Welcome to

IWCF Well control

Level 2

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Tháá ng 10/2011
All members of the Wellsite Operations team (pre-Driller) that directly
contribute to the creation, detection or well control of a well influx or
expected to have completed an accredited (eg: IWCF/IADC) well control
course at Level 2.
Training to have been completed within on year of assuming a position
that requires this level of training.
Pass/fail Examination: repeated every 5 years.
What if this course is not completed? Future tenders /projects may well
expect this level of certification of personnel to demonstrate the
necessary competence and understanding on their contribution to a well
site influx.
The integrity of the drilling operation may become compromised due to a
lack of understanding around basic safety standards.

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Tháng 10/2011
Who should do the course?
Drilling operations personnel at pre-Driller level who are undertaking a
well control course for the first time.
Recommended for oil field personnel with no drilling experience, for
example:
Derrickman, Assistant Derrickman, Barge Engineer, Casing Drew
Supervisor, Cementer, Coil Tubing Engineer/specialist, Completions
Engineer, Drilling Fluids Engineer, Facilities Engineer, Geologist, Marine
Supervisor, Mechanical Service Engineer, OIM (Offshore Installation
Manager), Operations Engineer, Operations Technician, Petroleum
Engineer, Safety Officer, Service Engineer, Subsea Engineer, Subsea
Supervisor, Dynamic Positioning [DP] Operators, Well Maintenance
Supervisor, Well Test Engineer, Wireline Crew Supervisor, Drilling
Contractor Wellsite Rig Engineer, Wellsite ROV Supervisor, Wellsite
Directional Driller, Fishing Engineer, Mud Loggers.
 Well control incidence's

• Personnel
• Employment
• Environment
 Well control incidence's
Personnel: The uncontrolled
release of pressure in a well can
easily lead to damage to equipment
and injury or even death to nearby
personnel.
Furthermore, the harmful chemicals
found in crude oil such as benzene
can have effects on those who
some into prolonged contact with it
which can cause health issues,
sometimes later in life.
 Well control incidence's

• Employment - well control

incidents are commonly
caused by worker negligence
and can result in massive
monetary losses and layoffs
 Well control incidence's
Environment - Well control can
have varying environmental
concerns or impacts ranging from
the controlled and licensed
discharge of BOP Stack control
fluids through to the catastrophic
and entirely uncontrolled
discharge of formation fluids as
was most recently experienced in
the Gulf of Mexico which had a
massive impact an the
surrounding environment and
marine life.
 Effects of a well control incident

• Capital loss
• Over regulation
• Moratorium on drilling
• Limiting areas of operations e.g.
Arctic/corral
 Understand the need for well control
training and assessment.
“Why are we here?" and how do we ????????

• Capability to apply well control skills

• Responsibility to colleagues
• Reduce the severity of impact of a well control event
 Barrier Envelope and barrier element
• A "Well Barrier Envelope" is defined as a combination of one or more
Well Barrier Elements that together constitute a method of containment
of fluids within a well that prevents uncontrolled flow of fluids into another
formation, or, to escape at surface.
• A "Well Barrier Element" is defined as a component part of a well
designed to prevent fluids or gases from flowing unintentionally from a
formation, into another formation or to escape at surface.
 Barrier
• Primary Well Barrier: is the first object
that prevents flow from a source.
• Secondary Well Barrier: is the second
object that prevents flow from a source.
Blue = Primary barrier = mud =drilling fluid
RED = Secondary barrier = casing,etc
In the example opposite you can see that the drilling
fluid is the primary barrier and shows that the fluid
(hydrostatic head pressure) is greater than the
formation pressure giving an overbalance (primary
barrier).
0.052 = Constant
(True Vertical Depth x Fluid Weight x 0.052 =
Hydrostatic Pressure)
Barrier envelope elements
Barrier envelopes
Well barrier during drilling, coring or stripping
 Useful Definitions
• Unintentional flow: This is any flow of fluid (liquid or gas) in or out of the
well through a failed barrier.
• Independent: Each type of mechanical closing barrier in/on a well shall
be able to be closed and contain the well bore fluids by its own control
system irrespective of any power failure.
• In a system with two independent tested levels of protection i.e. barriers
in place, there shall be always one barrier that acts as a first level of
protection and one as a second level of protection.
 The first level of protection is called a primary barrier.
 The second level of protection is called a secondary barrier.
 The primary barrier’s function is to prevent unintentional flow to the
environment or other formations.
 The secondary barrier is to prevent unintentional flow if the primary
barrier fails. To be qualified as a Barrier, it is required to be installed
where it is intended and to be tested upon installation
 Barrier testing criteria

• Pressure testing a barrier is by application of a differential pressure

across a “seal” and measuring the capability of this seal to resist this
differential pressure. This condition can be achieved by direct
application of pressure (pressure testing) and measuring its seal
tightness or by decreasing the hydrostatic pressure on the
downstream side of the “seal” (Inflow testing) and measuring its
effectiveness. Both are pressure testing in the direction of flow.
 Mechanical barrier & Hydrostatic Barrier
Mechanical barrier:
Pressure tested in the direction of flow from well to achieve required differential
across the barrier element by either
i) application of positive pressure,
Or,
ii) by use of inflow testing
If this cannot be realistically achieved the following can be utilized subject to
acceptable risk assessment.
• Pressure tested not in the direction of flow from well
• By verification of location (e.g. tagging, cementing etc.)
Hydrostatic Barrier
Required to be monitored and maintainable to qualify as a barrier. Some stable
fluids may qualify as a barrier without maintenance ( e.g. Water)
Note: Shearing devices that are required to seal should be capable of being
pressure tested after a shearing operation in order to qualify as a barrier .
 Risk Management

Risk= Probability x Severity

Risk Management is an
important part of any operation
and the management of risks is
vital in ensuring that tasks can
be comoleted safety and
efficiently. The mitigation of risk
during well control is achieved
by reducing the probability of an
incident occurring and/ or by
reducing the level of severity if
an incident were to occur
 Risk Management
A few of the measures we can take to reduce risk:

 Training  Equipment Testing  Risk Assessments

 Drills  Maintenance  Safety Cases
 Understanding of Equipment  Blow Out Preventers  Safety Management System
 Understanding of Risk  Subs/ Valves  Well Kill Procedures
 Communication  Choke Manifold  Well Monitoring
 Experience  Tubulars  Management of Change
 Attitude  Fail safes  Lessons Learned
 Mentoring  PPE
 Risk Management
The main processes of risk management:
• Hazard identification and mitigations
• Crew meetings and handovers
• Use instructions
• Toolbox talks.
 Management Of Change
• The MOC element helps ensure that changes to a process do not
inadvertently (accidently) introduce new hazards or unknowingly
increase risk of existing hazards
• The MOC element includes a review and authorization process for
evaluating proposed adjustments to facility design, operations,
organization, or activities prior to implementation to make certain that
no unforeseen new hazards are introduced and that the risk of
existing hazards to employees, the public, or the environment is not
unknowingly increased.
• It also includes steps to help ensure that potentially affected
personnel are notified of the change and that pertinent
(relevant) documents, such as procedures, process safety
knowledge, and so forth, are kept up–to-date.
 Well control drills

The following guidelines shall be followed for well control drills :

• Well control drills shall be initiated by the contractor or the Drilling

Supervisor and performed under the supervision of the Drilling
Supervisor to ensure that the crews are adequately trained and
prepared to implement well control procedures correctly.

• Well control drills shall only be conducted when they do not

complicate ongoing operations. A kick should be simulated by
manipulation of a primary kick indicator such as the tank level
indicator or the flowline indicator.
 Well control drills
• Reaction time in seconds from the moment the kick is simulated until
the well is closed in. The designated crew member is a member of the
drill crew who is present on the drill floor at the time of a BOP drill or
well control situation. All drill crew members must be capable and able
to react correctly to the drill or real well control situation.
• The total time taken for the drill. The time taken should be less than a
pre-determined benchmark. If not, the drill shall be repeated.
Types of drills
• Pit drill
• Trip drill
• Choke drill
• Diverter drill.
 Kick Drill While Drilling - Pit Drills Procedure
Before drilling out to any shoe, and at the discretion of the Drilling Supervisor, but not less
than once every week per crew while normal drilling operations are in progress.
1. INITIATE kick verbally or by raising a float (normally Drilling Supervisor or
Toolpusher).
2. On initiation the crew leader is to ALERT the crew and STOP the rotary.
3. PULL kelly above the rotary table until the lower kelly cock is above the drilling floor,
at same time SLOW DOWN the pump.
4. STOP the pumps.
5. CLOSE the annular preventer
6. OPEN the hydraulic operated valve in the side outlet from the BOP stack to the choke
manifold (The inner valve is always open under normal conditions).
Note : A diagram with all relevant measurement relating to tool joint position should be
available to the driller at the BOP control panel.
7. TAKE readings of the closed-in annulus and drillpipe pressures
8. MEASURE the ‘gain’ in the active mud tank.
9. END drill, RETURN all settings to normal operating mode.
 Kick Drill While Tripping – Trip Drills
Procedure
At the discretion of the Drilling Supervisor, but not less than once every two weeks per
crew while normal drilling operations are in progress.
1. INITIATE kick verbally or by raising a float in the trip tank.
2. On initiation the crew leader (Driller/Assistant driller) is to ALERT the crew.
3. BRING tool joint to rotary level.
4. INSTALL stabbing valve in open position (hand tight).
5. CLOSE stabbing valve.
6. CLOSE the annular preventer.
7. OPEN hydraulic operated valve in the side outlet from the BOP stack to the choke
manifold.
Note: A diagram with all relevant measurements relating to tool joint position shall be
available to the driller at the BOP control panel.
8. INSTALL circulating head, MAKE UP correct torque, OPEN stabbing valve and
TAKE readings of the closed-in annulus and drillpipe pressure.
9. READ gain in trip tank.
10. END drill, RETURN all settings to normal operating mode
 Choke drill
Choke drill is one of well control drills that will improve crew
competency in well control’s method. The advantages from the choke
drill are as follows:
• Get more familiar to practice controlling the pressure via a choke on
the rig
• Get more understanding about lag time
• Practice the procedure to obtain the shut-in drill pipe pressure
• Ensure the surface well control equipment as pressure gauges,
choke, BOP is ready for work
• Get more practices when attempting to bring the pump up to kill
speed, slow the pump down and change the pump rate
 Choke drill procedures
1. Trip in hole above top of cement
2. Fill the pipe and circulate seawater or mud around for few minutes
3. Close annular preventer or upper rams preventer
4. Pressure up annulus to 200 psi (the pressure may be different depending on the
company policy.)
5. Line up the pump
6. Pump slowly to bump the float and obtain shut in drill pipe pressure
7. Bring the pump to kill rate by holding casing pressure constant – personnel need
to adjust the choke
8. Measure lag time for the drill pipe gage after the adjustment of choke is made.
9. Change circulation rate by holding casing pressure constant. Crew needs to
adjust choke to achieve this.
10. Shut the pump down by holding casing pressure constant.
11. Bleed off pressure and line up for drilling operation
 Diverter drill procedures
1. Raise the kelly until a tool joint is above the rotary table.
2. Increase the pump rate to maximum output
3. Open the diverter line valve(s).
4. Close the diverter unit (or annular preventer).
5. Ensure diverter closed
6. Notify company personnel.
7. Open diverter
8. END drill, RETURN all settings to normal operating mode
 Pressure Gradient
One cubic foot holds If the fluid has a On the bottom of a
7.48 gallons of fluid. density of 1ppg cubic foot is 144 sq.in

1’ 1’
1’
7.48 7.48 7.48
galls/cu/ft lbs/cu/ft lbs/cu/ft

1’ 1’ 144 sq.ins 12”

1’ 1’ 12”

To calculate the pressure

exerted by this fluid on one sq.in 1’
7.48 = 0.052 psi
Divide 7.48 by 144 to get a
144
mathematical constant

12”

12”
 Hydrostatic Pressure
Hydrostatic Pressure is the pressure exerted by a column of fluid with
pumps off and is calculated by multiplying the gradient of the fluid by
the True Vertical Depth at the depth of interest

P = d x TVD x 0,052
P = psi
d = ppg
TVD = feet
Conversion factor = 0,052 psi/ft
Or:
HP = Fluid gradient x TVD
Fluid gradient = psi/ft
 Calculating examples
Example:
Calculate Pressure Gradient off 9.0 ppg Fluid Density?
PRESSURE GRADIENT= 9 ppg x 0.052= 0.468 (psi/ft)

Example:
Calculate Fluid Density off 0.465 psi/ft Pressure Gradient?
Mud Density= 0.465 ÷ 0.052= 8.94 ppg

Example:
Hydrostatic pressure= 8736 psi, TVD=12,000 ft. Calculate Fluid Density?
Fluid Density= Hydrostatic pressure ÷TVD ÷ 0.052= 8736 ÷12000÷0.052=14 ppg

Example:
Hydrostatic pressure= 7436 psi, Fluid Density =13 ppg. Calculate TVD?
TVD = Hydrostatic pressure ÷ Fluid Density ÷ 0.052= 7436 ÷13 ÷0.052= 11,000 ft
 Calculating examples
Example:

A 10,500 ft TVD well has two fluids in the well, a 15 ppg fluid from TD
to 7,125 ft, and an 8.33 ppg fluid to surface. What is the HP at the
bottom of the well?

HP of 15 ppg fluid = 15 ppg x 0.052 x (10,500 - 7,125) ft

= 15 ppg x 0.052 x 3,375 ft = 2,633 psi

HP of 8.33 ppg fluid = 8.33 ppg x 0.052 x 7,125 ft = 3,086 psi

Total HP = 2,633 psi + 3,086 psi = 5,719 psi

Seismic survey
 Sample 2-D marine seismic line. The line is merged from
individual shots (along the X-axis), and the Y-axis displays
the time in thousands of a second it takes the seismic wave
to travel from the surface to a reflector and back again
Source rock
(shale or coal)
Normal Formation Pressure
Normal formation pressure is
equal to the hydrostatic pressure of
the water occupying the pore
spaces from the surface to the
subsurface formation.
Native fluid is mainly dependent on
its salinity and is often considered
to be:
Normal pore pressure gradient
0.465 psi/ft at IWCF test
Average normal pore pressure Gulf
of Mexico
 Normal/ abnormal pore
pressure
PRESSURE

NORMAL PRESSURE IS NORMALY WITHIN THE

PORES DOWN TO 3000 FT EQUAL
0.465 PSI/FT

SUBNORMAL ABNORMAL
PRESSURE PRESSURE

DEPTH
 Formation pressure

0.4
65
psi
Abnormal P f
/ft

Normal P f
Depth

Subnormal P f

Formation Pressure
 Abnormal Pressure

A pressure that is higher than the definition given for normal pressure is
abnormal.
The principal causes of abnormal pressures are:
• Under-compaction in Shale’s
• Faulting
• Salt domes
• Aquifers.
Different oil traps
The most common reason for
abnormal pressure is
UNDERCOMPACTED SHALES

UNCONSOLIDATED

SHALE-DENSITY INCREASES WITH DEPTH - WATER ESCAPES

SAND WITH COMMUNICATION TO SURFACE

SHALE-DENSITY DECREASES WITH DEPTH-WATER ENCLOSED

Abnormal pressure
ENCLOSED SAND LENS WITH FORMATION FLUID
 FAULTING
These types of traps are formed when reservoir rock is split along a fault
line. Between the walls of the split reservoir, clay traps oil and prevents it
from leaving the trap. Other times there exists a pressure differential across
the two sides of the fault that prevents the fluids from migrating.
 Salt dome

A salt dome is a mound or column of salt that has intruded upwards into
overlying sediments. Salt domes can form in a sedimentary basin where
a thick layer of salt is overlain by younger sediments of significant
thickness. Where conditions allow, salt domes can rise thousands of feet
above the layer of salt from which they began growing.
 AQUIFER
An aquifer is an underground layer of water-bearing permeable rock, rock
fractures or unconsolidated materials (gravel, sand, or silt) from which
groundwater can be extracted using a water well.
If the impermeable area overlies the aquifer, pressure could cause it to become
a confined aquifer
 Mud weight window

A narrow mud-weight
window determined by the
formation pore pressure
and fracturing pressure
gradients
 Fracture Pressure
 Formation Fracture pressure is the amount of pressure necessary to
permanently split or break the rock structure of a formation.
 Just overcoming formation pressure is normally not enough to create a
fracture.
• Porous permeable formations allow formation, or pore fluid to flow
• As such, fluids must be pumped into it
• The pore fluid flow rate is limited
• Once the pore fluid flow (if any) rate is exceeded the formation rock
becomes stressed and may deform, then fracture
Fracture Pressure
 OVERBURDEN GRADIENT (Onshore)

• If the average overburden gradient is = 1.0 psi/ft

• Calculate the overburden stress at 10000 ft.

OB
F=pxA A

10.000 ft x 1.0 psi/ft = 10.000 psi

What dose this mean? It means if we want to lift the
formation at this depth the nesessary force will be 10000
lbs pr sqare inch
OVERBURDEN GRADIENT (Offshore)

Salt Water Gradient 0.465 psi/ft

Overburden Gradient 1.0 psi/ft
0,465 psi/ft
Determe the overburden pressure at 10.000 ft. When the
water depth is 2000 ft. 1 psi/ft

Overburden stress at 10.000 ft is ?

2.000 ft x 0.465 psi/ft = 930 psi

OB
8.000 ft x 1.0 psi/ft = 8.000 psi

Pressure at 10000 ft TVD = 8.930 psi F

Overburden stress
Onshore
Formation gradient: 1,0 psi/ft
Overburden Stress:
10.000x1 = 10.000 psi

Seawater gradient: 0,465

Offshore
Depth = 10.000 ft

Formation gradient: 0,465 psi/ft

Overburden Stress:
2.000x0,465 = 930 psi
8.000x1= 8.000 psi
= 8.930 psi

Overburden Stress [psi]

 Effects of water depth on formation fracture
pressure.
• Onshore:
Convert 10,000 psi at 10,000’ TVD in to ppg
= 10,000/ (10,000 x 0.052) = 19.2 ppg

• Offshore:
Convert 10,000 psi at 10,000’ TVD in to ppg
= 8930/ (10,000 x 0.052) = 17.1 ppg

Water depth will reduce the formation fracture pressure and offshore
wells will have smaller margin between mud weight and fracture
pressure than land wells because of water depth effect.
 Well control Primary
Acitive
The function of Well Control can be subdivided into 3 main
categories:
1. Primary (active) well control is a overbalanced drilling
fluid which prevent an influx of formation fluid into the
well bore. Drilling fluid density must be consistent and
continuous measured (monitored).
2. Secondary (passive) well control is activated when
primary well control has failed to prevent formation fluids Secondary
from entering the wellbore. This is done by activating Passive
(closing) the blow-out preventers (BOPs). The number,
size and rating of the BOPs used depend on the depth
of the hole and the maximum anticipated formation
pressures.
3. Tertiary well control is to drill a relief well
 The differences between surface and
subsea
drilling operations.
• Vessel movement and weather (emergency
disconnect)
• BOP on the sea bed
• Water depth
• Riser above the BOP
• Choke and kill lines.
Vessel movement and weather (emergency
disconnect)
EQUIPMENT
Lower Marine Riser Package (Subsea BOP)
When this annular is used and has a failure
or is worn out, the LMRP can be released
and retrieved to the surface for servicing
while the Lower Blowout Preventer Stack
maintains pressure competency on the
wellhead. If the weather offshore is
reaching the rigs limit, the LMRP can also
be disconnected then reconnected without
having to return the LMRP to the surface.
In an emergency, the LMRP can be
unlatched. This could be due to several
reasons such as a Blowout or the
Dynamically Positioned Rig/ vessel driving
off the locatio inadvertenly or the weather
reaching the vessels limits.
 Circulating System
The Rig Circulating System consists of:
1. Mud Tanks ( where the mud is stored)
2. Mud Pumps ( which are supercharged with mud from the tanks to
their suction lines)
3. Standpipe manifold
4. Rotary Hose
5. Swivel and Kelly or Topdrive
6. Drillstring
7. Flowline
8. Shaleshakers mounted on top of mud tanks
Circulating
system
 Drilling fluids functions
• Maintaining primary control
• Carry and suspend drill cuttings
• Filter cake.
Drilling set-up
Drilling of a well
Mud Circulation System
DYNAMIC & STATIC PRESSURES

Dynamic Pressure = Pumps on

Static Pressure = Pumps off

What happens with BHP

when pums are turned off ?
Circulating Pressure
 Static Bottom Hole Pressure
Drilling fluid density in the well is 10 ppg
and the pumps are off

Static Bottom Hole Pressure

SBHP = d (ppg) x 0,052 x TVD (ft)

Example : Ps = ppg x 0.052 x TVD and the wells

drilling fluid density is 10 ppg and depth of the well
10,000 ft TVD
is 10000 ft TVD. Calculate static BHP.
10 ppg x 0.052 x10,000 ft = 5200 psi. 5200 psi
 Dynamic bottom hole pressure

ECD or Annular Pressure Loss

• Pump pressure with 30 SPM = 2600 psi
• Pressure drop in surface lines = 100 psi
• Pressure loss in drill string = 500 psi
• Pressure loss in BHA = 400 psi
• Bit pressure drop = 1300 psi
• APL = 300 psi

Static BHP = 10 ppg x 0.052 x10,000 ft = 5200 psi.

Calculate circulating Bottom Hole Pressure

Dynamic BHP = 10 ppg x 0.052 x10,000ft + 300 psi = 5500 psi. 5500 psi
 Equivalent Circulating Density
The ECP will increase circulating BHP with an amount equal annulus
friction pressure and is calculated by

Example:
• APL = 300 psi
• Mud weight = 10 ppg
• Depth = 10,000 ft

ECD = 300/ (0.052 x 10,000) + 10 = 10.5 ppg

 PUMP STROKE CHANGE 2600 psi
It is a good practice to calculate change in circulating
pressure before changing pump speed.
4063 psi
Calculate change in pumping pressure:

2
100 
P2  psi   2600     4063 psi
 80 
If we increase pump stroke from 80 spm to100 spm. What
will the new pump pressure become?
Drilling fluid density change Pump pressure = 2600 psi
It is a good drilling practice to
calculate new circulating pressure
before changing the mud weight.
Formula used to calculate change in
bottom hole pressure is

Calculate new pump pressure if MW is

increased from 10 ppg to 11 ppg.
The new pump
11 pressure would be
P2  2600   2860psi
10 approximately
2860 psi.
Roughneck/ Shaker Hand
Shale Shakers
Question: (given to a Roughneck /Shaker Hand)
Why are you in the shale shaker room‘?
Answers:
• To keep the area clean.
• To watch that the cuttings don’t block the screens
• To Change out screens as required.
• To take the Mud Weight every 15 to 30 minutes
• To Make sure the mud flows over all shakers by
adjusting the gates at the header box.
There is nothing wrong with the answers but what
about well control?
Roughneck/ Shaker Hand (cont)

A Roughneck/ Shaker Hand should also be aware

of the following when working in the Shaker
Room.
 The Driller must be Informed of any
changes/anomalies witnessed in the Shaker
Room.
 The need to know and understand how to
carry out a flow check when required
 If mud is coming over the shale shakers and
you know the mud pumps are not pumping,
inform the Driller (the well could be flowing)
Roughneck/ Shaker Hand (cont)
 If you see an in increase in fluid flow coming over the shale shakers (the well control
be starting to flow)
 If there are any changes the weight of the fluid being returned (there are several
reasons this could be happening such as the fluid could be gas cut and be lighter or
water flow was encountered down hole)
Roughneck/ Shaker Hand (cont)
• Changes in cuttings coming over the
shakers such as the shape and size of
cuttings. This could be the first indication of
a problem. Long splinter type slivers will
often indicate the mud weight being too low.
The splinters will often come from the wall of
the hole blown off by the formation
pressure..
Roughneck/ Shaker Hand (cont)

 Losing Mud over the shale shakers (inform

the Driller. He may be thinking that he is
losing mud down hole).
 Change out shaker screens as required.
 Understand and know the time it takes for
the mud/ fluid flow to stop at the shale
shaker once the mud pumps have been
switched off (if it takes longer than
expected the well could be flowing).
 Make sure the Degasser in working
correctly and always ready for operation.
Shale Shaker
The solids removal equipment includes mechanical devices for separating drilled
cuttings from the mud as it returns from the well bore. The Shale Shaker is the first
stage and removes most of the coarse rock cuttings and cavings.
A typical Shale Shaker is composed of two or three vibrating screens over which the
mud passes. The upper scren has a large mesh size that allows the mud to pass
through the scren out separates the coarse drilled cuttings.
The mud falls on to the lower screens which
have finer mesh size to catch the smaller
cuttings but again allows the mud to pass
through.
The screens vibrate or ‘shake’ to remove the
‘Shale’ hence the name. There are usually
three or more Shale Shakers run in parallel and
screen mesh sizes are changed regularly to
meet the changing conditions as drilling the
well bore progresses.
 Desilter and Desander
An item of solids-control equipment- consisting
of an inverted cone; the mud being fed
tangentially into the upper (larger diameter)
part.
The resulting spinning effect forces solids to
the wall of the device and they exit from the
bottom (apex) of the cone, while the cleaned
liquid exits at the top.
Hydrocyclones are classified by the size of the
cone as either desanders (typically 12" in
diameter) or desilters (4-6" in diameter) and will
separate particles in the medium and fine size
ranges.
The efficiency of hydrocyclones is poor in
viscous weighted muds and many units are
being replaced by more efficient, high-speed
shakers.
 CENTRIFUGE
The centrifuge removes fine and ultra fine solids. It
consists of a conical drum that rotates at around
2000-4000 rpm.
Drilling fluid is fed into one end and the separated
solids are moved up the bowl by a rotating scroll to
exit at the other end.
Centrifuges generally have limited processing
capacity (50-250 gpm) but are useful for
processing weighted drilling fluids and can remove
finer solids than a Hydrocylone or Shale Shaker
screens.
When Running a Centrifuge using mud from the
active mud system, caution must be taken not to
reduce the mud density too much, if this not
managed correctly it could lead to the Hydrostatic
Pressure being reduced down hole, causing a
Kick.
 Barite sag
Potential problems with the loss of barite, for
example:
• Barite sag: In vertical wells, barite sag
happens when circulation is stopped.
Whereas, in deviated wells, the complex
setting mechanism called
“Boycott settling” can cause quick settling.
Heavier particles settle at the low side of
the wellbore and lighter fluids are at the
high side
• Solid removal equipment: Solids are
added to increase drilling fluid density to
control pressure
 SLOW CIRCULATION RATE

Well Control Operations are conducted at reduced circulating rates in order to

• Minimise excess of annulus pressure

• Allows for more controlled choke adjustments
• Allows for the weighting up and degassing of the mud and
disposal of the influx
• Reduce the risk of choke erosion
• Reduce risk of over pressuring system if plugging occurs
 SCR on 2 pumps and 2 rates

• If practical, at the beginning of every tour at lease once a tour

• Any time the mud properties are changed
• When a bit nozzle is changed
• When the BHA is changed
• After repairs have been made to the mud pumps
• After long open hole section
SCR

• A minimum of 2 (two)
circulating rates should be
obtained for minimum 2
(two) pumps
• The pressure must be
recorded using the gauges
that will be used during
well kill operations
Different ways to determineChoke Line Friction (CLF)

1. Pump down string and up

Marine Riser. 500 psi
2. With the BOP closed, pump
down string and up Choke Line.
700 psi

Subtract the two recorded pressures and

CLF is obtained.
CLF = 200 psi
2 With the BOP closed, pump down String and up Choke Line. Keep the Kill Line open.

The pressure read on the kill

Gauge is CLF.
 3 Pump down Kill Line between two closed Rams and up Choke
Line

.
The Pressure recorded
divided by 2 is CLF.
4 Pump down Choke and up Marine Riser.

Recorded pressure is CLF .

 Pressure losses Well Control – Subsea BOP

Considerations
• BOP pressure monitor present?
• Mud gel strength may influence
pressure readings
– Example: kill line used as
pressure monitor
• Riser pressure losses may
become significant in case of ultra
deep-water
Leak Off Test
Formation Strength Test or LOT

By pressuring up the formation we can determine at what pressure at surface the formation will
start to leak. The test is called a leak off test (LOT) and determines the pressure at which the
formation begins to take fluid.

 Is conducted after drilling out 10 to 30ft below the casing shoe.

 Circulate and condition mud.
 Pull the bit back into the casing shoe
 Line up calibrated pressure gauges, covering various pressure ranges and preferably
mounted on a special manifold.
 The LOT give us information about the strength of the formation and the integrity of
the cement job.
 LOT
 When performing a LOT we use a high pressure, low volume pump (0.25 - 0.5 bbl/min.)
such as the cement pump or a test pump whish can deliver smooth pumping.
 Rig pumps are not suitable to perform leak off tests.
 Record the cumulative volume pumped, the initial static pressure and the final static
pressure after the waiting period.
 The objective of a LOT is not to fracture the formation, but to determine “formation leak
pressure”.
 This “leak pressure” is observed when the strait line starts to bend. When formation
starts to leak we will stop pumping to avoid fracturing the formation.
 Leak of test
PRESSURE

1100

1000

900

800
MAASP =720 psi
* * *
700 *
* *
600
*
500 *
400 *
*
300
*
200 *

100 *
*

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
VOLUME
 Formation Integrity Test
Formation Integrity Test is the method to test strength of formation and
shoe by increasing Bottom Hole Pressure (BHP) to designed pressure.
 Formation Integrity Test
1. Drill out new formation few feet, circulate bottom up and collect sample to
confirm that new formation is drilled to and then pull string into the casing.
2. Close annular preventer or pipe rams, line up a pump, normally a cement
pump, and circulate through an open choke line to ensure that surface
line is fully filled with drilling fluid.
3. Stop the pump and close a choke valve.
4. Gradually pump small amount of drilling fluid into well with constant pump
stroke. Record total pump strokes, drill pipe pressure and casing
pressure. Pump until casing pressure reaches the pressure required for
formation integrity test. Hold pressure for few minutes to confirm
pressure.
5. Bleed off pressure and open up the well. Then proceed drilling operation.
Maximum Allowable Annular Surface pressure M.A.A.S.P

MAASP must never be exceeded.

 MAASP is defined as the surface pressure that when added to
the HH exerted by the drilling fluid density column, could result
in formation breakdown at the weakest point in the well, if
exceeded.
 The weakest point is normally considered to be under the shoe.
 This value of the MAASP is based on the Leak Off Test data.
MAASP= ( MAMW- Drilling MW) x 0.052 x Shoe TVD
 LOT

720 psi
720 psi

MW 9.6 ppg
MAASP= 720 psi

3,000’ +
1498 psi

FR =2218 psi

Calculate bottom hole leaking pressure

FP = MAASP + Hydrostatic Pressure
Maximum Allowable Mud Density
Is the highest drilling fluid density which the well can
take without leaking into the formation with the pumps
off. Rounded down one decimal 0 psi

Calculate static MAASP = 720 psi

3,000’ MW = 9.6 ppg

2218 psi
720
MAMD = + 9.6 = 14.2 ppg
3000 X 0.052
MAMD= 2218
= 14.2 ppg
3000 x 0.052
KICK
The well can go underbalanced if
 we encounter an unexpected increase in pore
pressure
 or if the level in the well drops

Other reason for a kick can be:

• Loss of hydrostatic pressure

• Gas cutting
• Lost circulation INFLUX
• Swab and surge effects
• Tripping
 Failing to keep the hole full
• If a week formation is drilled into we may start to
lose mud into that formation.
• If the mud level is allow to fall, the mud hydrostatic
will fall, potentially causing the well to become
underbalance and a kick taken
• When lose are encountered it is of paramount
important that the well is kept full.
• Tripping
Wet And Dry Tripping Calculations
 Tripping dry (POOH)

Open-End-Displacement
If the drill pipe is pulled out of hole without
starting the trip tank pump and lining up to
the trip tank. The volume in the well will
drop and the HH and BHP will drop
Tripping dry means we have open end
displacement and no float in the BHA. The
drop in volume will be equal to the volume
of open end drill pipe steel volume
displacement pulled.
 19. PRESSURE DROP PER FOOT TRIPPING DRY PIPE (psi/ft)
Drilling mud density x 0.052 x Metal Displacement (bbl/ft)]
Riser/ Casing capacity (bbl/ft ) - Metal Displacement (bbl/ft)

WELL DATA: Depth = 10000ft TVD

Bit size = 8 1/2"
Shoe depth = 8500ft TVD
Mud weight = 12.6 ppg
Collars - 600ft. capacity = 0.0077 bbl/ft
Drill-pipe 5" capacity = 0.0178 bbl/ft
Metal displacement = 0.0075 bbl/ft
Casing/pipe annular capacity = 0.0476 bbl/ft
Casing capacity = 0.0729 bbl/ft
One stand of drill-pipe = 94ft.
Over-balance = 200 psi.

19. PRESSURE DROP PER FOOT TRIPPING DRY PIPE (psi/ft)

= 0.0751 (psi/ft)
 23. LENGTH OF TUBULARS TO PULL DRY BEFORE OVERBALANCE IS LOST (ft)

Overbalance ( psi ) × [Riser or Casing Capacity ( bbl/ft ) - Metal Displacement (bbl/ft)]

Mud Gradient ( psi/ft ) × Metal Displacement (bbl/ft)
WELL DATA: Depth = 10000ft TVD
Bit size = 8 1/2"
Shoe depth = 8500ft TVD
Mud weight = 12.6 ppg
Collars - 600ft. capacity = 0.0077 bbl/ft
Drill-pipe 5" capacity = 0.0178 bbl/ft
Metal displacement = 0.0075 bbl/ft
Casing/pipe annular capacity = 0.0476 bbl/ft
Casing capacity = 0.0729 bbl/ft
One stand of drill-pipe = 94ft.
Over-balance = 200 psi.

23. LENGTH OF TUBULARS TO PULL DRY BEFORE OVERBALANCE IS LOST (ft)

= 2661.7 ft
Number of drillpipe stands = 2661.7/ 94 = 28 stands
 Tripping wet

Closed End Displacement

• When tripping out of the well we need
to keep the well full at all time. If we
POOH without starting the trip tank
pump and monitoring the trip tank. We
will start loosing the HH and reduce
the BHP.
• Tripping wet means we are pulling
pipe with closed end displacement.
CED is equal to the volume of closed
end DP pulled.
 20. PRESSURE DROP PER FOOT TRIPPING WET PIPE (psi/ft)
Drilling mud density x 0.052 x Closed End Displacement (bbl/ft)]
Riser/ Casing capacity (bbl/ft ) - Closed End Displacement (bbl/ft)

WELL DATA: Depth = 10000ft TVD

Bit size = 8 1/2"
Shoe depth = 8500ft TVD
Mud weight = 12.6 ppg
Collars - 600ft. capacity = 0.0077 bbl/ft
Drill-pipe 5" capacity = 0.0178 bbl/ft
Metal displacement = 0.0075 bbl/ft
Casing/pipe annular capacity = 0.0476 bbl/ft
Casing capacity = 0.0729 bbl/ft
One stand of drill-pipe = 94ft.
Over-balance = 200 psi.

20. PRESSURE DROP PER FOOT TRIPPING WET PIPE (psi/ft)

= 0.3482 (psi/ft)
 24. LENGTH OF TUBULARS TO PULL WET BEFORE OVERBALANCE IS LOST (ft)

Overbalance ( psi ) × [Riser or Casing Capacity (bbl/ft) – Closed End Displacement (bbl/ft)]
Mud Gradient ( psi/ft ) × Closed End Displacement (bbl/ft)
WELL DATA: Depth = 10000ft TVD
Bit size = 8 1/2"
Shoe depth = 8500ft TVD
Mud weight = 12.6 ppg
Collars - 600ft. capacity = 0.0077 bbl/ft
Drill-pipe 5" capacity = 0.0178 bbl/ft
Metal displacement = 0.0075 bbl/ft
Casing/pipe annular capacity = 0.0476 bbl/ft
Casing capacity = 0.0729 bbl/ft
One stand of drill-pipe = 94ft.
Over-balance = 200 psi.

24. LENGTH OF TUBULARS TO PULL WET BEFORE OVERBALANCE IS LOST (ft)

= 574.3 ft
Number of drillpipe stands = 574.3/ 94 = 6 stands
 Factors that affect fluid density
• Adding water to the mud system causes decrease in the mud density
and viscosity.
• Use of centrifuges:
 The cut point is proportional to the mud viscosity.
 The feed flow rate capacity reduces significantly as mud gradient is
increased.
 Gear box torque may rise and become unstable at elevated mud
gradients.
 Gas cut mud

Gas can enter the mud for one or more of the following reasons:
• Drilling a formation that contains gas even with a suitable
overbalance.
• Temporary reduction in hydrostatic pressure caused by swabbing as
pipe is moved in the hole.
• Pore pressure in a formation being greater than the hydrostatic
pressure of the mud column.
When gas-cut into your drilling mud, it will reduce mud weight causing
hydrostatic pressure decrease, the bottom hole pressure reduced most
when the gas is near the surface.
 Operations can reduce hydrostatic head.
• Cement setting: when cement is setting up cement will change from
fluid to solid. This period of time is called the transient time. To avaid
gas break through we add gas block and try to design the transient
time as short as possible. We also can set up the cement to set up in
different stages for better cement sealing properties.
• Temperature effects on well bore fluids: The downhole
temperatures while drilling will affects the viscosity and
drilling fluid density. Also frictional pressure losses swill be
effected by high temperature in the well leading to less
viscosity and less hole cleaning.
• Settling of weighting material
• Swabbing.
 Gas cutting
• Gas cut mud does not in itself indicate that the well is flowing
(gas may be entrained in the cuttings)
• The mud density reduction is usually caused by fluids from the core
volume being cut and released into the mud system. As the gas is
circulated to the surface, it expands and may reduce the overall
hydrostatic pressure sufficient enough to allow a kick to occur.
Classified of gas cutting:
• Background gas
• Connection gas
• Trip gas.
Actions to take if you are Driller:
- Alert the supervisor to trend changes
- Use the vacuum degasser.
 Background gas
• The gas that enters the bore hole during drilling or circulating
(correspond to dynamic well bore conditions). It is the average gas
level excluding peaks.
Remember: always check changes in background gas value because it
is able to help recognize underbalance situation while drilling, especially
drilling into high pressure zone.
 Connection gas
• Connection gases are caused by the temporary reduction in
effective total pressure of the mud column during a connection. This is
due to pump shut down (i.e. loss of ECD) and the swabbing action of
the pipe.
Action to take: Increase the mud weight few point

60

50

40

30

20

10

18 19 20 21 22 23 24
 Trip gas
• Trip gas is any gas that enters
the mud while tripping the pipe
with the hole appearing static.
• Trip gas will be detected in the
mud when circulating bottoms up
after a round trip.
• Significant trip gas may indicate
that a close to balance situation
exists in the hole.
Be prepared. A positive indicator
might come soon. Flow check /
Inform supervisor / confirm drilling
fluid density with mud engineer /
Check the trip-sheet,…
 Lost Circulation

Lost circulation is the loss of drilling fluid to the formation

Reason for Lost circulation is usually caused by
• Formation breakdown
• Fractures and Fissures
• Bad cement
How losses are recognized:
• The pit levels
• The rate of returns.
 Lost Circulation
Actions to take when losses are identified:
• Stop drilling or tripping
• Start the flow check
• Alert the supervisor
• Establish the rate and source of losses
• Prepare to fill the hole.
If your flow sensor suddenly showed a loss of returns, and when you did a flow
check you could see no mud in the annulus, what would be the best action to
take?

a) Pump at a reduced rate while mixing lost circulation material.

b) Stop all pumping and wait for orders.
c) Close the well in and check for pressure.
d) Immediately begin filling the annulus with water and record the amount
needed to stabilise and stop the fluid losses.
 Swab and Surge Effects
Swabbing: is a condition when the string is pulled out of the well and it creates
temporary bottom hole pressure reduction. If the hydrostatic pressure reduction is
large enough to create underbalance condition, the well will eventually flow.
Surge Pressure: When pipe moves downward with mud circulation through drill
string, additional bottom hole pressure called “Surge Pressure” is created.
The causes of swabbing and surging:
- Well and pipe/BHA geometry
- Measured depth (including horizontal)
- Fluid characteristics
- Hole conditions and formation properties
- Running and pulling speeds
- Bit/stabiliser balling.
 Swab and Surge Effects

Actions to take to minimise swabbing and surging:

- Use appropriate running and pulling speeds

- Identify gains and losses

- Optimise fluid properties

- Optimise the hole conditions

- BHA optimization

- Consider circulating during pipe movement.

 The risks of swabbing and surging due to vessel motion.
Rig heave movements cause the bottom hole pressure (BHP) to
increase and decrease, known as surge and swab respectively.

Excessive surge and swab pressures can lead to mud loss resulting
from high pressure fracturing the formation, or a kick-sequence
(uncontrolled influx from the reservoir) that can potentially grow into a
blowout, as a consequence of low pressure.
 Tripping
Process for Driller:
- Prepare the hole
- Optimise fluid properties
- Flow check
- Pump a slug (POOH)
- Pull out of hole/run in hole.
- Monitor displacement using trip sheet and trip tank (POOH and RIH).
Assess the appropriate trip management procedure, for example:
- Direct supervisory oversight
- Check tripping
- Swabbing behavior
- Wet/Dry Trip.
Risks: Swabbing/ Surging
 Well control procedure's while tripping

• To detect a kick while tripping

as early as possible, it shall be
standard practice to use the
trip tank at all times while
tripping both into and out of
the hole.
• The Driller is responsible for
monitoring the trip tank volume
at regular intervals to ensure
that the hole is either taking or
giving the correct fluid volume.
Trip tank • Trip tank is a small tank which has
a capacity of 20 – 50 bbl and its
shape is tall and shallow because it
can effectively detect volume
changes.
• The trip tank system has the ability
to continuously fill the well and take
return back to the tank. With this
capability, it will keep the hole full
all the time and the volume
changes either increasing or
decreasing can tell the condition of
the well.
 Trip sheet
Monitoring the well while tripping is one of the most critical in well
control because it will tell you about the well condition very quickly.
 Tripping
Actions to take when in correct volume from trip tank:
• Stop tripping
• Communicate to the supervisor
• Flow check.
If flow check is negative: run back to bottom to condition the mud and
investigate the cause of the problem.
If flow check is positive:
- Shut in the well
- Run (or strip) back to bottom
- Circulate the influx out through the chokes.
 Pumping slug
Reason for pumping a slug before POOH is to pull DP dry and avoid
drill fluid on the drill floor and emptying the well.
We pump in a drilling fluid with a higher density into the DP and
calculate the desired length of DP we wish to pull dry.

The BHP will not be effected as long as the slug is in the drill pipe.
The BHP will increase when the slug exit the pipe/bit and enters the
annulus.
 Kick warning signs while drilling and/or circulating

• Rate of penetration changes

• Cuttings size and shape
• Drilling fluid temperature increase Communicate to the Driller
• Changes in gas trends at the shakers
• Increase in torque and drag
 Increase in rate of penetration ROP

Formation pressure 10
ppg
Kick warnings (Cuttings size and shape) Density shape and
Size
Normally drilled shale cuttings tend to have a specific shape depending on
the bit.
• A rock bit tends to produce small, round or flat cuttings with rounded
edges and a PDC tends to produce cutting which look like “shavings”
• As the formation pressure increases and overbalance decreases, the
cuttings start to become long and splintery with angular edges
• As the well approaches balance, cuttings start to explode off the sides of
the hole by themselves-know as caving's
 Kick warnings:
Drilling fluid temperature increase
• Formation temperature normally increases
as we drill deeper. This is due to heat flow
from the Earths core.
• The trapped fluid in an abnormally pressured
formation causes a disturbance in this
geothermal gradient, because water
conducts heat less effectively than rock.
• Thus an abnormally pressured formation
may show a higher geothermal gradient-
showed by an increase in mud temperature
 Warning signs
Gas level changes

• If the formation porosity is

increasing and the pore spaces
contain gas, background gas may
increase.
• Connection gas may also occur as
the well approaches balance.
• Trip gas also must be considered
while tripping
 Warning signs: Gas level changes
• Connection gas is a slight increase in gas levels a lag time after a
connection, caused by the drop in bottom hole pressure when the
pumps are turned off. This indicates that the well is very close to
balance. Background gas
Warning signs: Increase in background gas
Kick warning sign: Increase in torque and drag
 Warning signs

Which of the following are often noted as warning signs that the formation
fluid pressure may be increasing? (Select THREE answers)

A. Increased cutting size.

B. Increase in torque and drag.

C. Decreased cutting size.

60
D. Presence of connection gas. 50
40
E. Decrease in torque and drag. 30
20
10

18 19 20 21 22 23 24
 Connection gas
If connection gas is noticed, which THREE of the following are good kick
prevention practices?

A. Raise mud weight a small amount.

B. Increase WOB to gain faster ROP.

C. Flow check for a minimum of 15 minutes at each connection.

D. Keep connection time to a minimum when pumps are switched off.

E. Control the ROP to keep only one connection gas in the hole.

F. Add filter loss chemical to reduce gas levels.

 Kick warning signs when tripping

• Swabbing
• Increased drag.

Swabbing
 Actions to take after recognising a kick
warning sign.
Communicate to the Driller
 Kick indications while drilling
Driller
 Increase in flow
must
 Increase in tank volume. react.
 Shut in practice
Justify the importance of detecting a kick early:

- Minimise the kick volume

- Minimise pressures on the well

- Minimise the chances of losses.

Possible well control (kick) indicators mean that there is possibility

to get influx into wellbore.

Positive well control (wellbore influx) indications mean indications

showing almost 100% kick (wellbore influx) into wellbore.
 HARD SHUT IN

1 Pick off bottom and position string

2 Stop pumps

3 Close BOP (Ram or Annular)

5
4 Open hydraulic side outlet valve

5 1
Observe pressure

2
3 4

143
The influence on pit volume readings and trend on a
floating rig
One pit volume sensor Pit totalisers have several pit volume
sensors and averages the volume

Pit Sensor
Influence on pit volume
readings and trend on a
floating rig
Crane operations
Pitch and roll
Rig heave
 Shallow Gas
• Shallow gas is defined as any
hydrocarbon-bearing zone which
may be encountered at a depth
close to the surface or mudline.
Generally it is not possible to
close-in and contain a gas influx
from a shallow zone because
weak formation integrity may lead
to breakdown and broaching to
surface / mudline.
• It is necessary to begin dynamic
kill (tertiary well control)
operations as quickly as possible.
 The consequences of shallow gas
• Gas around the rig leading to explosion risk and possible
H2S
• Equipment failure due to rapid abrasive flow
• Possible broaching of gas to the surface outside the well
• High noise levels making it difficult to communicate
• The situation can develop very rapidly.
 Prevention of shallow gas kicks

The critical factors when drilling top hole with the risk of shallow gas:
• Keeping the hole full
• Controlled penetration rate
• Drilling fluid density
• Trip speed
• Pump out of hole
• Pump rate: increase to maximum
• Hole diameter
• Prepare kill mud
 Secondary well control
• Secondary control: required
when primary control has
failed
• The aim of secondary control:
to stop the flow of fluids into
the wellbore and eventually
allow the influx to be
circulated to surface and
safely discharged, while
preventing further influx
downhole (maintaining
barrier envelopes).
 HARD SHUT IN

1 Pick off bottom and

position string

2 Stop pumps

7
Flow check
3
Inform supervisor 1
4
If the well is flowing

Close annulus or pipe

5 ram

2
6 Open HCR valve
5 6
Record: Pressure,
7 depth, time and pit gain

8 Monitor the well

149
 Gas reaching the rotary table

Action to prevent gas reaching the rotary table (Reference API

RP 64)
1. With vent lines open, activate the diverter
2. Close the upwind vent line if required
3. Keep the hole full.
4. Monitor for vent line erosion, and subsurface leaks.
 Confirm the well is shut-in by:
• Feedback from the BOP closure panels
• Monitor for unplanned flow
• Monitor for unplanned pressure
• Verify correct functions operated
• Monitor on trip tank.
• Use of flow meters.
Action to take if the well has not been successfully shut-in:
• Activate a second well barrier.
 Hang off procedures (subsea)

1. Space-out the tool joint(s) in the BOP

2. Close an appropriate ram (reference API RP 59)
3. Land off the tool joint on the ram
4. Confirm weight on the ram
5. Check ram seal (by bleeding pressure between closed
preventers).
Surface Pressure After Shut-in
At what point would you note the SIDPP and SICP
Initial build up

Use the drill pipe pressure of 210 psi because the increase in the following
periods is caused by gas migration.
 Shut-in Drill Pipe Pressure (SIDPP) and
Shut-in Casing Pressure (SICP) gauge readings

• Influx density (influx gradient)

• Influx height
• Annulus fluid composition (cuttings loading, varying fluid densities)
• Position of the bit and or pipe (drilling/ tripping)
• Influx in the drill string
• Blockage in the annulus
• Inaccuracy of the gauges
• Well deviation (horizontal well).
 Shut-in Drill Pipe Pressure (SIDPP) and
Shut-in Casing Pressure (SICP) gauge readings
The limitations of pressure gauges:
• Scale
• Accuracy
• Gauge calibration
Pressure reading (SIDPP & SICP)
 Trapped pressure
"Trapped pressure" is any pressure recorded on the drillpipe or annulus
greater than the amount needed to balance the bottomhole pressure.
Pressure can be trapped in the system in several ways.
• Well supercharging
• Unexpected pressure caused by injection
• Incorrect shut-in procedure.
• Using pressure readings containing trapped pressure results in erroneous
kill calculations
 Actions to take if trapped pressure
1. Bleed from the casing side only when checking for trapped pressure
2. Use drillpipe pressure at a guide
3. Bleed small amounts (1/4 to ½) of mud at a time
4. Close the choke after bleeding and observe the pressure on the
drillpipe
5. Continue to alternate the bleeding and observing the pressure as
long as the drillpipe pressure continues to decrease. When it cease
to fall, stop bleeding record the true SIDPP and SICP
6. If the DP should decrease to zero during this procedure, continue to
bleed and check pressures on casing side as long as the casing
pressure decrease
 SIDPP with a float valve in the drill string
A well has kicked, and is shut in. There is a float in the drill string
(SIDPP = 0 psi). What would be the correct course of action to
determine the kill mud density?
1. Start raising the mud density by 0.1 ppg increments until the well is
dead.
2. Pump very slowly into the drill string with the well shut in. When the
casing pressure rises the float valve has opened. This pressure on the
drill pipe is the Shut In Drill Pipe Pressure.
3. Remove Kelly and drop float opening tool.
4. Use the annulus pressure to calculate the kill mud density.
 Useful Equations when killing a well

SIDPP DP CSG SICP

+ +

HH HH drilling fluid
drilling fluid

+
= HH Influx (kick)

P f≥ BHP
BHP = SIDPP + HH drilling fluid = SICP + HH drilling fluid + HH kick
HH shoe = HH shoe + SICP = BHP – HH up to shoe from TVD
MAASP = HH maximum p at shoe – HH at shoe
 WELL DATA
Example
HOLE SIZE
well 8-1/2 INCH
HOLE DEPTH TVD/MD 11536 FEET
CASING 9-5/8” TVD/MD 9875 FEET
DRILL PIPE CAP. 0.01741 BBL/FEET
HEAVY WALL DRILL PIPE 600 FEET
CAPACITY 0.00874 BBL/FEET
DRILL COLLARS 6-1/4” 880 FEET
CAPACITY 0.00492 BBL/FEET
DRILLING FLUID DENSITY 14.0 PPG
CAPACITY OPEN HOLE/COLLARS 0.03221 BBL/FEET
CAPACITY OPEN HOLE/DRILL PIPE-HWDP 0.04470 BBL/FEET
CAPACITY CASING/DRILL PIPE 0.04891 BBL/FEET
FRACTURE FLUID DENSITY 16.9 PPG
SIDPP 530 PSI
SICP 700 PSI
PIT GAIN 10.0 BBL
PUMP DISPLACEMENT 0.1019 BBL/STRK
SCRP@ 30 SPM 650 PSI
Well Data:
DC-OH Cap = .03221 bbl/ft
DC Length = 880 ft
HWDP-OH Cap = .0447 bbl/ft
Height Of Influx
700 psi 700 psi
Determine if the influx is below or above the collars
DC/OH Volume = Ann Cap x Length
= .03221 x 880 = 28.3 bbls

Influx Height (ft) = Kick Size (bbls) .

Ann Cap (bbl/ft)

Example One Example Two

10 .
= 310 ft 35 - 28.3 = 6.7 bbls
.03221
6.7 . = 150 ft
.0447
880 + 150 = 1030 ft

150 ft
1030 ft 28.3 bbls = 880 ft
310 ft
10 bbl Kick 40 bbl Kick
Well Data:
SIDPP = 530 psi
SICP = 700 psi
Current Mud Weight = 14 ppg
Gradient Of Influx
Influx Height = 310 ft
The formula for Gradient of Influx (psi/ft)
530 psi 700 psi

= (Mud Wt x .052) - SICP - SIDPP.

Ht of Influx

= (14 x .052) - 700 - 530.

310

= .728 - .548
14 ppg
= .18 psi/ft

310 ft
A kick was taken at 11536 ft and the driller
spaced out, turned the pumps off and stopped
rotation.
He closed the upper pipe rams and opened the
Hyd. Side Outlet Valve.(HCR) and monitored
shut in pressures.
530 Time 14:00 700
• DP pressure stabilized at 530 psi.
• CSG pressure stabilized at 700 psi.
• Pit gain 10 bbl. 0

All pressures will increase.

0

The well is closed and p in the gas bubble is 8928 psi

Gas gradient 0.18 PSI/FT
Gas height around DC: 310 FT
Gas height around DP: 204 FT
What happens with pressures in the well if the gas bubble is not
allowed to expand when it migrate to surface ?
 MAASP
1489
ISICP
700
1341 1489
Time 14:30

We have excided the MAASP. What should the

supervisor done ?

He should have bleed down SIDPP back to SIDPP= 530 psi to control BHP
before reaching MAASP
 SICP
700 psi
SIDPP
530 psi
1591 1739
Time 14:45

0
8779 Time 24:45 8928

0
 Gas Expansion Uncontrolled (Well Open)
• If a gas bubble is allowed to expand without control, it will eventually
unload the well. With the well unloaded, kick sizes will increase, causing
more unloading. This cycle of influx and unloading has caused the loss
of many wells.
 Different influx behaviour
• Water kick:
– Water is virtually incompressible and so, does not expand
significantly as the pressure on it reduces.
– While circulating a water kick there should be no change in pit level,
provided no further influx is allowed to enter.
– Casing pressure only change due to different size of annulus.
• Oil kick: Oil has gas in solution, the effect will be similar to that
produced by a gas kick although again some what reduced in scale.
 Different influx behaviour
•• Gas kick: Gas is compressible. The volume occupied by quantity of
gas is related to both pressure and temperature. The volume of gas
must be allowed to expand in order to drop the pressure as it come to
the surface, the pit volume will increase.
• BOYLE'S GAS LAW
PV = CONSTANT or P1 V1 = P2 V2
V is the volume of gas (bbl), P the pressure (psi), and disregarding
temperature.
Example: Gas kick volume: V1 = 10bbls; Formation pressure P1 = 8928
psi; Surface pressure P2 = 14.7 psi. Calculate the volume of gas you
will have downstream of the choke?
V2 = = = 6073 bbl
 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.

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 Darcy's, from a few milli Darcys 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
 KILL SHEET

Complete kill sheet on example well data as

above
 The essential steps of killing a well

• Removing the influx

• Regaining primary control
• Controlling the BHP to avoid another influx or break down of the
formation
• The method for rounding kill mud weights.
 Well control method

Once the well is shut in we need to control the pressures in the well. We
need to keep a pressure above the formation pressure and below
the fracture pressure which in this case is assume to be below the
casing shoe. The selection of kill method which results in the lowest
casing shoe pressure. The kill methods are :
• Driller’s method
• Wait and Weight method
• Volumetric
 Driller’s method procedures
First Circulation – Removing Kick
1. bringing the pump up to the desired kill rate while using the choke to
maintain its casing pressure at the value.
2. Pump pressure should be equivalent to calculated ICP. If not
equivalent, investigate and recalculate if necessary.
3. Maintaining pump pressure equal to ICP, kick/influx is circulated out
of the well, adjusting pressure with choke as required.
4. Slowly shut down the pump maintaining pressure on the choke
(casing) gauge equivalent to the original SIDPP.
Notes: Avoid trapping pressure or allowing additional influx if shutting
back in.
 Driller’s method procedures
Second circulation – Killing The Well:
5. Line up to kill mud weight
6. start up pump procedures are again used.
7. Circulate the kill fluid to the bit/end of string following step down
chart in the kicksheet.
8. Once kill fluid is at the bit/end of string, maintain FCP until kill fluid
completely fills the well.
9. Shut down pump and check for flow.
10. Close choke and check pressures.
11. If no pressure is noted, open choke (bleeding any trapped
pressure/ or gas trap in the subsea BOPs), open BOP.
 Wait and Weight Method
Can called Engineer’s method, only 1 circulation
1. Pits are weighted up as other calculations are performed.
2. When ready, bringing up the pump up to the kill rate while using the choke to
maintain constant casing pressure at its value.
3. Circulating pressure should be equivalent to (ICP) Initial Circulating Pressure. If
not, investigate and recalculate ICP if necessary.
4. Follow pressure chart/graph as kill fluid is pumped down the string to bit/end of
string.
5. Once kill fluid is at the bit/end of string, maintain constant FCP circulating pressure
until the kill fluid completely fills the well.
6. The gain in HP should necessitate slowly reducing choke pressure.
7. Once the kill fluid reaches surface the choke should have been fullyopened.
8. Shut down pump and check for flow.
9. Close choke and check pressures.
10. If no pressure is noted, open choke (bleeding any trapped pressure), open BOP.
WAIT &
WEIGHT METHOD
 Running and Pulling Casing and Liner
The precautions to be used when running casing.
• Change the rams to the casing size (on surface stack) and testing
• Prepare a circulating head.
• Ensure a cross-over from casing to drill pipe is available to allow the
string to be hung off if needed.
• Take care while filling up the casing. Use clean mud and ensure that junk
does not fall into the casing.
• Record the annular volume between the casing and open hole and Outer
casing.
• Calculate the running speed to allow an acceptable fluid velocity and a
limited surge into the open hole.
• A record of the tank level is necessary and should be compared with the
calculated volume increment due to the metal displacement of the casing.
 Shut-in Procedures When Running Casing
• Shutting in a well while running casing is similar to shutting in a well
when tripping drill pipe. The main differences involve the device used
to stop potential flow up the casing and whether to close a BOP or a
diverter, which depends on the type of casing being run.
• Ram BOPs will need to be properly sized to close around the casing.
Further annular closing pressure may need to be reduced to prevent
collapsing the casing.
• Observed the pressure
 Cementing Casing and Liner

• Kicks that occur while cementing are the result of reducing the mud
column pressure during the operation. Several wells have been lost
because of improperly designed cementing programs.
• Different events can lead to a reduction of the hydrostatic pressure
below the formation pressure
• Cement will dehydrate as it sets up. This may reduce the effective
hydrostatic, allowing well to flow. Often the cement is designed to set
in stages to minimize this effect.
• Meaning the first stage will set up later then the second stage above
the shoe.
 Cementing Casing and Liner
The factors that affect the quality and effectiveness of cement placement
to achieve a reliable primary barrier:
• Verification of cement location
• Expected pressure profile to maintain BHP greater than pore
pressure and less than
• fracture pressure
• Expected returns
• Correct weight and quantity
• Expected setting time
• Plugs bump at expected volume
• No back flow
• Verification of cement seal.
 Shut-in Procedures While Cementing Casing
and Liner
• Before casing is run:
 BOPs should be equipped with casing rams and pressure tested
before running casing. Annular Pressure regulator may have to be
reduced to prevent casing collapse.
 A circulating swage with a high pressure/low torque valve must be
made up on cement head and positioned near the rotary table,
installed as soon as the BOPS have closed.
 There should be a crossover from the casing to the string on floating
rigs to allow the string to be hung off if necessary.
 Shut-in Procedures When Cementing Casing
and Liner
• When shutting in using casing rams ensure TJ is not across ram
face.
• Close BOP (casing ram or annular according to procedure).
• Install cement head.
Note: The inner diameter of the string is usually shut off first because it
is the smallest and most vulnerable. When casing is run, and in some
slim hole and workover applications, the smaller diameter is often the
annulus. In these cases, the annulus smallest diameter should be shut in
first.
 Shut-In with Wireline
• Wireline operations usually have a lubricator in case there
is pressure at the surface during the operation. The
lubricator contains a:
 Stuffing box or pack off head.
 Grease injectors.
 Lubricator joints or tube bodies.
 Blowout preventers.
 A bleed or pump-in valve.
 Shut-In with Wireline
• Equipment may be nippled differently:
 Flanged up to an annular preventer.
 Secured inside annular preventer or rams.
 Made up to a gauge flange on a Christmas tree.
• The shut in sequence is as follows:
 Tell wireline operator to cease operations.
 Driller should close the bleed or pump in valve.
 The driller tells the designated wireline supervisor to close the
wireline BOPs.
 Inform supervisor that the well has been shut in.
Just in case, there should be a planned way to cut the wireline
allowing it to be dropped and a blind ram or crown valve to be
closed .
Shut-In with Wireline
 WHAT IS A BOP
A Blow Out Preventer (BOP) is a large piece of
equipment used for sealing, controlling and monitoring an
Oil or Gas well. It comprises of a collection of hydraulic
valves connected to the well head which can be stacked
in different orders (creating BOP stacks) to provide
options for different BOP operations and requirements,
as well as redundancy in case a piece of equipment fails.
They come in a variety of shapes, sizes and styles but all
are designed to hold the pressure from the wellbore
beneath them.
The BOP can close in an open wellbore by closing the
Blind Rams or Blind Shear Rams. The Blind shear
Rams are fitted with hardened steel shearing surfaces
that out through Pipe Tubulars and seal the wellbore.
Pipe Rams are designed to close and seal around pipes
and the Annular Preventer can seal around a variety of
shapes and sizes.
 WHAT IS A BOP (cont)
The diagram opposite shows the break down of a BOP. The
BOP components are typically described upward from the
bottom of the BOP stack starting from the BOP connector.
The picture here is a representation of a 18 ¾ “ 15k, Class 7-
A2-R5. BOP. This means the following:
18 ¾ “ - is the inside diameter of the BOP
15 K - is the rated working pressure 15000 psi (103.42 MPa)
Class 7- is the amount of rams and annular preventers in the
BOP stack.
A2 - is the amount of Annulars in the BOP Stack. Please
note that the Annulars may have a different pressure rating,
usually a lesser rating.
R5 - is the amount Rams or Ram cavities installed in the
BOP stack regardless of their use.
BOP
 WHAT IS A BOP (cont)
The BOP stacks are assembled in certain
sequences, most commonly with the Shear Rams
fitted in the top ram cavity, allowing the Shear Ram
to shear the Drill String whilst the Drill String tool
joint is hung off on the Pipe rams below. This
sequence ensures there is not a Drill Pipe tool joint
at the shearing point of the shear rams and also
stops the Drill Pipe from falling into the wellbore.
 Annular Preventer Types
• Shaffer
• Hydril GK
• Hydril GX
• Cameron ‘D’

Operating pressures

• Range between 500 and 1500 psi for normal operations

192
 Annular Preventers
• Annular preventers are BOPs which use circular
rubber or rubber-like elements.

• They are extremely versatile in use and can close

on most items.

• They are normally used on top of several ram type

BOPs.

• The annular BOP is usually the first to be closed

when a kick occurs.

193
 EQUIPMENT
Annular BOP Operating Pressure
The Annular Closing pressure should be set at 1500 psi and when the annular is closed the pressure can
be reduced to betweem 500 and 1000 psi. This is achieved by adjusting a regulator on the Accumulator
Unit.
If you close in a flowing well at a reduced pressure you may allow wash out of the element if the closing
pressure is not as per OEM recommendations.
When the button is pressed to close the annular from the Drillers or Toolpushere BOP panel, the fluid and
pressure from the Accumulator unit will close the Annular Preventer.
The Annular can also be closed from the Accumulator Unit itself by moving the valve handle to the closed
position.
 Annular Preventers are designed to
• Seal around smooth objects in the wellbore e.g. drill
collars, drill pipe, casing, tubing, square kelly and
wireline.
• Seal off an open hole although not necessarily at
full R.W.P. (this will shorten the working life).
• Allow stripping of drill pipe under pressure while
maintaining a seal.
• Allow reciprocation of the drillstring during well
control operations.
• It can be secondary barrier

195
 Packing Element Materials

Three types of materials are used:

• Natural rubber
– WBM from -20o F to 170o F
– Good wear resistance

• Nitrile synthetic compound

– OBM from 40o F to 170o F

• Neoprene synthetic compound

– OBM from -30o F to 170o F

196
 General Operations

• Closing on tool joints

– Can cause severe damage
• Closing on casing
– Consider initial closing pressure
• Stripping Operations
– Provide for tool joints
• Operating pressures
• Closing with no pipe in the hole
• Closing on wireline

197
 Annular elements
• All annular elements should be
delivered wrapped in black
plastic material to protect them
from sunlight and atmospheric
deterioration.
• All elements and seals should be
stored in a cool, dry, dark
storage area until used.
• The elements should be stored
and or shipped in an upright
position, never on their side.
• If annular deterioration/failure:
activate secondary barrier
 RAM BOP
• Ram preventers are designed to seal the annulus by forcing two front
packing elements which make contact with each other and seal around
the object in the well bore.
• Pipe ram: It seals around the well bore and the fixed size of pipe
• Blind ram: It seals the well if no pipe in the well bore
• Variable bore ram: It seals around several pipe sizes depending on
the range of variable bore ram.
• Shear ram: It shear the pipe in the well and seal the wellbore
simultaneously.

199
 Ram design
Rams for Ram-type BOP designed to:
1. Hang off drill string
2. Tested and hold pressure from bottom
3. Top and bottom plates provide Elastomer with self feeding (extrusion) in the wear
direction.
4. Standard pipe rams are designed to centralise and seal around one specific size of
pipe (or casing).

200
 Pipe Rams
Standard pipe rams are designed to centralise and
seal around one specific size of pipe (or casing).

Hang off capability

Feed able rubber

201
Cameron U type ram preventer

202
Complete assemblies type “U” blowout
preventer

Ram
Intermediate Flange
Assembly

Piston Cylinder Body

Bonnet

Connecting rod Seal Ring

Locking Screw
203
 Variable Pipe Rams

Designed to close and seal on a range of pipe diameters

2 7/8 inch - 5 inch

3 1/2 inch - 7 inch

Limited hang off capability

204
 Blind-Shear Rams

• The Intermediate Flange is Thicker in the

shear Rams.

Note: Increase pressure to maximum closing

pressure if you need to cut the DP = 3000 psi

205
 Shear ram operational procedures.
• Space out string
• Centralise the pipe by closing the pipe ram below the shear ram
• Hang off and reduce tension (subsea)
• Open bypass valve to deliver full accumulator pressure
• Operate the shear rams
• Verify that the string is sheared
• Ensure and verify well closure.
 Ram preventer

A ram BOP should never be attempted opened unless the

pressure above and below the rams are equalized.

If rams are attempted opened while containing pressure

a major equipment destruction can occur.

207
 Closing Ram

Wellbore assisted

Opening ram
 Ram preventer

RAM SHAFT OPENING CHAMBER

PISTON CLOSING CHAMBER

RAM

209
 Locking System
Ram type preventers should be equipped with extension hand wheels or
hydraulically operated locks
Surface BOP
Manual locking systems
Subsea BOP
Automatic locking systems
1. Cameron: Wedgelock or ST locking system
2. Hydril: MPL
3. NOV Shaffer
Poslock (locks in one position only)
Multilock (locks in 2 positions for Multiram)
Ultralock (locks in all positions)

210
 Manual locking system

Manual Lock Piston in Closed Position

Manual Lock Piston in Open Position

Manual Lock Piston in Closed and Locked Position

211
Wedge lock

212
 Pipe Ram Closing Time
Response time between activation and complete operation of a function
is based on BOP or valve closure and seal off.

Closing time should not exceed

30 seconds for all surface ram BOP installations

45 seconds for all subsea ram BOP installations

Measurement of closing response time begins at pushing the button or

turning the
control valve handle to operate the function and ends when the BOP or
valve is closed effecting a seal.

A BOP is considered closed when the regulated operating pressure has

recovered to its nominal setting.
213
 Side Outlet valves
Side Outlets for choke/kill lines are available on all models, no smaller
than 2 inches inside diameter

Normal Operations
The BOP is open, the automatic choke
line failsafe (HCR) valve is closed and
the manual choke line valve open. The
Remote Auto Choke is in the closed
position
 Upper Kelly Cock

The upper kelly cock is a

standard part of the upper kelly
assembly.

Basic purpose of the upper kelly

cock is to protect the kelly
hose, swivel and surface
equipment from high well
pressure.

215
 Lower Kelly Cock

The lower kelly cock is Drillpipe safety valve or

full-opening safety valve which back up the upper
kelly cock.

It allows removal of kelly when pressure on the string

is grater than surface equipment rating.

It is common practice to use the lower kelly cock as

fluid or mud saver valve.

The valve is operated at every connection so it is

kept free and in operating condition.

216
 Top Drive Safety Valve

The upper and lower safety valves

on top drive systems are connected
together.

They are ball valves

Both are very likely to be

inaccessible should a kick occur
during drilling operations, so the
upper valve is remote operated.

217
 DPSVs or FOSV

Drillpipe Safety Valve

or
Full Opening Safety Valve
or
TIW (Texas Iron Works)

Or

Drill Pipe
Safety Valve

218
 Drill Pipe Safety Valve and Inside BOPs

Drill Pipe Safety Valve (kelly cock)

Always available during tripping and

casing running operations
Correct connections or crossover to allow
stabbing in
In open position
Key readily available
OD suitable for running downhole

219
 Non-return valve
A method of closing off the string is a basic part of well control equipment.

Equipment for closing off tubing or drill pipe includes DPVS, floats and
ISBOP inside blowout preventers.

The equipment is handled by the floor crew.

It is essential that the driller and Toolpusher make sure the crew
understands the rules for operating and maintaining this essential
equipment and can connect to the pipe at all time (x-overs)

220
 Inside BOPs

Inside BOPs
Gray valve
Stab-in non-return valve
Allows (kill) fluid to be pumped
Stripping Operations
Drop-in check valve
Pumped down
Float valve
Prevents back flow

221
 DPSVs and IBOPs testing

• Pressure test: At least equal to 70% of the rated internal pressure at

minimum yield for new pipe of the size and grade used in the upper
part of the drill string, but limited to the rated working pressure of the
BOPs up to a maximum of 10,000 psi.
• Frequency of testing:
- Before installation
- On installation
- During well operations
 Inside Blowout Preventer

The inside IBOP (sometimes called Grey

valve) is a backpressure or check valve.
Its primary use to stripp back into a
closed in well
The inside BOP allows the well to be
circulated and prevents pressure or flow
up back into the drill string.
It is a simple and reliable tool, but since
it is not full-open, the inner diameter of
the drill string is restricted and do not
allow WL through passage or reverse
circulation.

223
 Drop-in check valves

Drop-in check valves are used as a means for closing the drill string from
well flow, by means of dropping (or pumping) a check valve down to its
recess in the drop-in sub. It is different from an ordinary float valve in that it
does not work as an check valve assembly until the Check Valve is set in
the drop-in sub.

224
 Float- Backpressure Valve (BPR)

Floats, inside BOPs, backpressure and

check valves all act similarly to prevent flow
and pressure flowing up the drill string.

The standard float valve are installed just

behind the drilling bit and stops back flow
and inside blowout up the drilling string.

The two most common types or floats are

spring operated piston (plunger) and flapper SPRING
types. FLAPPER TYPE BPV
LOADED FLOAT
VALVE

225
 Float valves Float valve Flapper type
• Solid or with a bored hole
• Will need to pump valve open Float valves are used to:
to monitor SIDPP • Prevent sudden influx entry
• Will not allowed WL through it into the drill string.
• Will increase surge pressure • Prevent back flow of annular
• Will require pipe fill while cuttings from plugging bit
running drill string down the nozzles
well
• Will not allow reverse circulate

226
Control backpressure when circulating out a kick

MANUAL OPERATED
CHOKE

HYDRAULIC OPERATED
CHOKE

227
 Choke Control

A choke controls the flow rate of fluids. By restricting flow through an

orifice, friction or backpressure is placed on the system, allowing a
control of flow rate and well bore pressure.
Well control chokes are of different design than gas and oil production
chokes. In general, the production choke is not suitable for well control.
Manual adjustable chokes are used for some well control applications
but most pressure operations use remote adjustable chokes.

228
 Diverter
• Annular preventer coupled with a large diameter piping systems
underneath.
• Are used to protect personnel and equipment from shallow gas flows.
• Typically installed on conductor casing or as part of the marine riser, with
diverter lines running to a safe downwind area.
• The gas/sand mixture to approach critical velocity, resulting in extreme
wear and short life expectancy of the surface piping.
• Diameter pipe used for diverting the gas overboard.
Two main types of diverter:
- Conventional annular
- Insert type diverter
 Diverter

Conventional Annular Insert type diverter

 Diverter
On manually operated systems the proper sequence for diverting is as
follows: Open overboard line valve down wind of the rig; close shaker line
valve and then close diverter.

Wind direction

2
 Diverter system
The Diverter and all valves should be function tested when installed and at appropriate
times during operations to determine that the system will function properly.

Fluid should be pumped through the Diverter and each Diverter line at appropriate
times
during operation to ascertain the line(s) is not plugged.

Inspection and clean-out ports should be provided at all low points in the system.
232
 What is a Mud Gas Separator?
A Mud Gas Separator are
designed to separate mud and
gas while circulated out a kick
from the well by leading gas up
the vent line and mud back to
down to the active pit.

233
 MUD GAS SEPARATOR U-TUBE

Vent line
Siphon

Inlet Hot fill Mud Mud gas separator should be

Tangential Inlet
operated taking into account
the risk of hydrate formation.
Where necessary, a hydrate
suppressant such as glycol
Degassed should be employed.
mud
Seal

Shaker

234
Mud Gas Separator
PRESSURE BUILD UP

LENGTH OF VENT LINE

ID OF VENT LINE

PRESSURE LIMITATION
HEIGHT OF U-TUPE/DIP TUBE

GRADIENT OF FLUID
235
Mud-gas separator Poor boy (Gas poster)
Length and Diameter of vent line creates pressure build-
up in vessel as gas is vented

Mud wt x 0.052 x length of liquid seal = Blow-through pressure

If the mud weight is 12 ppg and the mud leg

is 20 ft. Calculate the maximum pressure we
can see on the pressure gauge

12ppg x 0.052 x 20ft = 12 psi

This pressure acts on the
liquid seal.

If the pressure in the vessel exceeds the mud seal hydrostatic a blow-through to the
shakers would occur.
Action to take: Reduce pump rate

236
 Degasser

• Separates small entrained gas

bubbles from fluid
• Installed downstream of the
mud/gas separator
• The vacuum makes the gas less
soluble
• It should be used to remove gas
from the mud when drilling,
circulating or killing a well.
• It has capacity limitations.

237
 Testing
The criteria for a successful pressure test:
• Direction of pressure applied
• Volume to be pumped
• Instrumentation
• Test fluids
• Test duration
• Test records
• Safe pressure bleed off and monitored flow returns.
 Function test
• Every week, personnel must perform function test BOP alternating
between remote panels.
• Function tests should be alternated from the Driller’s panel and
from mini-remote panels, if on location.
• Actuation time of each equipment should be within the limits specified
by API RP 53
• Record final accumulator pressure after all functions should not be less
than 1200 psi or 200 psi above the pre-charged pressure of
accumulator which ever is maximum
 Pressure testing BOP
TEST PROCEDURES:
In general; a BOP test consumes a lot of rig time and often more than
necessary.
The main reasons why these tests take longer than required are not
related to equipment problems. The reasons are related to:
Little understanding of the wellhead and test-tools.
The wrong set-up.
The preparation, before the actual testing commences, is not
thoroughly enough.
This leads to downtime

241
Pressure testing of Well Control Equipment
Initial pressure test
When subject to well pressure:
Pressure test to RWP of BOP or wellhead (whichever is lowest)
Drill pipe safety valves (FOSV/IBOP) pressure test to RWP of BOP
PT Annular to 70% of RWP
Pressure test with water or water with additives

Subsequent pressure test to maximum anticipated wellhead pressure

for the hole section

Rated Working Pressure-Inside BOP-Pressure Test - Full Open Safety

Valve

242
 Pressure test
All Blow-out prevention components that may be exposed to well pressure
should be tested first to a low pressure of 200 to 300 psi and then to high
pressure.
A stable low pressure test should be maintained for at least 5 minutes.
Initial high pressure test on BOP stack, choke manifold and choke/kill lines
should be to rated working pressure on the ram BOP’s or to the rated working
pressure of the wellhead that the stack is installed on, whichever is the lowest.
Subsequent high pressure tests on well control components should be to a
pressure greater than the maximum anticipated surface pressure, but not to
exceed the working pressure of the ram BOP’s.
A stable high pressure test should be maintained for at least 5 minutes.

243
 Pressure test frequency
Pressure tests on well control equipment should be conducted at least:

• Prior to spud or upon installation

• After disconnection or repair of any pressure containment seal in the
BOP stack etc.
• Within 21 days

TEST FLUIDS

Well control equipment should be pressure tested with water.

Air should be removed from the system before test pressure is applied.
Control systems and hydraulic chambers should be tested using clean
control system fluids with lubricant and corrosion additives for the
intended service and operation temperatures.

244
 Pressure testing BOP
Well head

Cup tester
Tensile force on DP is equal F = p x A Test Plug
The pressure test is done on 5 ” DP in 7 ”
casing.Test pressure = 5000 psi.
Calculate the tension on the DP.
The tension on the DP is eqaual 94.247 lbs

A
Circle l

245
 Pressure testing BOP

The preparation of a BOP-test starts with a proper

understanding of the wellhead, the way the test-tools are
situated in there and the BOP's itself.
A manual should be onboard/onsite and should be
consulted.
Most(All) manuals have proper drawings of the test tools
and the way they fit.
Two test-tools are available:

Plug-type tester
Cup-type tester.

246
 Pressure testing BOP
A Plug-type tester sits in the top of the wellhead and
does not enter the casing. Normally, the wellhead is rated
higher than the casing and therefor the test-pressure with
a plug tester can be higher.

Apply test
pressure
To safeguard the casing against a too high a pressure;
with a PLUG-type tester:
Always have a outlet on the wellhead, below the Plug,
open to atmosphere in case the tester leaks past the
seals. Calculate the volume required to get to test
pressure.
Often not more then a few gallon. Open outlet

247
 Plug Type Tester (test plug)

• Installed TP inside wellhead

• Open side outlet valve below test plug to
protect casing when pressure test take place
and see if the TP holds pressure.
• Pressure test BOP valves with
• DP inside BOP
• Close pipe ram or annular
• Pressure test from below.
• W/O DP pressure test blind/shear ram
from below.

248
 Pressure testing BOP
A Cup tester enters the casing. A standard F tester can be
put anywhere in the casing. The Test-pressure should not
exceed 80% of the casing burst pressure.
There have been occasions, where the test pressure
exceeded the rating of the Cup-tester and the drillpipe
parted or the cup failed. (In smaller size casings with a high
burst-pressure).
Therefore Shell-Cameron designed a Cup-tester which is
Casing
wellhead supported and there is no strain on the drillpipe. out
With a CUP-type tester: Always have the drillpipe open let valves
to atmosphere in case the Cup leaks into the casing. closed
(The casing might be drilled out and the test pressure will
go onto the formation)
Well head
Cup-tester
in casing

249
Pressure test with cup type
tester

Run DP with cup tester inside the casing

open ended.

Pressure test:
• Annular / pipe rams and lower wellhead
valves

250
HCR and Pipe rams test
1. Pick up top drive, connect test plug on the bottom of 5-1/2″ DP, run test plug and seat in wellhead.
2. Connect pressure source to the kill line and open kill line valve 1 and 2, valve 3, and keep HCR
(valve 4) close.
3. Close pipe rams.
4. Pump into the well through kill line. Monitor and record the test pressure.
5. Conduct low-pressure test and high-pressure test
6. Bleed off pressure at choke line(close J1,open 4,then open J1 to bleed off).
7. Open pipe rams.

3-7
5
6
p 2 4
1

251
Body Test at manufacturer Plant
1 ½ times BOP rating I.e. 150% of pressure rating.

Closing Ratio
Ratio of well head pressure to pressure required to close the BOP.

252
 Pressure Testing the Diverter System
Diverter systems are required to be pressure tested and function tested on a
regular basis. The required tests are described below:
Upon initial Nipple-Up:
a. Pressure test the diverter bag, diverter valves, and vent lines (if
possible) to 200 psi.
b. Function test all equipment and circulate through the overboard
lines. Make a record of the test in the tour/morning report.
While drilling ahead:
c. Function test all equipment (open and close) at least once every 24
hours. Make a written notation of the test in the tour/morning report.
d. The diverter bag, spool, diverter valves, and vent lines (if possible)
should be pressure tested weekly. This test will require a test plug.
Record the test on a test chart and make a written notation of the test in
the tour/morning report.
 Inflow Testing Procedures
• Inflow tests are generally carried out to verify if there is
communication with the formation through the casing, a liner lap
or past a cement plug (bridge plug).

• Most of the applications are in connection with testing or

squeezed off perforations and casing leaks, testing liner-laps,
float shoes and float collars, cement plugs and bridge plugs.

• An inflow test is performed by reducing the hydrostatic head

above the item to be tested by circulating to a lighter fluid.

• In the event of a failure or loss of a well barrier, immediate

measures shall be taken in order to prevent escalation of the
situation by activating the secondary well barrier. The situation
shall then be normalized by restoring the primary well barrier or
establishing an alternative well barrier before
activities/operations can be resumed.
 Procedure for Circulating to Lighter Fluids (Diesel etc.)
1. RUN retrievable packer with circulating valve, safety joint and short tail
on drillpipe, to depth to be advised by Operations Engineer.
2. SET retrievable packer at advised depth and test annulus with 1000 psi
in order to check that packer is properly sealing and that the tool
assembly is functioning properly before RIH any further.
3. Generally, the retrievable packer should be set at some 50 ft above the
interval to be tested (or 50 ft above TOL) in order to minimise any
possible influx. OBTAIN prior approval from the Head of
Onshore/Offshore Operations for inflow testing during the hours of
darkness.
4. CIRCULATE the drillpipe to a lighter fluid until the required drawdown is
accomplished. (An air cushion may be used)
5. After having circulated the well to achieve the required drawdown,
PERFORM the inflow test on the well for 15minutes as detailed in the
Drilling Programme.
6. REVERSE well to completion fluid.
7. UNSEAT retrievable packer. CIRCULATE and OBSERVE well dead.
8. POOH and L/D retrievable packer.
EQUIPMENT
BOP Control System

The BOP control system is set of

controls that operate all of the
functions of the BOP.
Basic control systems are entirely
built as hydraulic systems; but
modern systems have introduced
electro-hydraulics and multiplexed
electro hydraulic control.
Remote control stations allow tho
user to operate the BOP Stack from
a remote location.
EQUIPMENT
Accumulator Unit
A Blowout Preventer (BOP) Control System is a
high-pressure hydraulic power unit fitted with
directional control valves to safely control kicks end
prevent blow-outs during drilling operations.
The primary function of the accumulator unit is to
provide the atmospheric fluid supply for the pumps
and to store the high-pressure operating fluid for
control of the BOP Stack.
It includes:
 The accumulators and piping.
 Reservoir.
 Air operated pumps.
 Electric motor driving triplex pumps.
 Master control panel.
 Interface module for remote control oi the BOP
functions.
EQUIPMENT
Accumulator Bottles

The storage reservoir should haves a

capacity twice the volume of the usable
fluid.
Accumulator bottles are used to store
hydraulic power fluid under pressure to
provide fast closure of the BOP and
provide a back-up source of hydraulic
power to close the BOP in-the event of
rig power failure.
Each bottle consists of two
compartments separated either a rubber
bladder or a piston device. One
compartment is filled with inert Nitrogen
gas and the other with hydraulic power
fluid.
 EXAMPLE
Accumulator Bottles Example
Here we have an 11 gallon accumulator bottle with a
bladder installed.
The volume occupied by the bladder is usually taken
to be 1 gallon.
The Nitrogen gas is pre-charged to a pressure of
1000 psi (A)
The power fluid is then pumped under pressure into
the second compartment, compressing the Nitrogen
until system working pressure is reached.
To achieve a pressure of 3000 psi, 6.67 gallons of
hydraulic fluid is required. (B)
Hydraulic fluid volume at 1200 psi equals 1.67
gallons.(C) This is the minimum required pressure to
safely operate a BOP annular.
Therefore usable fluid operating under pressure is
6.67-1.67 = 5 gallons.
EQUIPMENT
EQUIPMENT
BOP Accumulator Pressure

The Accumulator pressure gauge reads the

amount of pressure in the Accumulator
Bottles
On a normal 3000 psi system, the
Accumulator Pressure would be kept at
3000 psi
EQUIPMENT
BOP Accumulator Manifold Pressure

The Manifold Pressure gauge reads the the

amount of pressure required to function the
Rams and fail safes valves
This pressure in e normal system is set to 1500
psi
EQUIPMENT
BOP Accumulator Air Pressure

Air pressure is required to operate the function

valves on the BOP Accumulator Control Unit.
When the signal is received at the Accumulator
unit from the Drillers or Toolpushers BOP
control Panel, it operates the required function
by moving the valve to the correct position.
EQUIPMENT
EQUIPMENT
Surface BOP Selector Valves
These selector valves are installed as control valves for
the function of the surface BOPs on the HPU Accumulator
panel on jack up rigs and land rigs when the selector valve
is put in “block” it will isolete the output pressure in the
lines and hoses to the BOP. However, it still means the
entire system remains pressured. Selector Valves should
not be left in the blocked position, however, they can be
used to troubleshoot any leaks
EQUIPMENT
Driller’s Control Panel

The Drillers control panels is usually found in

the Drillers dog house. However; on some
older land rigs, they are situated just outside
the dog house.
There are many different panels available.
However, they all carry out the same
operational functions of the BOP from the
remote location.
The Driller can control all functions of the
BOP from their panel. Certain operation
controls such as the Shear rams and BOP
connectors have safety flaps installed over
them to make you think twice before
operating.
EQUIPMENT
Driller’s Control Panel
There are many different control panel
available from small basic ones on older land
rigs to the sophisticated ones on the new
generation rigs.
EQUIPMENT
BOP Control Panel
The BOP control panel shown -opposite has
two coloured main lights for the functions. A
green light on the panel indicates that the panel
is in a Drilling Mode, i.e. rams are in the open
position and the fail-safe valves are in the
closed position. This indicates that all functions
are in the required position for Drilling.
A red light will indicate that a function has been
operatd, i.e. a ram has been closed. or a fail-
safe valve has been opened.

To operate a function on this panel you must first

push and hold this button (Master Control) while
selecting the required operation.
EQUIPMENT
The Toolpushers BOP Panel
There are many different types of mini
panels available.
One of these is situated in the
Toolpushers office; this panel controls
the functions on the BOP from the
remote location.
To operate this panel you have to first
hold in the energising button (Master
Button) then push the required function.
This panel would be used in an
emergency if the Drillers control panel
was unable to be used.
EQUIPMENT
Subsea BOP Control Panel
Most subsea Driller's BOP control panels have 3
different coloured lights: Red, Green and Amber. The
green light on the function panel indicates that the
panel is in Drilling mode, i.e. rams are in the open
position and the fail-safe valves are in the closed
position. This shows that all functions are in the
required position for operations.
A red light will indicate that a function has been
operated, i.e. a ram has been closed, or a fail-safe
valve has been opened.
An amber light shows that a function is in the
Blocked position. The Blocked position vents the
open and closed function, leaving the rams, etc. in
their last operated position.

To operate a function on this panel you must first

push and hold this button.
EQUIPMENT
Accumulator Control Valves
These valves are four-way/three-position valves; they have insert plates used for different applications
in three different types: Manipulator, Selector ancl Bypass valves.
Manipulator valve
A Manipulator valve is a four-way/three-position valves; the Manipulator type valves are defined as a
valve that, when placed in blocked position, closes the pilot pressure port and vents all other ports back
to the Accumulator tank.
Selector Valve
A Selector Valve is defined as a valve that selects to direct fluid between two possible functions; used
as a two position, four way valve.
The Bypass Valve is a valve defined as a two position three way valve, used to permit bypassing the
Pressure Reducing Valve/Regulator. This would give full Operating Accumulator Pressure to the Ram
Operators.
EQUIPMENT
Accumulator Equipment List
EQUIPMENT
EQUIPMENT
What Are The Main Elements?
The elements of the subsea BOP control system
normally include:
 Storage (reservoir) equipment for supplying
ample control fluid.
 Pumps for pressurising the control fluid.
 Accumulator bottles for storing pressurised
control fluid.
 Hydraulic control manifold for regulating the
control fluid pressure and directing the power
fluid flow to operate the system functions (BOP
and Choke and Kill valves).
 Hydraulic control fluid.
 Umbilical control hose bundle (s) and reel(s).
 Control pod(s) located on the BOP.
 Remote control panels for operating the control
manifold from remote locations.
 EQUIPMENT
BOPs operating in water require a complex hydraulic system
including subsea control pods attached to the BOP frame. Control
pods contain a number at "pilot valves" and pressure regulators,
and are doubled up in parallel for redundancy.
The hydraulic fluid is mixed, pressurised and delivered from the
hydraulic unit at the surface and then delivered at pressure (3000
psi) to the control pod’s pilot valve manifold through a hose
bundle, which includes individual, small diameter pilot lines ( ¼ “
or 5/16 “ hydraulic lines) as well as a larger diameter (minimum 1")
hydraulic line containing the power fluid. The 1/4" pilot lines attach
to individual pilot valves, which are 3 way hydraulic valves, each of
which control the power fluid to a specific BOP component, such
as the pipe ram or annular preventer.
Pilot lines are signal carriers from the surface to seabed. When
commanded to do so from the surface, fluid flows into the pilot
lines until enough pressure is available to operate the pilot valve.
Once opened, the pressurised fluid can flow to the BOPs via
regulators that regulate the pressure to 1500 psi.
EQUIPMENT
Jumper Hoses

Jumper Hoses are the hoses from

the BOP Accumulator Unit to the Blue
and Yellow Hose Reels. (Item 2 in
diagram).
The pilot signals are routed to the
hose reels through the appropriate
length of surface umbilical jumper
hose bundle from the hydraulic
connections located on the control
manifold.