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en1 sanpem WELL KILLING PROCEDURES
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DISCIPLINE PROCEDURE

WELL KILLING PROCEDURES

RIG5829-PRO-DRL-004-E

MASTER COPY

Issued for
06Aug 14 02 improvement and
updatin
Description of
Date Revision Prepared Checked Approved
Revision

This document is the property of saipem who will safeguard its rights according to the civil and penal provision of the law.
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Revision Summary

Approved Issued Revision Section/Page

Description of Revision Approved By
Date Date No. Revised
28 Jun 12 28 Jun 12 01 N/A Issued for approval and implementation S. Trinchero
06 Aug 14 06 Aug 14 02 All Issued for improvement and updating G. Stramazzo
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INDEX

1 SCOPE AND PURPOSE 4

2 REFERENCE DOCUMENTS 4
3 DEFINITIONS 4
4 RESPONSIBILITIES 5
4.1 OPERATION M ANAGER AND DRILLING SUPERVISOR 5
4.2 TOOL PUSHER / TOUR PUSHER 5
4.3 DRILLER 6
4.4 DRILLING CREW 6
5 ACTIVITIES DESCRIPTION 6
5.1 WELL KILLING METHODS 6
5.1.1 Engineer’s Method (Wait and Weight Method) 7
5.1.2 Driller’s Method 9
5.1.3 Volumetric Well Control Method 12
5.1.3.1 Basic Volumetric Control Principles 12
5.1.3.2 Description of the Method 12
5.1.3.3 Volumetric Control 13
5.1.3.4 Lubricate and Bleed Method 15
5.1.4 Bullheading 15
5.1.4.1 Prior to Bullheading 16
5.1.4.2 Bullheading Procedure 16
5.1.4.3 Bullheading Complications 17
5.1.5 Off-Bottom Kill Method 17
5.1.5.1 String Out of Hole 17
5.1.6 The Low Choke Pressure Method 18
6 ATTACHMENTS 18
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1 SCOPE AND PURPOSE

The scope of this procedure is to state general procedures to be used during killing the well operations.

The procedures described below shall be followed while planning and during killing activities, in order to
regain the well control.

Main purpose of this document is to make all parties involved in well operations aware of the basic rules and
procedures related to Well Control issues.
The contents of this document cannot foresee all aspects of the operations that may be encountered; it is
consequently required to personnel to conform to the principles of this Procedure in dealing with unexpected
situations different from those planned or anticipated.
Any deviation from Saipem Procedures that can be reasonably foreseen shall be treated through the
“Management of Change” principles.
It applies in case of emergency at well location and defines the requirements, methodologies and rules that
enable to operate, uniformly and in compliance with Saipem, to restore the full control of the well. This,
however, still enables each individual rig to operate according to local laws or particular environmental
situations.

Well Killing Procedures should be agreed by Saipem and Operating Company. If the Operating Company
have stated similar document, the Operating Company procedure shall be followed and this procedure shall
be used as a guideline. All Well Control procedures and instructions released by Operating Company must
be communicated only through official channels.

2 REFERENCE DOCUMENTS

The following documents have been used as reference during preparing of this document:

Corporate Operative Procedure “Well Control” (Doc. n. OPR-COR-DRIL-002-E)

Discipline Procedure “General Principles of Well Control” (Doc. n. RIG5829-PRO-DRL-001-E)
Discipline Procedure “Detection and Prevention of Kicks” (Doc. n. RIG5829-PRO-DRL-002-E)
Discipline Procedure “Shut-In Procedures” (Doc. n. RIG5829-PRO-DRL-003-E)
API RP 59 “Recommended Practices for Well Control Operations”

3 DEFINITIONS

Back-pressure The pressure resulting from restriction of full natural flow of oil or gas.

Bleed-Off / Bleed-Down Operation to release pressure slowly from a well or from pressurized
equipment.

Circulation Movement of drilling fluid from mud pits, down drill stem, up annulus, and
back to mud pits.

Circulating rate Circulating fluid volume per unit of time.

FCP Final Circulating Pressure

GKm Drilling / completion fluid weight necessary to achieve the well control.

Gom Actual drilling / completion fluid weight.

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ICP Initial Circulating Pressure

Kill Rate A predetermined fluid circulating rate, expressed in fluid volume per unit of
time, which is to be used to circulate under kick conditions.

LCM (Lost circulation A substance added to cement slurries or drilling mud to prevent the loss of
materials) cement or mud to the formation.

Overbalance The extent to which the hydrostatic pressure of the mud column exceeds
formation pressure.

FCP Final Circulating Pressure

SCR Slow circulation rate

SF Safety Factor

SICP Shut-In Casing Pressure

SIDPP Shut-In Drill Pipe Pressure

TVD True Vertical Depth

4 RESPONSIBILITIES

4.1 OPERATION M ANAGER AND DRILLING SUPERVISOR

The Operation Manager and Drilling Supervisor will be responsible for the implementation of this procedure.

Operation Manager and Drilling Supervisor shall be also responsible to:

 Ensure that Well Control procedures are reviewed whenever necessary and kept updated;
 Ensure proper communication of Well Control procedures to the Drilling Rig;
 Ensure the application of Well Control procedures during Drilling Rig activities;
 Monitor correct implementation of Well Control procedures and provide necessary support to the Drilling
Rig;
 Be informed about the Well Control activities ongoing and also planned.

4.2 TOOL PUSHER / TOUR PUSHER

The Tool Pusher / Tour Pusher are responsible to instruct the Drillers in execution of the drilling activities and
supervise the drilling crew in order to ensure the activities are carried out in accordance to the program.

Tool Pusher shall be in charge of:

 Checking that all personnel on the rig have had a medical examination and ensuring that all personnel
have received proper safety instructions and training;
 Ensure that all personnel involved with the well control activities are competent, certified and fully trained
in their duties;
 Determining that all equipment is working correctly;
 Being part of the Well Control Response Team to assist in handling well control operations;
 Ensuring spares are available for the equipment malfunctions;
 Assume complete control of the work required in order to regain control of the well;
 Provide specific well control procedures;
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 Being familiar with calculations needed for well control response (influx calculations, bull heading, etc.)

Tool Pusher is also responsible for following activities:

 Concurring in the preparation of the Well Control Response Plan;

 Inspecting BOP and systems for leaks and malfunctions;
 Checking all valves, accumulator pressures as per preventive maintenance plan;
 Being present at the rig floor during the start of killing operations;
 Being present at all times on the rig floor during Well Control situation.
 Providing briefing to the off duty drill crew prior to starting a new shift;
 Ensuring that the Driller and the drill crew are correctly deployed during the well control operation;
 Maintaining communication with Well Control Response Team to ensure all observations are taken into
account.

Tool Pusher / Tour Pusher shall be familiar with the kick control worksheets in use and with the relevant
calculations involved. Also, shall be able to fully understand and implement the results of these calculations.

4.3 DRILLER

The Driller shall be responsible also for:

 To ensure correct application of received instructions for drilling parameters as well as other work
procedures;
 To monitor the well at all times and to regularly record the key parameters;
 Ensure the safety status of the rig if the evacuation of all personnel become necessary;
 Initially detect the kick and shut-in the well;
 Be responsible for the drilling crew during the well control operations.
 Be familiar with the kick control worksheets in use and with the relevant calculations involved. Also, shall
be able to fully understand and implement the results of these calculations.

4.4 DRILLING CREW

The drilling crew is responsible to perform the activities as instructed by supervisors.

5 ACTIVITIES DESCRIPTION

5.1 WELL KILLING METHODS

After the well shut-in and the pressure stabilization have been carried out, different methods can be adopted
in order to control the kick. The objectives of killing methods are to bring the influx to the surface and to
restore the hydrostatic equilibrium inside the well.

All methods to be used to bring the well under control are based on the „Constant Bottomhole Pressure‟
concept, as recommended by API-RP 59 „Recommended Practices for Well Control Operations‟.
These methods require a constant bottomhole pressure, slightly higher than the pore pressure, to be
maintained at all times throughout the killing operations in order to prevent further influxes occurring.
The drilling / completion fluid weight (Gkm) necessary to achieve the well control, shall be calculated as a
function of the Shut-In Drill Pipe Pressure (SIDPP), hole depth (TVD) and actual drilling / completion fluid
weight (Gom).

Recommended well killing methods to be used, in an order of preference and depending on particular
situations, are:

 Engineer‟s method (Wait and Weight method)

 Driller‟s method
 Volumetric control method
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Bullheading may also be considered when the other preferred killing methods are not applicable. Bull
heading is often an operationally acceptable permitted method in killing producing wells, e.g. actual
production wells or production well tests in cased wells.

Other well killing methods may be considered if the above methods are not practical and depending on
specific situations.

Depending on situation, Tool Pusher needs to agree with Operator / Client Representative about the
killing method which will be used.

5.1.1 Engineer’s Method (Wait and Weight Method)

The Engineer‟s Method (Wait and Weight Method) requires only one complete circulation.

The kill mud is circulated at the same time the influx is removed from the annulus. During this circulation, the
bottomhole pressure is maintained at a level equal or slightly greater than the formation pressure throughout
the entire process, while the pump rate is maintained at the predetermined rate.

A working sheet (plot and table) shall be prepared in order that the drill pipe pressure can be properly
tracked through choke position.

It is important that the volume of the killing fluid, position of the influx, borehole and drill string geometry are
known at all times throughout the kill operations. The key control points in this process are:
 the kill mud reaching the bit;
 the top of the influx reaching the casing shoe;
 the influx reaching the choke on surface

The advantages of this method are lowest wellbore pressure and lowest surface pressure, this meaning less
equipment stress. Also, „on choke‟ circulating time is minimum; existing less chances of washing out the
choke.

Disadvantages of Wait and weight method are that the waiting time while weighting up the mud is
considerable and gas can migrate into the annulus. Also, a large increase in mud weight is difficult to be
done uniformly in one stage.

After the well is shut-in and all data have been observed and recorded, the next steps should be followed to
kill the well:

1) Perform the Kick Control Calculations

All calculations should be performed before the kill mud is circulated into the well. Critical items to be
determined include:
 drill pipe pressure schedule
 bottomhole reservoir pressure
 mud weight necessary to balance the kick
 maximum surface casing pressure during the kill circulation
 maximum excess mud volume gained during the kill circulation

While performing the calculations, to keep in mind that the formation fluids in the annulus (especially
gas) may migrate up the hole and cause an increase in the SICP. Any excess pressure may be bleed-off
in small increments until equal readings are observed after two consecutive bleed-offs.

Before starting with the killing operation, it is necessary to determine:

 Initial Circulating Pressure:
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 Final Circulating Pressure, of the killing fluid being pumped down hole:

2) Raise the Mud Weight in the Pits

Raising the mud weight in the pits should start as soon as the required mud weight is calculated. It is
recommended to weight up enough mud to displace the entire hole before the killing operation to start.

It is important to start as quickly as possible, therefore formation fluids in the annulus (especially gas)
may migrate causing an increase in the casing pressures. Also, the longer formation fluids are in the
annulus, the more likely pipe sticking becomes.

3) Establish Circulation

Before breaking circulation the following items must be checked:

 All members of the crew knows exactly their duties and responsibilities before the killing
operation to start
 Eliminate all sources of ignition in the immediate vicinity of the rig and vent lines. Vent lines on
the mud-gas separator and mud degasser must be secured properly and downwind of the rig, if it
is possible.
 Circulating system, including manifolds and pits, is lined-up correctly.
 Zero the stroke counter and time mud be noted.

Every member of the crew should know exactly what are his duties and responsibilities, before the kill
operation begins.

Backpressure on the well can be very difficult to control when establish circulation in a closed in well. If it
is held to little, backpressure and additional influx will result; or the formation can break down if too much
pressure is held.

Procedure to establish circulation requires simultaneous manipulation of the remote power choke and
the pumps speed. Next steps must be followed:
 Start the pumps to bring up the speed.
 Open the remote power choke following pumps start up, and ensure that casing pressure is
maintained equal (or slightly in excess) of the original SICP.
 As the pumps speed is increased up to the desired kill rate, drill pipe pressure will increase but
casing pressure must be held constant.

The pumps should be brought up to the SCR speed slowly. Once SCR pressure is reached, the remote
power choke should be adjusted until the standpipe gauge reads the ICP calculated.
If the ICP is close to the calculated value, continue with the displacement operation. If it is substantially
different, investigate the cause and recalculate the ICP.

Important is that the predetermined pump rate must be held constant throughout the killing of the well.

4) Follow the Drill Pipe Pressure Schedule while Pumping Kill Mud

After circulation has been establish and pumps are operating at the desired kill rate, the previously
calculated Initial Circulating Pressure should be observed. As the kill mud goes down the drill pipe,
remote power choke must be adjusted gradually so that the drill pipe pressure closely tracks drill pipe
pressure schedule calculated (in accordance with the kill sheet graph and table). Pump pressure should
not be allowed to drop below the calculated values.
At this point, the bottom-hole pressure is maintained constant by following the drill pipe pressure
schedule and by making slight adjustments on choke. The pump rate should not be changed.

When the kill mud gets to the bottom of the drill string, the pressure on the drill pipe should be the Final
Circulating Pressure. From now on, the FCP value shall be kept constant by continuously adjusting the
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remote power choke, until the influx is completely circulated out.

5) Hold the Drill Pipe Pressure Constant for the Remainder of the Kill

When kill mud starts to be circulated up the annulus, the remote power choke must be manipulated so
that drill pipe pressure is maintained constant at the final circulating pressure.

During displacement, the pit return volume will be recorded so that the position of the influx in the well
can be estimated.
As the gas and contaminated mud are circulated to the surface, the gas will begin to expand, increasing
both the casing pressure and pit volume. This gas need to be bleed-off.
If the gas cannot be released fast enough from the annulus to prevent an increase in drill pipe pressure,
the pumps may have to be slowed or even stopped until the casing pressure is bleed down. The pumps
must be returned to the original rate as soon as possible.

Circulations should continue until the entire system is full of the kill mud.

6) Shut Down and Check for Flow

When entire hole volume has been replaced with kill mud, the following steps must be followed:
 Close the remote power choke gradually, holding casing pressure constant, and shut down the
pumps.
 After the well is shut-in, the casing pressure should be zero.
 Confirm that the well is not flowing, by cracking open the choke.

The casing and drill pipe pressure will both be checked. There should be no pressure on either of the
gauges. If, however, there is still some pressure, through-choke circulation will be resumed until the
contaminated fluid is removed from the annulus

Once the well has been killed, a flow check via choke line will be carried out prior to open the BOP. Extra
caution when opening the preventers should be taken, existing possibility that a small volume of gas to
be trapped between the preventer and choke line. Drilling crew shall be aware also that there may be
gas trapped under the BOP rams; hence safety procedures should be implemented prior to open the
BOP.

7) Circulate and condition the mud

Prior to resume the operations, a full circulation will be carried out with the drilling / completion fluid being
weighed up to a suitable overbalance.

5.1.2 Driller’s Method

This method requires, as a minimum, two complete circulations.

During the first circulation the influx is circulated out at a constant pump rate, using the same drilling /
completion fluid density (original mud weight) that is in the hole at the time of the kick. The Initial Drill Pipe
Pressure shall be held constant, by remote power choke manipulation, to ensure the bottomhole pressure
remains constant. The choke pressure during this circulation will be higher and this leads to greater down
hole, stress and pressures.

During the second circulation, the well is brought under control by circulating the required kill drilling /
completion fluid (kill weight mud) into the hole, in order to displace the kick, in the same manner as described
in the „Wait and Weight method‟.

The main advantages that this method offers are that the circulation can begin immediately and minimum
information and calculations are required.
Disadvantages of this method are that the well is under pressure a longer time and annular pressure
produced is highest.
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After the well has been shut-in, all the data have been recorded and decision to use Driller‟s Method was
taken, the next steps need to be followed:

First Circulation – Circulating out the influx from well and maintaining constant Bottomhole Pressure

1) Perform the Kick Control Calculations

Calculations should be performed before the influx is displaced from the well on the first circulation.
Critical items to be determined include:
 Bottomhole formation pressure,
 Mud weight necessary to balance the kick,
 Maximum surface casing pressure during the first circulation,
 Maximum excess mud volume gained during the first circulation.

Keep in mind that the formation fluids from the annulus, especially gas, may migrate up the hole and
cause an increase in the SICP. In this case excess pressure needs to be bleed-off in small increments
until equal readings are observed after two consecutive readings.

2) Establish Circulation

Before breaking circulation the following items must be checked:

 Eliminate all sources of ignition in the immediate vicinity of the rig and vent lines. Vent lines on
the mud-gas separator and mud degasser must be secured properly and downwind of the rig, if it
is possible.
 Circulating system, including manifolds and pits, is lined-up correctly.
 Zero the stroke counter and time mud be noted.

Every member of the crew should know exactly what are his duties and responsibilities, before the kill
operation begins.

Backpressure on the well can be very difficult to control when establish circulation in a closed in well. If it
is held to little backpressure and additional influx will result, or the formation can break down if too much
pressure is held.

Procedure to establish circulation requires simultaneous manipulation of the remote power choke and
the pump speed. Next steps must be followed:
 Start the pumps to bring up the speed.
 Open the remote power choke following pumps start up, and ensure that casing pressure is
maintained equal (or slightly in excess) of the original SICP. The pumps should be brought up to
speed slowly.
 As the pumps speed is increased up to the desired kill rate, drill pipe pressure will increase but
casing pressure must be held constant.

Once the pump has reached the required SCR speed, record the Initial Circulating Pressure.
If the ICP is close to the calculated value ( ), continue circulating holding
constant pump speed and drill pipe pressure.
If the ICP is substantially different, investigate the cause and recalculate the ICP.

Important is that the predetermined pump rate must be held constant throughout the killing of the well.

3) Circulate Out the Influx Holding Drill Pipes Pressure Constant

When the pumps are operating at desired kill rate, the drill pipe pressure must be observed and
recorded. This pressure must be held constant for the entire first circulation.

Continue circulating, maintaining the Drill Pipe Circulation Pressure and pump stroke constant, until the
influx is completely circulated out.
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The remote power choke will be continuously adjusted to maintain constant drill pipe pressure. The most
critical moment is when the influx reaches the choke.

The pit return volume during displacement should be recorded so that position of the influx in the well
can be estimated.

4) Shut Down the Pumps and Weight Up the Mud Pits

After the contaminant has been circulated out from the well, the next steps must be followed:
 Shut down the pumps and close gradually the remote power choke as the pump speed is
reduced.
 As the pumps speed decrease, the drill pipe pressure will decrease, but casing pressure must be
held constant at its value.
 When the well is shut-in after first circulation, SICP and SIDP should be equals and should start
to weight up the mud in the pits.
If the casing pressure is higher than the drill pipe pressure then some of the influx will still be in
the annulus, or there will be some differential mud pressure inside and outside the drill string.

Second Circulation – Displacing the well with kill drilling / completion fluid (kill mud weight) keeping
Bottomhole Pressure constant

5) Re-Establish Circulation and Circulate Kill Mud

A full circulation will be carried out with the drilling / completion fluid being weighted up to a suitable
overbalance.

 First step of the second circulation is to establish the desired pump rate by holding the SICP
constant, while bringing the pump up to the kill rate.
 As the kill mud goes down the drill pipe, casing pressure must be maintained constant by
adjusting the remote power choke. The casing pressure must be kept constant until the mud
reaches the bit.
 Pressure on drill pipe when the kill mud reaches the bit must be recorded. This drill pipe pressure
must be kept constant throughout the remainder of the kill operation, by adjusting the remote
power choke.
 Operation will continue until the hole is full of kill mud.

6) Shut Down and Check for Flow

When entire hole volume has been replaced with kill mud, the following steps must be followed:
 Close the remote power choke gradually, holding casing pressure constant, and shut down the
pumps.
 After the well is shut-in, the casing pressure should be zero.
 Confirm that the well is not flowing, by cracking open the choke.

The casing and drill pipe pressure will both be checked. There should be no pressure on either of the
gauges. If, however, there is still some pressure, through-choke circulation will be resumed until the
contaminated fluid is removed from the annulus

Once the well has been killed, a flow check via choke line will be carried out prior to open the BOP. Extra
caution when opening the preventers should be taken, existing possibility that a small volume of gas to
be trapped between the preventer and choke line. Drilling crew shall be aware also that there may be
gas trapped under the BOP rams; hence safety procedures should be implemented prior to open the
BOP.

7) Circulate and Condition the Mud

After the BOP‟s are opened and prior to resume the operations, a full circulation will be carried out with
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the drilling / completion fluid being weighed up to the desired properties.

5.1.3 Volumetric Well Control Method

This is more a method to control the bottomhole and surface casing pressures as the gas migrates up the
hole.

It is used when is not possible to circulate an influx out of wellbore, due to different problems. This may be
due to several things:
 Pumps are inoperative,
 Drill string or bit are plugged,
 Drill pipes are well above the influx,
 Kick is taken during tripping operations,
 Pipe is out of the hole completely,
 A wash out or hole is detected in the drill string,
 The drill string has parted and dropped.

When one of these problems occurs, the well cannot be circulated with kill mud until corrective measures are
taken and the ability to circulate out the influx is regained.

If the bit is plugged, can be necessary to perforate the drill pipe or, if drill pipe is off bottom, it is necessary to
strip back to bottom.

5.1.3.1 Basic Volumetric Control Principles

Successful of this method requires a good understanding of three basic principles:

1) Boyle‟s Law – which states that the pressure of a gas is directly related to its volume.

Where: P1 = gas pressure at condition 1

V1 = volume of gas at condition 1
P2 = gas pressure at condition 2
V2 = volume of gas at condition 2

2) Hydrostatic pressure and calculation

3) Fluid volume and height, as determined by annular capacities

Annulus capacity factor will be calculated with following formula:

Where: ACF = Annulus capacity factor (bbl/ft)

OD = Outside diameter of annular space (inside diameter of the casing)
ID = Inside diameter of annular space (outside diameter of the drill pipe)

Note: Both, OD and ID are measured in inches.

5.1.3.2 Description of the Method

The volumetric control is a method to control the bottomhole pressure until provisions can be made to
circulate or bullhead kill mud into the well.
The essence of this method is to allow controlled expansion of the gas bubbles as it migrates up the hole, by
bleeding off mud at the surface and while holding casing pressure constant when bleeding.
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Each barrel of mud that will be bleed-off at the surface, change the wellbore environment in four ways:
 Gas bubble is expanded by one barrel
 Hydrostatic pressure of the mud in the annulus is decreased
 Bottomhole pressure is decreased
 Surface casing pressure remains the same

5.1.3.3 Volumetric Control

Volumetric control is accomplished in a series of steps that causes the bottomhole pressure to rise and fall in
succession. The gas bubble is allowed to rise and the bottomhole pressure goes up. Then, the mud is bleed-
off from the annulus and the bottomhole pressure goes down. The operations will continue alternating from
allowing the gas bubble to rise and bleeding-off the mud.
In this way, bottomhole pressure is held within a range of values that is high enough to prevent another influx
and low enough to prevent an underground blowout.

Steps that must be accomplished during Volumetric Control method are:

1) Perform Calculations

The following calculations need to be performed:

 Safety Factor – is an increase in the bottom-hole pressure which is allowed to occur naturally as
gas migrates up the annulus.

 Pressure increment – is the reduction in hydrostatic pressure which occurs each time we bleed a
given volume of mud from the annulus. This value is one-third of the Safety Factor value.

 Mud increment – is the volume of mud which must be bleed-off from the annulus in order to
reduce the annular hydrostatic pressure by the amount of the pressure increment determined.

Where: PI = Pressure Increment (psi)

ACF = Annulus Capacity Factor (bbl/ft)
MW = Mud Weight (pcf)

2) Allow Casing Pressure to Increase Establish Safety Factor

The next step of the Volumetric Control method is to wait for the gas bubbles to migrate up the hole and
cause an increase in the SICP. While gas bubble migrates up the hole, casing pressure will increase by
an amount equal to the safety factor.
How no mud was bleed-off from the annulus, hydrostatic pressure of the mud will remain the same since
the well was first shut-in.

While gas bubble migrates:

At this point, the Bottomhole Pressure has also increased by the amount of the safety factor and the well
should be safely overbalanced.

3) Hold Casing Pressure Constant by Bleeding Off the Mud Increment

The mud must be bleed-off in such a way that the casing pressure remains constant throughout the
entire bleeding.
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During the bleeding process, the hydrostatic pressure is reduced by the pressure increment while the
surface pressure is held the same, so the bottomhole pressure is also reduced by the pressure
increment.

While bleeding mud from annulus:

Each time mud is bleed off from annulus, the gas bubble expands to fill the volume vacated by the mud.
As the gas bubble expands, the pressure in the bubble decreases (according to Boyle‟s Law).

4) Wait for Casing Pressure to Rise as the Gas Bubble Migrates

Each bleeding of mud from the annulus reduces the bottomhole pressure by the amount of the pressure
increment. This decreases the safety factor overbalance.

In order to get the full value of overbalance back on the well, must to wait for the gas bubble to migrate
up the annulus. As the gas bubble migrates, both surface pressure and bottomhole pressure increase
just as when the safety factor was applied.
At the point when the gas bubble is raised until casing pressure has increased by an amount equal to the
pressure increment, bottomhole pressure is also increased by the amount of the pressure increment and
the well is back at full overbalance.

5) Hold Casing Pressure Constant by Bleeding Mud from the Annulus

Once the well is back at full overbalance, another mud increment from the annulus can be bleed off.
While bleeding another mud increment from the annulus and holding casing pressure constant,
bottomhole pressure will be reduced by the amount of the pressure increment and also, will cause the
gas bubble to expand by the volume of the mud increment.

6) Wait for Casing Pressure to Increase as the Gas Bubble Migrates

After the bleed-off, must wait again for the gas bubble to migrate with the well shut-in.
The bottomhole pressure will rise back to its full overbalanced condition, when the casing pressure will
rise by the amount of the pressure increment.

7) Alternate Holding Casing Pressure Constant and Letting It Rise

This step consists in a succession of bleeding and migrating operations, until the gas has finally migrated
all the way to the surface.

During each bleeding, the bottomhole pressure is lowered, and during each migration the bottomhole
pressure is raised.
During each bleed step, the gas bubble is allowed to expand, which lowers the pressure in the bubble.
By the time the gas reaches the surface, it has expanded too many times its original volume so its
pressure is greatly reduced.

8) Lubricate Mud into the Well

The casing pressure should stop increasing after the gas reaches the surface; the well being stable at
this point.

This step involves bleeding gas from the well to reduce the casing pressure by a predetermined
increment, then to pump a measured volume of mud into the well to increase the hydrostatic pressure in
the annulus. The increase will be made by the amount of surface pressure which was lost when the gas
was first bleed-off. These steps must be repeated until gas can no longer be bleed from the well.
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5.1.3.4 Lubricate and Bleed Method

Sometimes during major well control situations, there comes a time when gas is at surface and is not
possible to circulate, and the well has to be lubricated and bleed.

The theory involving lubricating and bleeding is the same as that for volumetric control but in reverse. Mud is
pumped into the well on top of the gas, replacing surface pressure with hydrostatic pressure. The gas and
mud will change places in the hole and some of the surface pressure is bleed-off.

Lubricate and bleed procedure is listed in the following steps:

1) Calculate

Calculate the hydrostatic pressure that will be exerted by 1 barrel of mud.

2) Lubricate

A given volume of mud is slowly pumped into the well. The amount chosen will depend on many different
well conditions and may change throughout the procedure.
The rise in surface pressure can be calculated by applying Boyle‟s Law and realizing that for every barrel
of mud pumped into the well, the bubble size decrease by 1 barrel.

3) Wait

The gas is allowed to migrate back to the surface.

This step could take quite some time and is dependent on a number of factors such as mud weight and
viscosity.

4) Bleed

Gas from the well is bleed until the surface pressure is reduced by an amount equal to the hydrostatic
pressure of the mud pumped in. Only gas must be bleed-off. The well should be shut-in if at any time
during procedure, the mud reaches the surface and starts bleeding.

5) Repeat Previous Steps

Steps 2 through 4 must be repeated until all of the gas has been bleed-off or a desired surface pressure
has been reached.

5.1.4 Bullheading

If normal well killing methods with conventional circulation are not possible or will result in critical well control
conditions, bullheading may be considered as a useful method to improve the situation.
The essence of this method is that the mud and influx are displaced / squeezed back downhole into the
weakest exposed open hole formation. If the influx is suspected of containing H2S, it may be acceptable to
squeeze it away down hole provided that casing profile and nature of the formation overlaying the weakest
strata, ensures proper isolation. In other circumstances, e.g. where surface permeable formations are
exposed or only a surface casing is set not ensuring proper strata isolation, this practice is prohibited.

Major factors that will be considered to determine the feasibility of bullheading are as follows:
 Characteristics of the open hole formations, including fracture gradients and estimated permeability.
 Rated pressures of casing, making allowance for wear and deterioration whereas needed (i.e. work-
over).
 Size, location and nature of the influx.
 Consequences of fracturing a section of open hole.

Bullheading may be considered when the following well control situations occur:
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 Rig personnel and equipment cannot handle H2S or high pressure gas influx safely.
 Normal circulation is not possible because:
 Pipe has been sheared or no pipe in the hole;
 String is off bottom;
 String is blocked;
 String is washed out or parted.

 When circulating the kick out may result in excessive gas rates at surface.
 The kick tolerance and / or MAASP have been severely exceeded.
 A combined kick and losses situation is experienced. Should make sure that downhole annulus bullhead
rates to exceed the gas migration rate, in order to ensure that the situation does not deteriorate further.
 Kick calculations shows that casing pressure during conventional kill operations will probably result in a
detrimental well control situation.
 The casing is set near the reservoir, avoiding other loss zones, and reservoir permeability is high,
enabling lower bullhead pressure.
 When killing completed wells (i.e. actual producing wells or production well tests in cased wells).

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

Bullheading will be considered as the prime killing method in the following instances:
 When killing high pressure, high temperature or H2S wells,
 When killing wells in populated areas,
 When killing a well after a well test,
 Before workover operations.

5.1.4.1 Prior to Bullheading

Prior to start bullheading operation, the following steps should be checked:

 Position of the influx in the wellbore is fundamental to deciding whether to bullhead. The nearer the influx
is to the formation; the more likely the bullheading operation will be successful.
 To eliminate the complication of the migrating gas, volumetric method can be considered prior
bullheading. If the gas can be largely removed this way, the bullheading operation will be much easier
and more effective in killing the well.
 Must be kept in mind the pressure limitations of pumping equipment, wellhead equipment and casing.
 If a gas influx is suspected (shut-in pressures continue to rise indicating migrating gas), pumping rate for
bullheading must be fast enough to exceed the rate of gas migration.
 Must be kept in mind that it is a chance, particularly with relatively long open hole sections beyond the
last casing shoe, when bullheading can breakdown the formation at the shoe rather than at the
producing formation.
 Where possible, bullheading should be carried out through an upper choke or kill line outlet on the
BOP‟s, so that in case of washout or equipment failure, a lower outlet and preventer can be used.
 A check valve must be used between the pumping unit and the well to act as a failsafe valve in the event
surface equipment should fail during the procedure.
 If possible, cementing unit should be used for better control and adequate pressure rating.
 Large mud volume and LCM pills should be available in case major losses are experienced during the
operation.

5.1.4.2 Bullheading Procedure

In general, bullheading procedures can only be drawn up bearing in mind the particular circumstances at the
rig site.

Main steps to be followed in bullheading operation will be drawn up along the following lines:
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 Calculate the surface pressure that will cause formation fracturing during the bullheading operation.
 Calculate the tubing (or drill pipe) burst pressure as well as casing burst (to cover the possibility of tubing
failure during the operation).
 Calculate static tubing head (or drill pipe) pressure during bullheading.
 Ensure that enough mud volume is ready to displace the entire open hole volume by 50% excess.
 Slowly pump fluid down the tubing. Monitor pump and casing pressure during the operation. Leak-off test
information should be available to compare.
 Continue pumping until minimum volume displaced is influx volume plus 50%. In some situations, the
entire open hole volume must be displaced plus a margin.
 Shut down and observe the well. Drill pipe and annulus pressures should be approximately the same.
 Raise the mud weight (if necessary) and circulate by Wait and Weight Method until annulus is clear of
influx and the well is killed.

5.1.4.3 Bullheading Complications

If unable to inject at chosen pressure, increasing it to the maximum may be necessary.

If injection is established but injection pressure begins or continues to rise, this could be due to either:
 Gas migration, in which case the injection rate must be increased to overcome the migration rate.
 The permeability of the reservoir is decreasing due to damage by the mud. Bullheading should continue
until maximum surface pressure is reached and then the kill method to be re-evaluated.
 If losses are evident after completion of the bullhead or during the bullhead operation, attempts should
be made to stabilize the well with loss circulation material, gunk squeezes or if necessary with cement
squeeze.

5.1.5 Off-Bottom Kill Method

This method involves circulation at the point of shut-in or at the point stripping has ceased prior to reaching
total depth. The bit will not be at bottom and the kill operation will be more complicated.

An off-bottom kill might be considered if following reasons occur:

 Casing pressure is too high to allow continued stripping,
 Heave becomes a problem,
 Drill pipe is stuck,
 Other equipment problems arise.

This method becomes more difficult as the further off bottom bit and as the weaker formation at the casing
shoe. If the casing seat is strong enough, it might be possible to kill the well by weighting up the system and
pumping heavy mud.

The density of the mud used should not exceed the Equivalent Mud Weight based on leak-off data if the bit
is in open hole.

Because the bit is at a shallower depth relative to TD, the well will be “over killed” and the chances of
becoming stuck are considerable. The heavier mud may not prevent gas migration.

If the well can be stabilized and the influx evacuated with this method it will be necessary, once well is
opened up, to run into the hole and circulate in stages, a lighter mud weight.

5.1.5.1 String Out of Hole

If the string is out of the hole when an influx is detected and the closed-in surface pressure allows safe
lowering the first stands of drill collars or drill pipes into the well, decision can be made to start stripping since
it will improve the well control situation.

Top Drive / Kelly may have to be used in conjunction with singles for extra weight.

Drill collars used should be slick drill collars, but not more than three stands.
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The maximum surface pressure that can be overcome by the weight of the first stand, ignoring the friction
between the annular preventer and string, will be calculated as follows:

A bit without nozzles should be used to reduce the chance of plugged nozzles.

The procedure to enter the string back into the well is as follows:

1) Install inside BOP (Gray Valve or preferably, float valve) on the first stand of slick drill collars or drill
pipes.

2) Lower the stand to just above the blind/ shear rams and close the annular preventer. After that, pressure
between wellbore and annular must be equalized.

3) Open the blind / shear rams and strip through the annular preventer. Should allow to the choke pressure
to increase by the working pressure increment and maintain constant.

4) Fill the string with mud. If drill collars are used instead of drill pipes, continue stripping the slick BHA and
maintain a constant choke pressure.

5) Allow the choke pressure to increase, without bleeding-off any mud when stripping the first stands of drill
pipes.

6) Continue the killing operation with stripping methods, as described in previous sections. If it is not
possible to strip the string into the well, the volumetric method or bullheading may have to be used.

If it is not possible to strip the string into the well, the volumetric method or bullheading may have to be
employed.

5.1.6 The Low Choke Pressure Method

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

To prevent casing burst or formation breakdown while circulating out, choke pressure must be reduced
sufficiently.

In kick situations requiring weight increase, the mud weight should be increased as soon as practical. If a
kick occur during while drilling tight formations or after trips where tight formations have been drilled may be
circulated out using this method without increasing the mud weight.

The formation will continue to flow until the combined effect of the new kill mud, of light weight mud, and low
choke pressure all balance the formation pressure.

In formations with high permeability, the influx will exceed that controllable by even the maximum rate used
to circulate out the kick, so these types of formations cannot be effectively killed by this method.

The low choke pressure method is not recommended to be used when there is uncertainty about formation
permeability.

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