered the
annulus, it is no longer full of drilling mud,
the annulus is contaminated with formation
fluids.
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Using the SICP to calculate KMW is
inaccurate and must not be used.
The SICP is used to:
i) calculate the kind of influx(gas, oil or
water)
ii) determine the pressures acting on BOP
equipment, choke and lines
iii) the pressure acting on the formations
at the casing shoe, which are usually the
weakest and most susceptible to fracture
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1. Diverters – used on top hole when
BOPs are not installed. Fluid is diverted
away from rig.
2. Hard Shut In – the BOP is closed;
Remote choke is kept closed while
drilling.
3. Soft Shut In – the BOP is closed;
Remote choke is left open while drilling
and is closed last.
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During a trip, the Floorhand stab a fully
open ball-type valve(TIW/Kelly Cock) and
then close it before the Driller initiates the
rest of the shut [Link] actual technique
used depends on rig procedures.
Once the well is shut in, the shut in
pressures and pit gain are recorded. These
help in killing the well, either by using the
Drillers or Wait and Weight method.
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When killing a well, mud is circulated
down the drill string and up the
annulus. Knowledge of circulating
pressures at selected pump rates is
vital to the drilling crew, especially the
Driller and Toolpusher
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The Kick has occurred and the well is Shut
in. Pressures are noted on the Standpipe
gauge and the Choke/Annulus Casing
Gauge. The well is under control but we
must kill the well to restore Primary
Control. To kill the well, two operations
must be performed:
A. Circulate kick fluid out of the hole
B. Replace the mud in the hole with heavier
mud to balance formation fluid pressure.
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Both require circulating with mud pumps(or
cementing pumps). The well is circulated at a
slower rate, usually half to one-quarter of
Pump rate when drilling. This is done to:
Reduce Annular Circulating friction
Allow rig to keep pace when weighting mud
Give longer reaction time for any adjustments
Prevent over-pressuring mud pumps
Better hole cleaning characteristics for influx
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This is the lower pump pressure given
by the Slow Pump Rate.
Pump Pressure represents the force
required to move mud around the well
since Friction occurs between the
moving mud and all surfaces it is in
contact with. These surfaces are rig
circulating equipment lines, pipe wall,
hole wall, casing wall and nozzles. Most
friction occurs through the NOZZLES.
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Friction in the Annulus acts against the
borehole wall. This friction pressure loss acts
with the Mud Hydrostatic giving pressure in
the hole. When pumping slowly; the friction is
reduced hence less Pump Pressure is needed.
It is important to know the Pump Pressure at
the selected Slow Pump Rate. This was
achieved by taking Slow Pump Rate Tests at
regular intervals noting the SPM and Pump
Pressure.
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The Kill would be made holding this
SPM constant throughout the Killing
operation.
NOTE: Slow Circulating Rate Pressures
are taken Tourly. Be warned that the
values taken at one time may be
different later if depth and mud
condition has changed significantly.
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The following looks at where pump pressure
comes from.
A typical circulating system can be
considered to be made up of four parts:
1. Surface equipment – from pump to rig floor
2. Drill string – drill pipe and BHA
3. Bit – nozzles or flow path through the bit
4. Annulus – from the bottom back to surface
This makes up the total circulating system.
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Pumping mud through this system will
create friction. A force is required to
overcome the friction of moving the mud.
This force is the PRESSURE.
Each part of the system will create a
pressure, sometimes called a ‘’pressure
drop’’ or ‘’pressure loss’’. The sum total of
these ‘’pressure losses’’ around the
circulating system will be the pressure
seen at the pump(pump pressure)
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Using the above example, each part of the
system has an associated friction or
pressure loss ie.
Surface equipment – 150psi
Drill string - 950psi
Bit - 1000psi
Annulus - 200psi
The pump pressure would be:
150+950+1000+200 = 2300psi
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MODULE 6 :
KILL METHODS
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As stated before, the reason for
shutting in the well is to:
A) STOP ANY FURTHER INFLUX OF
FORMATION FLUIDS
B) TO HELP DETERMINE THE PRESSURE
OF THE FORMATION FLUID SO THAT
THE WELL CAN BE KILLED WITH
HEAVIER MUD
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There are 2 main methods that can be
used to kill the well
1. DRILLER’S METHOD
2. WAIT AND WEIGHT METHOD
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Before reviewing each of these
methods, there are three key aspects
of Well Control that must be covered
first.
Principle of Constant Bottom Hole
Pressure
Role of the Adjustable Choke
Start Up Procedure
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The main aim is to keep Bottom Hole
Pressure constant, at a value equal to
or slightly higher than Formation
Pressure. This ensures that no
formation fluids enter the wellbore
during the Kill operation.
To maintain Constant Bottom Hole
Pressure requires correct use of the
choke. BHP is calculated from pressures
existing in the drill string.
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These pressures are
a) Mud Hydrostatic in the drill string
b) Shut In Drill Pipe
Pressure(backpressure inside the string
due to the kick)
Any time the drill string is not full of
correct mud weight, then backpressure
has to be maintained with the choke.
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If we hold too much backpressure with
the choke, then there is a risk of breaking
the formation and creating losses.
Both the Driller’s and Wait and Weight
methods are designed to maintain a
correct and constant Bottom Hole
Pressure.
If the correct procedure is not followed,
then you run the risk of letting in more
influx or breaking the formation.
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If you squeeze a Hose Pipe, you create
a pressure – because the amount of
water passing along the Hose Pipe
(FLOW) needs a greater pressure to
push it at the same rate of flow.
If Pump Pressure at 40SPM was 900psi
with the choke fully open, it is possible
to increase the pressure by partly
closing the choke and keeping SPM
constant at 40.
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By using the choke, we can adjust Pump
Pressure to the value we want. When the
pumps are started at the beginning of the
Kill operation, the choke is used to achieve
a circulating pressure of:
SCR + SIDPP, when pumping at slow pump
rate. In effect, the choke is used to create a
backpressure equal to the SIDPP at the
pumps. This is achieved by following the
Start Up Procedure
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The well is shut in and circulating pressure
at Slow Pump Rate has been calculated.
It takes time to get pumps up to the right
speed. During this time, it is possible that
Bottom Hole Pressure will be reduced
enough to cause a further influx, or
increased enough to cause formation
fracture. To prevent this, there is a
standard Pump Start Up Procedure that can
be used any time after the pumps are
stopped and the well shut in.
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Procedure For Stable Rigs:
1. Slowly open choke and start pump
simultaneously
2. Use Choke to hold casing pressure
constant at shut in Value(SICP)
3. When Mud Pumps are at SCR, the Drill
Pipe Pressure(Pump Pressure) can be
read (this value will be the actual
circulating pressure)
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Use Choke to allow casing pressure to
fall by an amount equal to the choke
line friction pressure as pumps are
brought up to kill speed.
All the time, note that the Casing
Pressure is being held constant and drill
pipe pressure is gradually increasing as
pump speed increases.
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This method involves two circulations
to kill the well.
1ST CIRCULATION: This involves
pumping mud of the present mud
weight around the system to circulate
the kick fluid out of the hole.
Because the mud does not have to be
weighted up to Kill Weight, it means
the well can be circulated immediately.
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Procedure:
1. Bring Pumps up to Kill speed holding
casing pressure constant(Fixed Rigs)
2. Look at Drill Pipe Pressure and circulate
complete well holding SPM constant by
manipulating the Adjustable choke.
This cleans the influx out of the hole and
maintains backpressure to hold constant
BHP.
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Rules: Hold SPM Constant at Slow Pump
Rate(Kill Rate)
Maintain Drill Pipe Pressure at value
seen after start up (this should
approximate the calculated ICP)
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2ND CIRCULATION: This involves replacing
the light mud with the kill mud.
After the first circulation, the influx is out of
the hole but the mud weight is not heavy
enough to establish Primary Control.
SIDPP will equal original SIDPP and SICP will
equal SIDPP
Therefore, both gauges will read the same.
Now with mud weighted up to Kill Weight
the 2nd circulation can be started.
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Procedure:
1. Start up till Pumps are at kill rate
2. Hold casing pressure constant at Shut
in Value until heavy mud reaches the
bit(calculate strokes required)
3. When heavy mud reaches the bit,
change over and hold Drill pipe Pressure
constant until kill mud returns at the
shakers
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4. Stop Pumps and Shut the Well in.
SIDPP and SICP should read zero.
5. Open well and check for flow.
NB: Strokes required are Pit to Bit, add
the surface line volume to the drill
string capacity to obtain total strokes to
bit.
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This method requires only one circulation. The
influx is circulated out at the same time as the
heavy kill mud is pumped down the hole.
This method involves a few more calculations.
As kill mud is pumped down to the Bit, the
hydrostatic pressure increases until it balances
the formation pressure. At this point, the drill
string is killed, but the Annulus is not. If you
shut the well in now, the SIDPP would read zero.
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This requires calculating the Kill Mud
Weight, the Initial Circulating Pressure and
the Final Circulating Pressure.
As Kill Mud is pumped down to the bit, the
pumping pressure is reduced from Initial
Circulating Pressure(ICP) to Final
Circulating Pressure.
With the heavy mud at the bit, the FCP is
held constant using the adjustable choke
until heavy mud returns at the shakers.
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Procedure:
1. Determine Kill Mud Weight
2. Mix up mud to required weight
3. Start up pump and use choke to keep
casing pressure constant at SICP until
pumps reach Slow Pump Rate(Kill Rate)
4. Use adjustable choke to reduce Pump
Pressure from ICP to FCP as kill mud is
pumped from surface to bit down the drill
string.
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5. Hold pump pressure constant at FCP
until heavy mud returns at the shakers.
NB: Constant Pump Rate must be
maintained during Kill operation.
If pumps are stopped and the well shut
in, when heavy mud reaches bit the
SIDPP should read zero. If not, it is
possible that your Surface to Bit
Strokes Calculation is wrong or Kill Mud
Weight is not heavy enough.
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The most important requirement of kill
methods is to keep annular pressures
as low as possible.
The Wait and Weight Method produces
the LOWEST annular pressures.
For minimum calculations and waiting
time, the Driller’s method is the best.
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EASE OF CALCULATIONS – Driller’s
method
LESS WAITING TIME – Driller’s method
LOWEST ANNULAR PRESSURES – Wait
and Weight method
SHORTEST CIRCULATING TIME –Wait and
Weight method
The longer you circulate, the more the
risk of washouts and erosion.
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Formation Fluids can be either Oil, Gas or
Water. Oil and Water are not compressible
and will not expand. Gas is compressible
and will expand. For this reason, Gas Kick
is the most dangerous type of kick.
As the Gas Kick is circulated up the
Annulus, the pressures above are getting
lower. This allows the Gas to expand
causing mud to be displaced out of the
hole. Pit Gains are noticed as the gas nears
the surface.
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The expansion causes the gas bubble to get
longer, thus reducing hydrostatic pressure
in the annulus. In order to maintain
constant BHP, the casing pressure rises to
redress the balance. These high casing
pressures put strain on the BOP equipment
and can increase pressures at the casing
shoe enough to fracture the formation, if
the Gas bubble is still below the shoe. To
minimize these dangers, it is essential to
detect the kick quickly keeping the influx
volume as small as possible.
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With the well shut in, gas has a tendency to
rise. This can be seen as steadily increasing
SIDPP and SICP. Because the Gas cannot
expand with the well shut in, it maintains
it’s original pressure as it migrates upward.
This causes the well to pressure up in all
directions creating higher SICP, higher
SIDPP, higher Casing Shoe pressure and
higher BHP, while the gas itself stays the
same.
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When killing the well, gas is allowed to
expand so the gas pressure decreases. It
is essential not to stay shut in for periods.
To minimize the pressures caused by Gas
migration(if shut in for long periods), it is
advisable to bleed off some pressure at
the choke. This should be done by
maintaining the SIDPP at a constant value
equal to it’s original value(or just slightly
higher).