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Presentation JB – AG – JCN – JR 3 NOT TO COPY -- NO DISSEMINATE WITHOUT WRITTEN AGREEMENT
Kicks & blowouts
A kick is an unexpected influx into a well of a formation fluid.
Should this influx be uncontrolled ....
-- during its way from the bottom of the hole up in the open hole or
-- when at surface ,
an internal or a surface blowout will occur.
Blowout: is an incident where formation fluid flows out of the well or between formation
layers after all the predefined technical well barriers or the activation of the same have
failed.
DRILLING HAZARDS: well control - blowout prevention
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Kicks & blowouts occurrences
When ….
- in exploration / appraisal drilling activities …
many geological and technical uncertainties leading to higher risks,
- in workover activities …
risks of release of hydrocarbons during removal or installation of surface
wellhead or BOP equipment.
DRILLING HAZARDS: well control - blowout prevention
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Source SINTEF - period 1980 - 2008
DRILLING HAZARDS: well control - blowout prevention
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Kicks & blowouts occurrences – some figures
34% are “surface blowouts” 66% are “underground blowouts”,
60% of occurrence while drilling, 27% while completion/WO,
(8% during production, 5% others)
Expenses associated with a blowout can reach
several million of US$,
Expenses for well control, costs for pollution control
and containment measures, losses of facilities,
penalties, fines ....
and tragedies, people can be killed.
DRILLING HAZARDS: well control - blowout prevention
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Blowouts ….
“Surface blowout” or “blowouts”
Onshore or by mid-waters (“drilling wellheads” with BOP’s above waters)
BOP’s are easily accessible.
“Subsea blowouts”
Offshore, with subsea wellhead and BOP’s ; BOP’s are not easily
accessible !
“Shallow gas blowouts”
A shallow gas blowout is difficult (or impossible ) to control; it may
result in losses of lives and loss of the rig/platform; all effort must be
made to divert the flow away from the rig: use of diverter and diverter
lines
“Underground blowouts”
Uncontrolled flow of formation fluids from a high pressure zone into a lower
pressure zone; the direction of fluid flow (up or downwards) is an important
concern when choosing a control procedure.
DRILLING HAZARDS: well control - blowout prevention
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DRILLING HAZARDS: well control - blowout prevention
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CADRE Semi-submersible “Actinia” blowout shallow gas – Vietnam - 1993
KICKS & BLOWOUTS - Generalities
DRILLING HAZARDS: shallow gas
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DRILLING HAZARDS: well control - blowout prevention
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DRILLING HAZARDS: well control - blowout prevention
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Nowadays blowouts are major catastrophic events
Nowadays blowouts are major catastrophic events
DRILLING HAZARDS: well control - blowout prevention
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DRILLING HAZARDS: well control - blowout prevention
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OVERVIEW OF MAIN WELL ENGINEERING STUDIES AND TASKS
Mud studies & program
Well profile
(deviation, hole & casing size)
Casing setting depth selection
Fracture pressure prediction
Pore pressure prediction
Environment studies
and well data collection
Drillstring design
Cement: studies & program
Drilling bit program
Casing , wellhead design
Rig sizing and selection
Cost / budget - AFE **
Rock mechanic studies
Drilling engineering
Well abandon: program Well completion studies *
Contingency plan
(incld. BOCP)
* complulsory for developt well
** Authorisation For Expenditures
WELL DRILLING PROGRAMME
Well test program
Drilling progress curve
for ….
Max expected surface pressure
WP of well control equipment,
….
for ….
Well control procedures,
Internal blowout prevention
….
for ….
Well control procedures,
Internal blowout prevention
….
Well Collision Avoidance
BLOWOUTS & Well Engineering Studies
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OVERVIEW OF MAIN WELL ENGINEERING STUDIES AND TASKS
Mud studies & program
Well profile
(deviation, hole & casing size)
Casing setting depth selection
Fracture pressure prediction
Pore pressure prediction
Environment studies
and well data collection
Drillstring design
Cement: studies & program
Drilling bit program
Casing , wellhead design
Rig sizing and selection
Cost / budget - AFE **
Rock mechanic studies
Drilling engineering
Well abandon: program Well completion studies *
Contingency plan
(incld. BOCP)
* complulsory for developt well
** Authorisation For Expenditures
WELL DRILLING PROGRAMME
Well test program
Drilling progress curve
First safety barrier
Impact of mud type on
kick detection
hydrates
Cement = one safety barrier
….
Casing: burst
resistance
….
Selection of BOP WP
….
BLOWOUTS & Well Engineering Studies
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OVERVIEW OF MAIN WELL ENGINEERING STUDIES AND TASKS
Mud studies & program
Well profile
(deviation, hole & casing size)
Casing setting depth selection
Fracture pressure prediction
Pore pressure prediction
Environment studies
and well data collection
Drillstring design
Cement: studies & program
Drilling bit program
Casing , wellhead design
Rig sizing and selection
Cost / budget - AFE **
Rock mechanic studies
Drilling engineering
Well abandon: program Well completion studies *
Contingency plan
(incld. BOCP)
* complulsory for developt well
** Authorisation For Expenditures
WELL DRILLING PROGRAMME
Well test program
Drilling progress curve
All BOP data are needed
(capping, ….)
BLOWOUTS & Well Engineering Studies
Presentation JB – AG – JCN – JR 17 NOT TO COPY -- NO DISSEMINATE WITHOUT WRITTEN AGREEMENT
Typical circuit of the influx while controlling the well
Pipe rams
closed
Drillpipe
In-hole
Influx (kick)
returns
In the annulus
DRILLING HAZARDS: well control - blowout prevention
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Surface pressure 0 psi 6 864 psi
Bottom Hole Pressure 6 864 psi 10 296 psi 13 728 psi
Equivalent Mud Density at bottom 11 ppg 16.5 ppg 22 ppg !
12 000 ft
6 000 ft
0
Well shut-in: pressures in the well
Gas influx
critical
critical
EMW 33 ppg !
Casing
shoe
casing press. ?
DRILLING HAZARDS: well control - blowout prevention
Fracturation
will occur in
open hole
Presentation JB – AG – JCN – JR 22 NOT TO COPY -- NO DISSEMINATE WITHOUT WRITTEN AGREEMENT
DP pressure = Pt1
Initial MW =
di
(known)
Initial mud +
Influx =
da
( unknown )
Annulus press. = Pa1
Formation pore press. ( > coeff* D*di )
P = coeff *D * di + Pt1 = P =coeff * D * da + Pa1
Well kick control:
principles (1/2)
Initial pressure
regimes (well shut in)
di > da
Pt1 = reference pressure indication
for calculation
D = well vertical depth,
Coeff. = depends on units,
DRILLING HAZARDS: well control - blowout prevention
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Well kick control:
principles (2/2)
Formation pore press.
Circulating pressure
for well control =
P1 = Pc1 * + Pt1 + S Annulus press. Pa = Pa1 + S
choke
Note: circulating pressure
to be maintained if no
change of the initial MW,
di
P = coeff *D * di + Pt 1 + S = P= coeff * D * da + Pa1+ S
Pressure regimes
(starting well control)
* Pc1 = circulating pressure
measured at reduced flow rate
DRILLING HAZARDS: well control - blowout prevention
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Pann = 0
PR
Pfrac
BOP
Pann
PR PR PR
Ps max MAASP
max
Pann Pann
critical
critical
MAASP
max
Pfrac
Drilling
conditions
Well Control Procedures in progress
“new” mud weight
BOP
closed
DRILLING HAZARDS: well control - blowout prevention
Presentation JB – AG – JCN – JR 25 NOT TO COPY -- NO DISSEMINATE WITHOUT WRITTEN AGREEMENT
Important data required prior initiating well control procedures: - drillstring geometry - hole geometry - mud density, - pump flow rate per stroke - pressure losses at low flow rates (kill-flow rates) for different well control mud circuits - fracturation pressure & weak points in the open hole - Surface to bit time at kill rate (in stroke and minutes) - Bit to surface time at kill rate (in stroke and minutes) - Maximum Allowable Annular Surface Pressure (MAASP) - Formula for calculating the kill mud density - Formula for calculating circulation pressures due to the effect of heavier mud
WELL CONTROL SHEET
WELL CONTROL: Principle & Methods
Presentation JB – AG – JCN – JR 28 NOT TO COPY -- NO DISSEMINATE WITHOUT WRITTEN AGREEMENT
The basic principle of well-control methods is to keep
the bottomhole pressure (BHP) constant while circulating
the fluid influx out of the well.
DRILLING HAZARDS: well control - blowout prevention
The simplest method of doing this is to control the drillpipe pressure
by running the pump at a constant rate and controlling
the pressure by regulating the choke on the choke manifold
Presentation JB – AG – JCN – JR 29 NOT TO COPY -- NO DISSEMINATE WITHOUT WRITTEN AGREEMENT
SAFETY BARRIERS while drilling and workover operations.
Associated well control barriers include drilling fluid, casing, cement, casing
shoes, wellhead seals, blowout preventers (BOPs) and the interaction among all
of them.
Drilling and workover operations shall at all times be conducted with two
barriers on each internal and external leak path, capable of operating
independently and simultaneously and isolating potential hydrocarbon
reservoir from the surface
Two barriers are considered as independent if any incident considered in risk
analysis cannot induce the loss of the two barriers simultaneously.
Source / Illustrations: TOTAL
DRILLING HAZARDS: well control - blowout prevention
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External leak path
mud *
WH seals
cement
Internal leak path
Inside DP
BOP
WH seals
BOP’s
mud
mud
Drill pipe
Source / Illustrations: TOTAL
HC
Cem. Equipt.
Safety barriers
Presentation JB - 30
DRILLING HAZARDS: well control - blowout prevention
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External leak path
mud *
WH seals
cement
Internal leak path
Inside DP
BOP
WH seals
BOP’s
mud
mud
Drill pipe
Source / Illustrations: TOTAL
HC
Cem. Equipt.
Safety barriers
DRILLING HAZARDS: well control - blowout prevention
Note:
When drilling deepwater wells, the percentage of drilling time
– rotating on bottom while drilling new hole – is sometimes
less than 20%.
It is important to understand that barriers can be impacted
significantly during all well operations, not just drilling.
Presentation JB – AG – JCN – JR 33 NOT TO COPY -- NO DISSEMINATE WITHOUT WRITTEN AGREEMENT
DRILLING HAZARDS: well control - blowout prevention
Blowout
Loss of well control
Well collision
Loss of rig stability
Loss of well integrity
Filt
ers
fo
r p
reve
nti
on
Soil instability
Pollution
Fire, explosion
Causes Consequences
Filt
ers
fo
r p
rote
ctio
n
Swabbing
Pore Press prediction
Bad cementing
….
Punch through
Bad weather
….
Damages to wellheads
….
Engineering
Procedures
Equipment
Personnel
Polution control equipt.
Capping equipt.
Presentation JB – AG – JCN – JR 35 NOT TO COPY -- NO DISSEMINATE WITHOUT WRITTEN AGREEMENT
Drilling hazards – blowout prevention
- …. before drilling operations = engineering studies,
. Refer to casing architecture and casing design versus evaluation of
formation pore pressure / evaluation of formation fracturation pressure /
evaluation of maxi. acceptable surface pressure and set up of the proper
BOP equipment.
- … . while drilling = procedures
. permanent monitoring of mud volumes in circulation (gains or losses),
. permanent monitoring of mud weight (and mud viscosity),
. permanent monitoring of ROP: “drilling breaks”,
. tests (and maintenance) well control equipment incld. BOP, choke manifold,
inside-BOP, (tests after each new installation and on regular basis (e.g. each
week)),
. training of rig-crews: regular “kick drills” to test rig-crews preparedness,
. calculations for immediate application of pre-set procedures.
DRILLING HAZARDS: well control - blowout prevention
Presentation JB – AG – JCN – JR 36 NOT TO COPY -- NO DISSEMINATE WITHOUT WRITTEN AGREEMENT
Drilling hazards – blowout prevention (contd.)
- … while tripping = procedures.
. permanent monitoring of mud filling the hole when RIH or POOH,
. training of rig-crews: regular “kick drills” to test rig-crews preparedness,
. calculations for immediate application of pre-set procedures.
Well control procedures imply an intensive use of the BOP.
If a BOP failure occurs then the kick will be uncontrolled
leading/meaning to/a blowout.
DRILLING HAZARDS: well control - blowout prevention
Presentation JB – AG – JCN – JR 37 NOT TO COPY -- NO DISSEMINATE WITHOUT WRITTEN AGREEMENT
Alerts or warnings - “drilling breaks”,
- increase of mud level in the active mud tanks,
- gas-cut mud or gas/oil shows,
- changes in mud properties (chlorides, …), changes of shale densities,
- light influx when circulation is stopped,
- uncorrect filling of the hole while pulling-out-of hole the drillstring,
- decrease in the mud pump discharge pressure.
- information provided by MWD,LWD,PWD (gamma ray, resistivity, density,
neutron, sonic).
WHEN WARNING SIGNS ARISE, PERFORM THOROUGH
ASSESSMENTS BEFORE MOVING ON.
DRILLING HAZARDS: well control - blowout prevention
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Source: TOTAL
DRILLING HAZARDS: well control - blowout prevention
Overpressure detection – Gas Readings – Increasing ROP …
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DRILLING HAZARDS: well control - blowout prevention
Other precautions …..
- when drilling with oil-based mud, gas remains in solution as the fluid is
circulated up the hole until the bubble point is reached; then a violent kick
occurs as gas bursts out of solution in the upper portion of the hole (casing or
drilling riser),
- When drilling (HP/HT wells) some supercharging/balloning & “well breathing”
effects must be detected to avoid confusion with a kick
- When drilling high deviated wells (near horizontal), detection and behaviour of
gas bubbles are of important concern.
REMEMBER
The probability of a well control problem may be low, but the consequences are high enough to justify considering all causes, warnings ...
Presentation JB – AG – JCN – JR 40 NOT TO COPY -- NO DISSEMINATE WITHOUT WRITTEN AGREEMENT
Immediate corrective actions
- CLOSE THE WELL: implementation by the driller of the well shut-in procedures,
When applicable (kick during tripping): whenever possible, attempt to run the
drillstring down hole, (stripping),
- As soon as possible, implementation of well kick control method and
procedures to evacuate the influx from the well bore,
Ultime method: If necessary and possible, squeeze/bullhead the influx back
into the formation.
If an unforeseeable event occurs or if a BOP equipment failure occurs a
blowout situation will be imminent; then activate immediately the Blowout
Contingency Plan
DRILLING HAZARDS: well control - blowout prevention
Presentation JB – AG – JCN – JR 43 NOT TO COPY -- NO DISSEMINATE WITHOUT WRITTEN AGREEMENT
43
Some concerns about offshore well control procedures
“Conventional” well control procedures applicable for land or shallow waters. Early kick detection: is necessary
- to minimize the influx volume, and
- because of the large expansion of gas in the drilling riser that can occur .
Notes:
- BOP positioned at mudline sometimes nearer to well TD than to surface !
- Managed Pressure Drilling (MPD) techniques (equipment & procedures) can provide a precise and real time measurements for early kick-loss detection.
Space out: the Driller must quickly determine the space out of the drillstring for closing rams. position of BOP elements (e.g. shear rams) relative to rig floor must be displayed on driller’s panel.
Hang-off procedures: ? ?
WELL CONTROL: Principle & Methods
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Some concerns about offshore well control procedures (contd.)
Shut-In procedures: “Soft” or “Hard” shut-in procedures can be implemented.
Whenever the well is shut-in, gas in the riser shall be considered as the first priority and diverted directly overboard.
“Driller’s” versus “Wait and weight” kill method: ? ?
Riser margin: it is recommended (when applicable or if relevant ) to include a riser margin in the mud weight.
WELL CONTROL: Principle & Methods
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Some concerns about offshore well control procedures (contd.)
Long kill and choke lines: pressures losses in these lines ** are high even at low circulation rates; consequently MAASP is reduced. It is compulsory to measure all pressure losses at reduced flow rates through different sections of the mud flow paths. ( ** Potential use of choke and kill lines in well control circulation).
BOP’s: High shear rams capacity must be assessed due to high drillpipe specifications (grade and size).
BOP response time: this is a key issue;
All systems to operate the BOP’s in emergency situations must be tested in due time.
For offshore operations, special training courses
for Rig Personnel and Office Engineers must be given.
WELL CONTROL: Principle & Methods
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Main calculations
. Maximum annulus pressure well shut-in and filled with gas == > to evaluate well equipment strength . MAASP * == > to avoid risk of fracturing the formation at the weak zone ( * Maximum Allowable Annulus Surface Pressure)
. Maximum casing pressure during the circulation of a gas kick with the initial mud weight == > evaluation of well equipment strength and maxi allowable kick volume . Maximum pressure at weak zone during the circulation of a gas kick with the initial mud weight = = > evaluation of maxi allowable kick volume at shut-in . Maximum allowable kick volume at shut-in == > to avoid risk of fracturing the formation at the weak zone . Quick evaluation of the influx pressure gradient = mud pressure gradient + (Pt1 – Pa1) / h ( h = initial height of the influx in the annulus)
DRILLING HAZARDS: well control - blowout prevention
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weak point
flow outside
the wellhead
Underground blowout
Initial too large
influx, or
driller’s
mishandling
Bad cementing job
or,
Weak point(s) in the
openhole
DRILLING HAZARDS: well control - blowout prevention
Catastrophic
situation
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Lusi mud flow – Indonesia (may 2006)
Source: photos M.Tingay and Channel 9, may 2007
DRILLING HAZARDS
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Results / consequences of ….
- Engineering works ?
(questionable casing-setting-depth
design ? )
- Operational human error ?
- External events ?
DRILLING HAZARDS: well control - blowout prevention
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weak point
Tubing failure
(leak)
packer
HP zone
loss zone
or
depleted zone !
Underground blowout
(internal blowout)
DRILLING HAZARDS: well control - blowout prevention
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Underground blowout (internal blowout)
Such blowouts are catastrophic as they can lead to
- the loss of the well,
- new hazards when drilling wells in the vicinity,
- subsurface / internal contamination between reservoir layers, ….
Precaution – first preventing measures:
- perform engineering tasks === > casing point selection,
- update blowout prevention data sheets,
- perform regularly “kick drills”,
- evaluate, as necessary, cement bond behind casing after cementing job,
- check casing/tubing integrity tests as necessary ( … before DST),
DRILLING HAZARDS: well control - blowout prevention
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BLOWOUT - WELL CONTROL
Whenever an exploration well is planned, the drilling team must prepare a
“Blowout Contingency Plan”.
Such plan, to list actions to be taken for the safeguard of the People, the environment and
the assets; to list all updated contacts for assistance.
A special team “blowout task force” is mobilised with all competencies (geoscientist, reservoir,
drilling, logistics, contract Engineers) as soon as possible.
At the same time …
- relief well(s) will be engineered; rig(s), special directional drilling equipment, pumping
means will be located and/or mobilized
- fire-fighters Specialists (*) will be mobilised together with their equipment for well killing
and/or well“capping”
( * Wild Well Control, Boots & Coots, Cudd, West, John Wright Co, Red Adair)
DRILLING HAZARDS: well control - blowout prevention
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Source / Illustrations: Wild Well control
ONSHORE / OFFSHORE BLOWOUTS
RELIEF WELLS
DRILLING HAZARDS: well control - blowout prevention
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Blowout
on the WP
Subsea
wellhead
Surface
wellhead
1000 to 1500 m
Relief well Blowout
well
reservoir
relief well drilled
directionally
Source / illustration: Books from IFP and
“Chambre Syndicale de la Recherche et de la Production du Pétrole et du gaz naturel”
Floating
rig
DRILLING HAZARDS: well control - blowout prevention
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Source / Illustrations: Wild Well control
ONSHORE BLOWOUT
Well capping
DRILLING HAZARDS: well control - blowout prevention
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DRILLING HAZARDS: well control - blowout prevention
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Source / Illustrations: Wild Well control
DRILLING HAZARDS: well control - blowout prevention
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Source / Illustrations: Wild Well control
DRILLING HAZARDS: well control - blowout prevention
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DRILLING HAZARDS: well control - blowout prevention
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Source / Illustrations: Wild Well control
DRILLING HAZARDS: well control - blowout prevention
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DRILLING HAZARDS: well control - blowout prevention
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Source / Illustrations: Wild Well control
DRILLING HAZARDS: well control - blowout prevention
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Source / Illustrations: Wild Well control
DRILLING HAZARDS: well control - blowout prevention
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Slides were prepared for presentation and information to Students of Schools and Universities only.
References
Slides presented were prepared with illustrations from the following referenced documents:
- API Standards and Recommended Practices,
- Neal J. Adams, Drilling Engineering , PennWell Books, Tulsa, Oklahoma, 1985,
- (Halliburton) - Petroleum Well Construction – J Willey & Sons
- Miscellaneous books from “Chambre Syndicale de la Recherche et de la Production du Pétrole et du gaz naturel”
- IFP Drilling data handbook
- Miscellaneous documentation from TOTAL Drilling Division
- Halliburton Completion Services
- Miscellaneous books from IFP
- Leading Edge Advantage Ltd (Under Balance Drilling).
- Miscellaneous documentation from web-sites: O&GJ, World Oil, SPE
- Transocean, Saipem, Pride Drilling Contractors
- Baker Hughes, Schlumberger, Weatherford, Wild Well Control Service Companies
- Cameron, Hydril, Companies.