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7. 7.1.

SUB-SEA WELL CONTROL: PRINCIPLES AND PRACTICES Sub-Sea Well Control

There are serious well control problems associated with drilling operations from floating vessels in any water depth. This section reviews the major problems likely to be encountered. 7.1.1. Introduction

Just as for drilling on rigs with surface stacks, well control problems can occur when using floating rigs with sub-sea BOPs. Although most of these problems tend to increase in complexity with increasing water depth, some can be more severe in shallow water. 7.1.2. Kick Detection

Two of the major early warning indications of kicks are relative changes in the return mud flow, and change of mud level in the pits. Flow rate tends to fluctuate with vessel heave and pit level tends to fluctuate with vessel pitch and roll, thus disguising the initial relatively small changes which occur at the onset of a kick. Equipment that compensates for vessel movement by averaging multiple sample points can minimise but not eliminate the problem. In doubtful cases there is no substitute for a visual flow check. 7.1.3. Fracture Gradients

In deep water drilling operations, fracture gradients at any particular depth are considerably less than those experienced at equivalent depths in shallow water or on land. One of the reasons for this reduction in formation strength is the reduction in overburden stress from the long, relatively light column of seawater overlying relatively unconsolidated sediments before dense, well compacted rock is encountered. The net result of this is that kick tolerance can be drastically reduced and hence the need for early kick detection. 7.1.4. Sub-Sea Choke and Kill Lines

The length of the choke and kill lines extending from the sub-sea BOP to the drilling vessel, causes two major problems for well control which increase in severity with water depth. The first problem is the substantial circulating friction pressure loss which occurs in the choke line during circulation of an influx from the well. The second problem is the dramatic change of hydrostatic pressure when gas displaces mud in the choke line and subsequently when the following mud displaces the gas. These topics are discussed in more detail in Section 7.2. 7.1.5. Shallow Gas

One of the most severe well control problems likely to be encountered from a floating rig is that of safely handling a shallow gas flow. When water depths exceed 200m it is generally reasonable to assume that riser-less drilling or diverting sub-sea in conjunction with procedures to move the rig away from the plume is the safest alternative. However, in shallower water there may be potential for a sudden gas eruption which is impossible to avoid, and riser-less drilling or sub-sea diverting may not be a viable option. Surface

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diverter procedures are covered in the Shallow Gas Procedure Guidance Manual (EP 881000). 7.1.6. Riser Margin

When drilling from a floating rig there is always the possibility that the marine riser may part or have to be disconnected. When this happens the hydrostatic pressure of the mud column in the riser from the BOP to the pitcher nipple will be lost and replaced with the lower hydrostatic pressure of a column of seawater from the BOP to sea level. This reduction of hydrostatic may be enough to cause the well to go under-balance and kick. It is normal procedure to use mud slightly more dense than required during normal operations so that the well will not go under-balance if the riser is disconnected. This increment of density is referred to as the Riser Margin. In many cases the normal Trip Margin will adequately cover Riser Margin requirements. Only the greater of these two margins should be applied. In instances where fracture gradients are critical and it is not possible to maintain a riser margin, procedures must be in place to ensure that the well is secured in the event of loss of mud from the riser. 7.1.7. Riser Collapse

The marine riser is a large diameter conduit designed to provide an open flow path for drilling mud between the subsea wellhead and the floating drilling vessel. It is not normally designed to withstand high burst or collapse pressures. Evacuation of the riser (unloading gas) or a significant drop in mud level (losses) will subject the riser to collapse differential pressure. The hydrostatic pressure of the seawater may cause the riser to collapse. The problem can be averted by maintaining liquid in the riser. This may be with a Riser Dump Valve or by closing the BOP and filling from surface. Regular riser wall thickness tests are advisable to monitor internal wear or corrosion that will reduce collapse resistance. 7.1.8. Trapped Gas

When a gas influx is circulated from the hole some gas may accumulate in the sub-sea BOP below the preventer and above the side outlet that was used. This gas must be removed before the BOP can be opened. This topic is discussed in more detail in Section 7.3 and in Section 7.5 for deepwater operations. 7.1.9. Killing the Marine Riser

After any well control operation that requires an increase of mud density, the well will be dead when kill density mud fills the drill string and the annulus to surface. On a sub-sea well part of the annulus that has been "killed" is the choke line. The density of the mud in the marine riser has not been increased during the course of the well control operation. Before opening the BOP it is necessary to circulate the riser to kill density mud. 7.1.10. Hydrate Formation

Gas hydrates can form in the BOP and kill and choke lines on deepwater operations when water based mud is used. This topic is discussed in Section 5.4 and Section 7.5

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7.2.

Choke and Kill Line Effects

Long, relatively small diameter subsea choke and kill lines strongly influence secondary well control procedures because of dynamic frictional effects and the effect of fluid displacement on hydrostatic pressure in these lines. This section reviews these friction and hydrostatic effects. 7.2.1. Friction Effect

The dynamic friction loss in long choke lines has been called the "hidden choke effect" because the effect is the same as if a second, non-adjustable choke in the system was generating a back pressure equivalent to the friction loss. It may also be considered as just another hole section with very, very small annular clearance. The effects are the same, and result in increased Equivalent Circulating Density (ECD) whenever well circulation is directed through the choke line rather than the open riser. The magnitude of this increase in ECD depends on;

The choke line configuration, internal diameter, length, tortuosity etc. These are fixed for a particular system. Circulating fluid properties. e.g. density and viscosity. These will differ over the life of the well and will also change dramatically during a kill operation, particularly if the influx is gas. The rate of fluid flow through the line. Even at constant circulation rate this can change substantially during the kill if the influx is gas.

During well killing operations, when surface shut-in pressures are also applied to the wellbore, the danger of formation fracture increases markedly if no attempt is made to compensate for choke line friction effects. For this reason all subsea wells should be killed using a procedure which compensates for choke line friction. On surface stack wells it is usually acceptable to ignore annulus circulating friction pressure and commence kill circulation maintaining constant choke manifold pressure, by choke manipulation, whilst the pump is brought up to speed. For subsea wells the initial circulating choke manifold pressure must be reduced by the magnitude of the choke line friction pressure for the particular circulation rate. During start-up the circulation rate, and therefore friction loss, is changing so a pressure reduction schedule is necessary. Choke line friction pressure can be measured during drilling operations by various techniques, details of which can be found in the Shell Distance Learning Training Manual Section 7.6. With this background data it should be possible to calculate approximate friction loss values for a range of circulating rates and mud properties. These can be used to make an approximation of the correct choke back pressure to apply when initiating circulation at commencement of a kill. However, it should be stressed that these are at best only rough approximations and will involve more complex calculations if the choke line is not filled with original density mud prior to start-up. The preferred, more accurate and simplest method is to disregard choke manifold pressure and hold BOP pressure constant, by choke manipulation, whilst the pump is brought up to speed. This technique is valid regardless of the contents of the kill and/or choke lines, is appropriate for any circulation rate and does not require any pre-recorded, calculated or

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estimated data. Furthermore, the BOP pressure (static kill line pressure or BOP pressure monitor) should be held constant, by choke manipulation, whenever it is necessary to change circulation rate, or to stop and restart during the course of the kill. All floating rigs must have a static kill line pressure gauge or BOP pressure monitor mounted at the choke control console. In instances where it is advantageous to use both the kill and choke lines during well control operations, a BOP pressure monitor should be installed, and this used in place of the static kill line pressure. During the course of the kill operation there will be a sequence of different fluids in the choke line, each of which will have different circulating pressure characteristics. (water or base oil, original mud, influx, original mud, kill mud). The choke must be manipulated to compensate for these variations and so maintain the required standpipe pressure for the particular circulating rate. However, when gas enters the choke line the choke line friction pressure drops markedly as gas, even at very high flow rates, has very low flowing friction pressure compared to mud or other liquids. At the same time, gas expansion is accelerating the mud ahead of the gas which produces higher friction pressure and higher choke backpressure. These effects, to a large degree, cancel each other out so little choke manipulation is necessary, but the choke manifold pressure will rise dramatically, as it must. Once gas reaches the choke the choke opening must be reduced rapidly and substantially to replace this loss of choke and choke line friction pressure with actual choke manifold back pressure. As the gas is vented the choke manifold pressure falls, again with little choke manipulation. However, when all the gas has passed through the choke, and mud returns, the choke opening must be increased rapidly and substantially to a diameter slightly larger than it was before gas reached the BOP. If this is not done there will be a large pressure surge that could fracture the well. 7.2.2. Hydrostatic Effect

In any well, whenever a gas kick is being circulated from the hole by a constant bottom hole pressure method, choke manifold pressure increases as the gas approaches surface. This is caused by the fact that the gas expands in the lower pressure environment, and as a consequence of this expansion occupies a greater vertical height in the well to the exclusion of mud. The higher choke manifold pressure must replace the lost hydrostatic pressure. In subsea wells this gas expansion problem is greatly magnified when a gas influx enters and occupies the relatively small volume, but substantial height, of the choke line. The mud hydrostatic head of the depth from Rotary Table to the subsea BOP may be lost due to the displacement of mud by low density gas. In order to maintain constant bottom hole pressure, as indicated by the appropriate standpipe pressure, choke manifold pressure must be increased by reduction of choke opening. This effect is in addition to the low gas friction pressure mentioned above, which also requires rapid reduction of choke opening. 7.2.3. Pressure Lag Time

The effects mentioned above can take place rapidly. When the objective is to maintain constant bottom hole pressure by keeping standpipe pressure constant by choke manipulation, it is possible that if the choke opening is not reduced as required, bottom hole pressure may drop below formation pressure before there is any indication on the

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standpipe pressure gauge. This is due to the fact that pressure transients through dense mud and long gas columns can be very slow. There may be a lag of as much as 1 second for each 300m (1000ft) of distance traveled. i.e. a change at the choke may not be reflected on the standpipe gauge for 30 seconds in a 4,600m (15,000ft) well. It is therefore necessary to anticipate the arrival of gas at the choke line and be prepared for rapid choke manipulation. As in start-up procedures, in the absence of a BOP pressure monitor, the most reliable indicator of pressures in the annulus is the static kill line. This gives a value indicative of the pressure at the BOP and will be a maximum when the gas influx first reaches the BOP. As gas enters the choke line the pressure at the BOP drops. This is in marked contrast to the choke manifold pressure which is rising rapidly. This is the warning signal to the choke operator to prepare to reduce choke opening rapidly as gas presents at the choke. During all other phases of the kill, the choke manifold pressure and the static kill line pressure will track each other separated by the magnitude of the choke line friction pressure.

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Choke manifold pressure

Static kill line pressure

Choke opening

Figure 7.2.1: Effect of gas in the choke line

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7.3.

Trapped Gas in Subsea BOPs

When a gas influx is circulated from the hole some gas may accumulate in the subsea BOP below the preventer and above the choke line side outlet that was used. This gas must be removed before the BOP can be opened at the conclusion of the well killing operation. 7.3.1. Overview

Whenever an influx is being circulated from the hole from a floating rig, the drill string should be hung off on the pipe rams and the closest side outlet below those hang-off rams should be used as the choke line. The annular should only be used if there is a choke line situated immediately below it. This will ensure that the volume of trapped gas is kept to a minimum. If at all possible, it should not be allowed to accumulate under an annular with no adjacent outlet as the distance from the choke line will result in a larger volume of gas and make removal more difficult. 7.3.2. Removal of Trapped Gas

Traditional methods for removal of trapped gas, such as the Turbulence Technique, the Back-surge Technique and the Toilet Flush Technique, have been demonstrated to have minimal success. Based on a series of tests performed by Shell in the Gulf of Mexico the following recommended procedure was developed. This procedure may vary in detail slightly from rig to rig and area to area. 1. 2. 3. 4. During the kill procedure, always use a preventer that has an adjacent outlet. On completion of the kill operation, isolate the well by closing a preventer below the trapped gas. Start boosting the riser with kill density mud. Open the preventer above the trapped gas whilst continuing to boost the riser. This has the effect of stringing out and dispersing the gas bubble as it migrates out of the BOP. Stop boosting and wait 30 minutes for the gas to migrate/string out more through the riser. Observe the well. Circulate one third to one half of the riser volume. Stop circulation and wait 30 minutes. Observe the well. Continue circulation monitoring the flow from the top of the riser, looking for indications of gas. Upon indications of gas at any stage, circulate slowly, being ready to close the diverter if necessary. When the riser is dead and filled completely with kill density mud, check for pressure under the lower preventer before opening and resuming operations.

5. 6. 7. 8. 9. 10.

Experience using this technique has shown that the worst "surge" of gas at the surface occurs when the rig is operating in 300-600m (1000-2000ft) of water.

In less than 300m (1000ft) the pressure of the trapped gas is not very great. In greater than 600m (2000ft) the riser volume is so large that the gas has time to string out while coming up and does not arrive at surface all at once.

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7.4.

In water depths greater than 1200-1500m (4000-5000ft) there may be insignificant impact. Subsea Well Control Procedures and Calculations

The basic principles of well control are the same for any well. However, Subsea BOP systems deployed from floating drilling vessels introduce complexities that may require additional calculations and special procedures. This section addresses those complexities. 7.4.1. Measurements

It is vital for hang-off, shearing, stripping and all wellhead operations that the distance from Rotary Table to the wellhead and to each ram and annular preventer of the BOP is known accurately. These measurements are best taken when the test tool is run for the first BOP test after landing the stack.

There must be an accurate dimensional stack-up drawing of the wellhead and BOP showing the distance of each component from a datum, usually the wellhead connector seal gasket. The mid point of each ram preventer is always a useful dimension. Rig up a tide gauge connected to the telescopic joint outer barrel and set it to agree with reference tide tables if available. Allowance should be made for fleet angle. Paint the test single with white or light coloured paint before running in for the BOP test. The white paint will be marked by the rams and annulars when they are closed around it during the pressure test. While the test tool is seated in the wellhead, mark the drill pipe at the rotary table (heave average) and simultaneously note the tide. After completion of the BOP test and while pulling out, accurately measure the distance from rotary table to each of the marks on the test single and to the landing shoulder on the test tool. Correct these depths to tide datum and record and display them prominently in the dog house. The depths should be checked when the wellhead bore protector is run after the BOP test. With the motion compensator, lightly tag the top of the closed shear rams with the bore protector on the running tool. Mark the pipe at rotary table and note the tide. Pick up, open the shear rams, land the bore protector in the wellhead. Mark the pipe at rotary table and note the tide. Release the bore protector. Pull back above the BOP, close the shear rams, lightly tag the top of the closed shear rams with the bore protector running tool. Note that the difference from previous recorded tag depth confirms that the bore protector has been released. All these depths should be tide corrected and checked against the original measurements.

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Determine the average drill pipe single length and using that in conjunction with the measurements taken above, calculate the stick-up above rotary that places a tool joint at every critical point in the BOP. This information must be readily available to the Driller at all times. Shut-in Procedure With the pump ON, unlock rotary bushing and raise the kelly or top drive to the predetermined position for landing the string on the designated hang off rams. (with the lower kelly cock above the rotary table, allowing for tidal condition). Note that the motion compensator may be stroked out or locked so ample clearance must be allowed for heave. Stop the pump. Function Close the upper annular preventer. Simultaneously function Open the outer fail-safe valve of the choke line. The rest of the choke line is always open to a closed choke under normal conditions. (Hard shut in) Close the valve upstream of the adjustable choke if it is a non-sealing choke. Do not close valves that isolate pressure sensators. Close the designated hang off pipe rams. These must have room below the shear rams to cut the drill pipe above the hang-off tooljoint if a disconnect becomes necessary. Land the string on the rams, set compensator to mid-stroke position and close locks on the rams (wedge locks). Observe closed-in drill pipe pressure SIDPP (Pdp) and closed-in annulus pressure SICP (Pa). Open Kill line subsea valves to give a static BOP pressure reading. Kill the well by the method previously determined as appropriate.

7.4.2. 1.

Offshore Floating Units (with drill string motion compensator operational)

2. 3. 4.

5. 6.

7. 8. 9. 10.

The use of a circulating head is mandatory for killing a high pressure well or when using circulating pressures of over 27,600 kPa (4000 psi). Follow the same closing in procedure as is described for offshore floating units with drill string motion compensator nonoperational. The circulating head assembly may be supported by the motion compensator, constant tension winches, or tensioners. Offshore Floating Uunits (with drill string motion compensator non-operational) 1. 2. 3. 4. With the pump ON, unlock rotary bushing and raise the kelly or top drive to put the lower kelly cock above the rotary table. Stop the pump. Function Close the upper annular preventer. Simultaneously function Open the outer fail-safe valve of the choke line. The rest of the choke line is always open to a closed choke under normal conditions. (Hard shut in)

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5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 7.4.3.

Close the valve upstream of the adjustable choke if it is a non-sealing choke. Do not close valves that isolate pressure sensators. Set the string in the slips. Close the lower kelly cock, bleed off pressure in the kelly or top drive. Disconnect the kelly or top drive above the lower kelly cock. Install the circulating head on one drill pipe single. Attach the supporting system to the circulating head assembly (using constant tension winches, or tensioners). Pick up the string, remove the slips. Position pipe at pre-determined space-out for hang-off. Close the designated hang off pipe rams. Land the string on the pipe rams with the circulating head assembly supported by the elevators riding on the handling sub. Close the ram locks. Pressure test the lines/hoses and connections to the circulating head and standpipe manifold to the pressure rating of the manifold. Remove the elevators (depending on heave) with the circulating head assembly supported by the supporting system. Pressure up the lines to the lower kelly cock to Pdp and open the lower kelly cock. Observe closed-in drill pipe pressure (Pdp) and closed in annulus pressure (Pa). Open Kill line subsea valves to give a static BOP pressure reading. Kill the well by the method previously determined as appropriate. Calculations

Once the shut in pressures and influx volume are known all the normal calculations required for well control can be completed and well kill schedules prepared. These include;

Kill mud density Initial Circulating Pressure Surface to Bit Strokes Final Circulating Pressure Influx Gradient and hence influx type. Approximate strokes for influx to reach critical points. e.g. casing shoe, BOP, surface.

Start-up procedures must be modified to reduce Choke Manifold Pressure by choke line circulating friction pressure as described in Section 7.2. If it is not possible to read static kill line pressure or there is no BOP pressure monitor, then a pressure reduction schedule must be calculated based on pre-recorded measurements of choke line friction pressure.

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7.5.

Deep Water Well Control

This section captures the key topics for deep water well control operations. For the purposes of this manual, deep water is a water depth >500m or 1500ft. 7.5.1. Overview

Summary The methods and approaches described in this section are applicable to all deep water wells with a subsea BOP. However, when dealing with wells that have only a small margin between formation and fracture gradients (as is the case in overpressured wells such as those found in the Gulf of Mexico) a higher level of detail must be considered. In particular, the impact of procedures and events on the annulus must be thoroughly understood, monitored and controlled. Additional considerations for this type of well are given in Sections 8 and 5.11. It is suggested that for this type of well, well and rig specific engineering is carried out. By contrast, for many wells there is sufficient margin between formation and fracture gradients such that the well can be controlled. For these wells, industry methods in existence for many years introduce safety factors into the circulating pressures and any potential for additional flow is stopped. Because there is sufficient margin, there is no negative impact on the well, such as lost circulation. Overall Approach to Deep Water Well Control

The Hard Shut in Method will be used (Typically using the Upper Annular) For all cases where there is a high SICP (or likelihood that this will result during the kill operations), movement of pipe through the BOP because of weather, or there is the potential for loss of rig position (e.g. use of Dynamic Positioning), the drill pipe will be hung off on a dedicated hang off ram following initial shut in. If none of these conditions apply, then it is possible to keep the well shut in on an Annular, with slow movement of the pipe to prevent stuck pipe. In this instance an outlet should be available below the annular used for shut in. When water base mud is in use, the Drillers Method will be the normal method of well control. If OBM (or SOBM) is in use, the Wait & Weight Method may be used. However, if there is only a small margin between mud weight and fracture gradient, the use of the Drillers Method is suggested such that the pit levels can be very closely monitored during the kill circulation. Alternative actions should be discussed between the Rig and shore based operations teams. If immediate actions are required, the Rig team has the full authority to proceed. If a kick is taken off bottom, the bit will be stripped to bottom wherever practical and safe, prior to attempting to kill the well. Under no circumstances will the drill string be run back to bottom with the well open and flowing. A kick will be assumed to be gas until shown otherwise. The major difference to well control with a surface BOP stack is the position of the BOP and the impact of having to circulate through the relatively long, small choke and/or kill lines. These lines impose a significant backpressure upon the circulation system with the pump on this backpressure must be accounted for.

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Consideration should be given to installing the following: BOP pressure and temperature gauges Insulated choke and kill lines (near the BOP) Drill pipe tool joint positioning system (based on the delta distance of the rotary table to top of riser)

If SOBM is being used, a pressurized riser and a gas handler (annular preventer at the top of the riser) is recommended. Hydrates have been considered a significant issue in deep water drilling. However, if the simple mitigation methods outlined in this document are taken, hydrates should not be a problem. Hydrates will not be a problem if SOBM is in use. Particular attention should be taken with wells where massive lost circulation is possible.

For all wells, steps should be taken to ensure that gas is stopped from rising into the wellhead connector and freezing the connector.

Ballooning may be a problem for a deep water well. Procedures must be in place to ensure that this phenomenon is dealt with in a safe, yet effective way.

See Section 8.3.5. Ballooning / Flowback / Backflow / Supercharging. The overall Well Control Process (for a kick with the bit on bottom) is: 1. 2. 3. Flowcheck and shut well in. Circulate out kick and kill well with kill weight mud. Sweep the stack and clear the riser of gas.

For WBM, a small gas bubble can be very easily dispersed within the riser by shutting down the pump and waiting. This approach is very effective for dealing with small gas bubbles such as those trapped in the BOP after a well control incident. For OBM (or SOBM) this will not be the case. Only one rig is known to have a combination of pressured marine riser and surface mud gas handler/outlet to choke. This is the Nautilus. For this rig a suspected gas bubble in the riser can be circulated out over a choke, with the riser gas handler closed. For all other rigs, great care must be taken if a gas bubble (dissolved in OBM) is suspected in the riser. Close attention must be paid to limiting the size of any potential bubble, by following the appropriate stack sweeping procedures etc.. Special consideration should be given to the contents of the choke and kill lines with regard to: Fluid Type Temperature Hydrate inhibition

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7.5.2.

Shallow Gas in Deep Water

Shallow Gas - Drilling the Top Hole Section (Riserless) Shallow gas in a deepwater context is taken to mean encountering a gas bearing formation when drilling the Top Hole section in a riserless mode. A gas influx may occur because the formation is effectively overpressured or because of an action (such as swabbing) that occurs during the drilling or tripping process. For deep water, the combination of low temperature and high pressure (due to water depth) should ensure that any gas pockets exist as hydrate. Hydrate will look like gas on a shallow seismic survey. The approach taken in this work will effectively deal with the situation whether the gas is in gaseous or hydrate form. If the gas is in hydrate form, there will be very little (if any) impact upon the drilling performance there may however be a very significant impact on future development operations and the presence of hydrate must be identified . Under no circumstances will a top hole section be drilled with the riser attached. Kicks Once the BOP has been Installed Once the BOP and drilling riser have been run all kicks must be treated in the conventional manner - the BOP must be closed and the influx will normally be circulated out in the conventional way (normally using the Drillers or Wait & Weight methods). As a general philosophy, on floating drilling rigs where there is any risk of shallow gas, drilling to the first casing point below structural casing will be carried out without taking returns to surface. Discussion of Shallow Gas Problems

Shallow sands filled with gas are overpressured at the top of the sand. The pressure at the base of the sand or at the gas/water contact, if there is one, is normally equivalent to hydrostatic pressure of seawater at that depth. In some locations, rapid deposition may have resulted in geo-pressured sands. The pressure at the top of the sand will be nearly the same as the pressure at the bottom, if the sand is gas filled. The amount of overpressure (if any) is directly a function of the height of the gas accumulation above the gas/water contact. Shallow gas hazards drilled without either a weighted mud or a riser will kick. The time between the start of a kick and the complete unloading of the well will be a matter of minutes. There is generally very little time to take corrective action. It is considered far safer to drill these top hole sections without a riser attached. When gas blows out it can produce a plume of aerated low density water. This can affect the buoyancy of a floating vessel if the gas plume comes to surface beneath it. In reality, problems have only occurred when hatches were left open on drilling vessels in a plume and the vessel simply flooded when it lost freeboard or heeled over and sunk as a result. Chain lockers can also be a danger if they can flood. With increasing water depth and sea current the plume will tend to come to the surface away from the rig. Mooring or positioning arrangements will be planned to

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enable the rig to move clear of the gas plume from the well, should it be necessary to do so. Other points to note are:

If the sea water is heavily gas cut, there may be a substantial decrease in the buoyancy factor making evacuation by sea with the standby boat very hazardous. Landing a helicopter on the rig with the wind blowing in the direction of the helideck would be impossible due to the risk of fire or explosion. If the rig has to be evacuated, the main engines will be shut down to remove the potential for a spark. This will cause the emergency generator to come on line. When and if it is safe to do so, the OIM will then shut down the emergency generator on his way to his point of evacuation. For most deep water situations, the combination of low temperature and high pressure due to water depth will mean that if low gravity natural gas exists, then it will exist as hydrates. As such there will be little or no danger of a gas blow-out. The existence of such hydrates must be noted for future development consideration. It should be noted that as temperature increases with drilled depth it is not impossible to drill into free gas below a hydrate cap.

See Section 5.3 for further details on Shallow Gas Typical Example of a Pre-Drilling Operations Safety Checklist:
Action 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Move off plan in place Anchors prepared for emergency release (designated winches depending on weather) Direction set for DP drive off. Constant monitoring of wind, current, sea state HVAC shut down procedures and mode to be reviewed Gas watch ROV & Continuous bubble watch Standby Vessel positioning (Moored Rig) Cables or chains marked for easy relocation Radio review Windsocks in place Float valve to be run in string as near to bit as possible Monitoring of seawater suction points No hot work unless absolutely necessary Test all gas detectors and alarms Prepare at least one hole volume of heavy mud Hold safety meeting & explain procedures Procedures for moving off in emergency Prevailing weather conditions Seismic data Historical data for area Use of LWD Maximum weather conditions for operations Reporting procedures Timing of drilling events Crew responsibilities

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Methods of preventing gas intrusion Summary of radio channels in use 15 16 17 18 19 20 Emergency drill Perform an emergency pull-off drill (if required) Hold an abandon ship drill Double check abandonment equipment Engine exhaust sprays to be on (if fitted) Close and dog deck level watertight doors and hatches

Drilling Operations
It is most likely that the rig can stay on location, even if a gas flow occurs. In deep water any gas flow is likely to flow away from the rig. The rig should only be moved if it is directly in the gas boil or downwind from the gas boil and in the gas pocket.

1.

While drilling, have the mooring/dynamic positioning controls manned at all times in case it is necessary to move vessel away from a gas boil in the event of a shallow gas kick. Do not hesitate to move the vessel in this event, even if drill pipe has not been withdrawn from the hole. If a gas flow occurs, switch suctions to heavy kill mud and pump at maximum obtainable rate.

2.

Drilling Solid (in-situ) Hydrates At the conditions to be encountered in the top hole section, it is possible to drill into insitu gas hydrates. In particular, the temperatures are low enough and the pressures high enough for solid gas hydrates to have formed anywhere that free (methane) gas existed. Typically 1 cubic foot of hydrate will release 170 SCF of gas as well as 0.8 cubic ft of water on decomposition. By contrast, 1 cubic foot of formation (9ppg formation pressure at 5000 ft RKB, 30% porosity) will release about 50 SCF of gas. Hydrates will dissociate to gas and water if the temperature is raised or if the pressure is reduced. Dissociation may therefore take place as the solid hydrates cuttings are circulated to the seabed and the pressure is reduced. However, as noted above, although the volume of gas that could be liberated is about three times the volume that would be liberated as drilled gas it is not significant and does not constitute a flow. Dissociation in the wellbore can also occur when the mud gradient is less than the inherent (gas) formation pressure and dissociation can also take place in the wellbore as the well is deepened and the mud warms during periods of continuous circulation. However, dissociation is a slow process and immediate disassociation of the hydrate will not take place. As a result, there will not be a flow of gas into the wellbore from a penetrated hydrate section in the same way that would be for a column of gas where the formation pressure was greater than wellbore pressure. If a hydrate section is penetrated, proper consideration must be given to the long term potential consequences. In particular, the potential for warming of the formation around the wellbore and subsequent production of gas must be considered. If any signs of potential in-situ hydrates are seen (drilling rate changes, gas at seabed etc..), these must be reported to the Senior Drilling Supervisor.

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Finally (and for all wells) it is most important to obtain a good cement job around the conductor casing. This may prevent gas migration around the conductor and potential hydrate formation in the BOP/Wellhead connector. 7.5.3. Shallow Water Flow

Shallow water flows are uncontrolled water flows which occur when drilling shallow top hole sections. The flow may be from one formation to another or from a formation to the seafloor through the wellbore or through the wellbore and then by broaching around the previously set casing string. General Information and Planning Shallow water flows have been seen in some areas, in particular the GOM deep water in water depths beyond 150m (500 ft) and at depths ranging from 60m (200 ft) to 600m (2000 ft) below the mudline. These flows may also be found in other similar depositional environments. Once a shallow water flow starts it is very difficult to stop because of the very small margin between pore pressure and fracture gradient. Typically the sands within which such flow occurs are geo-pressured because of rapid sedimentation. The flow may start:

After a sweep removes cuttings from the well and the hydrostatic pressure is reduced During a cement job with the cement in its transition phase

During the planning stage, potential shallow water flow zones may be identified using a combination of seismic and offset well information. The potential for shallow water flow is higher when sands are overlaid with sediments deposited at a high sedimentation rate. A cut-off rate is about 150m (500 ft) per million years if the sedimentation rate is greater than this, treat the sands below as having overpressure. If overpressures are suspected, it is prudent to consider relocating the surface location (if possible). A PWD tool may give a first indication of the existence of a shallow water flow. LWD can be used to confirm the actual depth of seismic markers. Potential Drilling Techniques for Shallow Water Flow (SWF) Zones

Try to avoid potential shallow water flow locations relocate if necessary Jet the conductor. Minimize seawater pumped before setting conductor Minimize the diameter of the hole drilled to allow for good cuttings removal. Pump sweeps every stand. Tracers can be added to sweeps (dye, mica) to try to evaluate flow, washouts etc.. The goal is to avoid charging of formations with cuttings load. Use a weighted drilling mud typically this may require shipping a heavy brine to the location, with on-board dilution, such that the large volumes required can be kept up with. When heavy mud is used to prevent a shallow water flow the mud weight should be targeted to offset the potential hydrostatic pressure, but not too high to cause fracturing or ballooning. The formation pressure may be 80-90% of the overburden. Fluid loss should be kept low (<10 cc/30 min) along with low, flat gel strength (10

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sec., 10 min, 30 min.), YP 10, PV 15. The low gel strengths should allow for efficient cement displacement at the low annular velocities.

Dynamic kills (if required) should be pumped at the highest possible rate (the annulus friction pressure will be low anyway, given the hole size). If not successful after 2 hole volumes, then success is unlikely. Use LWD and PWD near the bit to correlate to seismic and monitor downhole pressures. After penetrating a sand, clean the hole and check for flow. Allow time to observe if a flow dissipates. Charging of a sand (cuttings) can give a false indication of a flow zone. The casing point should be as close to the shallow flow zone as possible. If flow is encountered and casing is to be set above the flow zone, then heavy mud can be spotted below the proposed casing shoe. Pay very close attention to cementing practices. In particular, it is imperative to have as short a transition time (time from the onset of hydration until the cement has sufficient gel strength to prevent flow). Compressive cements are suggested, such as Microfine and Nitrogen Foamed. Surging should be avoided when running casing. For development wells (with clustered locations), well spacing should be maximized. Consider using other non-conventional approaches, such as use of in-situ polymerization, freezing the SWF zone etc.

A number of mechanical devices are available to help control SWF between casing strings. It is beyond the scope of this manual to discuss these, but consideration should be given to such devices.

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7.5.4.

Pre-Kick Preparation

Note: the following is taken from the IADC Deep water Well Control Guidelines
Casing Shoe Slow Pump Rate Measure pressure integrity of casing shoes, i.e. by leak-off/integrity tests Post both ppg equivalent and associated surface pressure for the mud weight in use Update this pressure periodically and when drill string, mud property, or other changes occur which may affect pressure. Post slow pump data (for at least two pumps) on both drill pipe friction loss and both C&K Line Friction Pressures (CLFP) Take pressures on two gauges reading from separate sources to guard against gauge failure Note the pressure required to break circulation the first time, and record this value for use in kick detection and circulation procedures Ensure that cuttings in hole and riser do not affect slow pump data Additional methods can be employed at the time of the kick to update this data, i.e. using static C&K line or subsea pressure sensor Note: Slow pump test rates should represent anticipated kill rates (which may be as low as 1-2 BPM in deep water). Use CLFP to help establish initial circulating casing pressure Recognize that in deep water the CLFP is likely to change such that test data are only estimates Measure and record pressure losses with low circulation rate through the lines in parallel* One option to reduce friction losses during well control in a deep water wells is to circulate the kick using the two choke and kill lines in parallel. Maintain an up-to-date kill sheet designed for a subsea BOP Use a float valve to prevent backflow, i.e. when removing the top drive (or kelly) from the drill string Use a float valve to guard against backflow through drill pipe during an emergency disconnect and/or failure of the shear rams to seal Note: Flow up from the drill pipe can impede the ability to stab a safety valve Show C&K line valve positions on a chart/white board indicating which valves are open/closed and C&K line fluid contents (mud versus water) Show the relationship between the surface tool joint location and corresponding tool joint location opposite the BOP stack rams and annulars Calculate and post the distance and proper spacing for each stand to help with space-out, if variation in stand length warrants Note: As water depth increases, the variation in drill pipe joint length can create too much uncertainty in tool joint position: this potential problem can be reduced by arranging joints so that 10-stand average lengths do not vary by more than a set amount, i.e. 0.1 feet. Post liquid and gas handling capacity of mud-gas separator Compare these to the maximum anticipated gas rates that would result from planned well control procedures and well and C&K line geometry,

C&K Line Friction Pressures Kill Sheet Float Valve

C&K line valve positions

Mud Gas Separator Capacity

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i.e. pumping rate, design kick Diverter Designated hang-off ram Personnel drills Keep diverter insert packer installed and locked except when handling BHA larger than manufacturers stated diameter capacity Post diverter element status (in/out) Identify designated hang-off ram If it is a VBR type, post the hang-off capabilities for the various DP sizes in the hole Specify if rams are to be locked after closure (independent locks) Perform BOP drills (pit and trip) regularly, including tool joint space out to ensure crew competency Consider having crews perform stripping drills prior to drill out of the casing shoes to ensure crew competency in handling stripping

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7.5.5.

Flowcheck / Shut In Procedures

Flowcheck/Shut In Procedure - Drilling

Flow Increase Pit Gain Other Indication: Pump Press. Drop Drill break Etc..

Stop drilling & raise pipe to shut in position with pumps on Stop pumps (incl. Boost pump)

1. 2. 3. 4. 5. 6. 7.

Flow Check
(keep pipe moving)

Yes
Obviously Flowing? If Flow Increase or Pit Gain, Shut In Immediately 8. 9. 10. 11. 12. 13.

No

Line up on Trip Tank & record level Monitor Trip Tank

Hard Shut In (Upper) Annular Pick up to predetermined space out height with the pumps running Stop pumping (incl. Boost pump) Close the upper annular Set the compensator to mid-stroke to minimize movement through the annular Open the fail-safes corresponding to the closed BOP against a closed choke Continue to flow check the riser and if flow continues Close the Diverter and (Upper) Pipe Ram (reconfirm space out before closing the (U)PR) Record pressures at the BOP, Choke and Standpipe at 1 minute intervals. The cold environment and gelled mud within the choke line may preclude measuring SICP. If this is the case, it may be necessary to close a second BOP and flush through the choke and kill lines before opening up below the lowermost closed BOP and measuring SICP. Record the Volume of the influx Close the standpipe back to the mud pumps Inform the Drilling Supervisor and Toolpusher Confirm that the choke is closed Check all surface systems for any leaks Run the Trip Tank on the Annulus if the diverter has not been closed note and record the level every 10 minutes

No

Flowing? Yes

Hang off the drill string on the Designated Hang-off Pipe Rams if: A. there is movement of the drill string through the annular due to weather B. the differential pressure across the BOP is greater than 1000 psi or likely to become greater than 1000 psi. Any pipe movement with this high a pressure may cause premature annular wear C. DP rigs D. There is no choke line outlet immediately below the annular

Resume Operation

Shut Well In

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Flowcheck/Shut In Procedure - Tripping

Prior to a Trip Incorrect fill-up Any indication that the well is flowing Before the BHA reaches the BOPs

Flow Warning Sign Occurs, or other requirement for Flow Check

Stab the FOSV (Open Position)

Pick up drill string to shut in Position

Yes Obviously Flowing? No Shut FOSV

Line up on Trip Tank. Note and record level of trip tank

Hard Shut In (Upper) Annular 1. Set the string in slips. Stab the FOSV and close the FOSV (unless already done) 2. Pick up to the pre-determined space out height 3. Close the (Upper) Annular and open the Failsafe Valves corresponding to the closed BOP against a closed choke 4. Continue to flow check the riser and if flow continues Close the Diverter and other (Lower) Annular. 5. Reset the slips and make up the top drive may need to strip a tool joint through (Upper) Annular to enable make up (to strip: lower Annular operating pressure to a value previously determined by the OIM/Toolpusher typically this may be 500 psi plus x SICP, but can be measured in a drill (before drilling out casing) to determine actual numbers. 6. Open the FOSV and confirm the top drive IBOPs are open. Pull the slips 7. Record pressures at the BOP, Choke and Standpipe at 1 minute intervals. The cold environment and gelled mud within the choke line may preclude measuring SICP. If this is the case, it may be necessary to close a second BOP and flush through the choke and kill lines before opening up below the lowermost closed BOP and measuring SICP. 8. Record the Volume of the influx 9. Close the standpipe back to the mud pumps 10. Set the compensator at mid stroke to minimize movement through the Annular Preventer 11. Inform the Drilling Supervisor and Toolpusher 12. Confirm that the choke is closed 13. Check all surface systems for any leaks 14. Run the Trip Tank on the Annulus if the diverter has not been closed note and record the level every 10 minutes 15. Hang off the drill string on the Designated Pipe Rams if: A. there is movement of the drill string through the annular due to weather B. the differential pressure across the BOP is greater than 1000 psi or likely to become greater than 1000 psi. C. DP Rigs D. There is no choke line outlet immediately below the annular.

Monitor Trip Tank

Flowing? Shut No Yes FOSV

Resume Operation

Shut Well In

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7.5.6.

Other Shut in Procedures / Considerations

Other Shut in Procedures/Considerations
Hang-Off on Designated Rams Shut In Procedure No Drill String in BOP 1. Open choke line valve(s) dont wait for valve to open 2. Close the blind/shear rams 3. Record pit gain monitor and record casing pressure at 1 minute intervals 4. Notify Toolpusher and Senior Drilling Supervisor Once the well has been shut in, preparations can be made to run a kill string into the well. Given the water depth, it should be possible to strip a drill string using the upper annular preventer, unless the pressure underneath the shear rams is very high

1. Reduce the (upper) annular pressure to allow free downward travel of the drill string. Pick up until a TJ tags the annular preventer and confirm space out 2. Close the designated Pipe Rams, reduce the operating pressure as required 3. Lower the drill string & hang the TJ off on the designated Pipe Rams (if weather conditions indicate the potential for rough weather it may be prudent to hang off on the (middle) pipe rams for some BOP arrangements, such as the one shown, there would be a greater potential for dealing with pressure underneath the shear rams following a disconnection) 4. Increase the ram operating pressure to normal 5. Set down the desired weight on the rams, keeping the compensator at midstroke 6. Start the trip tank pump and circulate over the well while recording for leaks through the BOP or gas in the riser 7. Prepare to kill the well as required (The annular is left closed in case of early gas at the BOP) Shut In Procedure Wireline in Hole 1. Stop logging 2. Open choke line valve(s) dont wait for valve to open 3. Close the (upper) annular preventer 4. Record pit gain monitor and record casing pressure at 1 minute intervals 5. Notify Toolpusher and Senior Drilling Representative If at all possible, the wireline should be pulled or stripped out of the hole. If the line must be cut and dropped, a surface cable cutter should be used (This must be available during logging jobs). The shear rams should be considered as a last resort and used only if the annulars fail to secure the well.

Shut in Procedure Drill Collars in BOP Stack This situation implies that a trip is in progress. The shut in procedure for tripping should be followed. Once the well is shut in, preparations should be made to strip in the hole to: a) put drill pipe across the BOP b) strip to bottom and carry out a conventional kill (Drillers Method)

Drill Pipe Float Valve Pump Off Test 1. Line up the mud pumps to the drill pipe 2. Pump in small increments, 50-100 psi into the well 3. Record DP and CP if the CP does not increase, the float is still closed and Shut in-Drill pipe Pressure (SIDPP) is less than the underbalance in the drill string 4. When CP is seen to rise, pumping should be stopped immediately 5. Record SIDPP this now reflects the amount of underbalance in the string this is the value to be used when calculating Kill Weight Mud 6. Bleed off any induced pressure

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7.5.7. General 1.

Kill Procedure General and Preparations The objective of a conventional kill is to circulate out the influx while maintaining the bottom hole pressure at slightly more than the formation pressure and displacing the well to an adequate kill weight mud The Drillers method is the method of choice for WBM. This will enable any gas to be circulated from the well as fast as possible and reduce the risk of hydrate formation. For OBM (or SOBM) the Wait & Weight method may be used there is a negligible risk of hydrate formation. However, if there is only a small margin between mud weight and fracture gradient, the use of the Drillers Method is suggested such that the pit levels can be very closely monitored during the kill circulation. Well control worksheets should be updated every 12 hours to reflect changes in the drill string, hole geometry, mud weight increases, slow circulating rate pressures and any other factors which will affect the kill calculations.

2.

3.

During the well kill operation, if anything appears to be wrong or unclear during the procedure, shut down the pump, close in the well, and evaluate the problem. 7.5.8. 1. 2. Kill Calculations The influx volume is taken to be equal to the pit gain. Accuracy in making this measurement is required. The bottom hole pressure is equal to the shut in drill pipe pressure plus the hydrostatic pressure of the mud inside the drill string. If the kick is taken off bottom, the drill pipe pressure is not a reliable indicator of formation pressure. If the influx is taken with the bit on bottom, the influx density can be estimated using the shut in drill pipe pressure (SIDPP) and shut in casing pressure (SICP) as follows: Influx Density (ppg) = MW SICP-SIDPP 0.052 x H Where H is the calculated vertical height (ft) of the influx above the bit determined from influx volume and annular capacities. This calculation can be inaccurate and all kicks should be handled as if they were gas until well conditions show otherwise. 4. The required kill weight mud density can be determined as follows: Kill Mud Density (ppg) = Current Mud Density (ppg) + { SIDPP (psi)} {TVD (ft) x 0.052} 5. 7.5.9. Well control calculations (as shown above) should be updated with the SIDPP, SICP and pit gain volume. Determination of Initial Circulating Pressure

3.

If no slow circulating rate is available, or a change in mud weight or configuration has occurred (e.g. blocked nozzle), then it will be necessary to determine the initial circulating pressure. The recommended procedure is as follows:

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1. 2.

Note the choke pressure and BOP pressure reading Bring the pumps up to the new kill rate while adjusting the choke to maintain the BOP pressure constant (the choke pressure should reduce by an amount equal to the choke line friction loss at the selected pump rate) As soon as the new pump rate is reached and the drill pipe pressure has stabilized, note the drill pipe pressure. This is now the valid initial circulating pressure. If during the constant drill pipe pressure phase of the Drillers method the drill pipe pressure changes unexpectedly, shut the well in and evaluate a new circulating pressure using the above procedure The pump should always be brought up to speed and shut down while maintaining the BOP pressure constant. On bringing the pump up to speed on a subsea well, the choke pressure should become smaller by an amount equal to the choke line friction pressure at the selected pump rate. When the pump is shut down (with the BOP pressure being maintained constant), the choke pressure should rise by an amount equal to the choke line friction pressure at the selected pump rate. The choke pressure can be used as a check on the BOP pressure readings. Choke & Kill Line Friction - Maintaining a Constant BOP Pressure

3. 4.

5.

7.5.10.

Well control procedures as written for a surface BOP/Land well will state..Bring the pump up to speed maintaining constant BOP or choke pressure. For a subsea well, the statement is correct if the BOP pressure is maintained constant as the pump is stopped or started (see Figure 7.5.1). In this case, the choke pressure must be adjusted to allow for the friction pressure in the choke and/or kill lines. When starting a pump (at the start of a kill circulation, for example) the choke pressure must be reduced by the amount of the choke and/or kill line friction pressure in order to maintain a constant BOP pressure. When stopping a pump the choke pressure must be increased by the amount of the choke and/or kill line friction pressure in order to maintain a constant BOP pressure. There are three alternatives (see Figure 7.5.2) for achieving this:

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Maintain constant BOP pressure when bringing pump up to speed or adjusting pump

Maintain constant choke (BOP) pressure when bringing pump up to speed or adjusting pump

Figure 7.5.1: Subsea vs. land / jack-up well control

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P
C. Back off choke pressure by amount equal to measured choke & kill line friction pressure

A. Utilize BOP pressure gauge

B. Utilize kill line as monitor

Figure 7.5.2: Maintain constand BOP pressure when bringing pumps up to speed or adjusting pumps A. If a BOP gauge is available, then use it. The choke will still have to be manipulated, but the control is achieved from the use of the BOP gauge. B. If the choke/kill line friction pressure is low enough, either the choke or kill line can be filled with fluid (less dense than the drilling mud) and lined up to a closed valve. This line will register a positive pressure, even if there is no excess pressure (other than mud hydrostatic) in the wellbore. The pressure reading on this line can be used as a measure of the relative pressure at the BOP and can be kept constant as the pump is started or stopped.

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C. If no BOP pressure gauge is available and it is not possible to dedicate a choke or kill line to BOP pressure monitoring then it will be necessary to back off (or increase) (start or stop) the choke pressure by an amount equal to the measured choke and/or kill line friction pressure loss. In reality, if A or B is chosen/available, use of the estimate generated for C. is probably appropriate as there will be a small time delay from action taken at the choke and register of the change at the BOP pressure gauge or at the surface pressure gauge being used to monitor BOP pressure. 7.5.11. Selection of Kill Rate & Use of Choke and/or Kill Lines
Determine SIDPP & Pit Gain

No

Yes

Is hang-off required Line up to Kill on (upper) annular & using both choke & kill lines Select kill rate Typically 3-5 bpm Hang off on PR. Typically line up kill with both Choke & Kill Lines

Will friction loss in c/k line at selected rate cause lost

No

Yes

Reduce kill rate

Check circulating Kick Tolerance OK?

No

Reduce kill rate

Will resultant gas rate at surface overwhelm

No

Yes

Reduce kill rate

Proceed with Kill Plan and Kill the well

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7.5.12.

Kill Procedure Drillers Method: 1st Circulation

Objectives: Return well to hydrostatic control (if a swabbed kick). Remove any gas from the well quickly such that the gas does not cool and form hydrates
Well Shut In on Annular Or Hung Off
Based on: Surface Gas Rate Choke operation Choke & Kill Line friction Hang off Bad Weather

Select kill rate and use of Kill line or Choke and Kill lines

Bring Pump up to speed

Maintain pump speed and pump pressure while circulating gas from the well (one complete circulation l )

Maintain constant BOP Pressure. Let a small additional influx in, rather than risk overpressuring the well

Shutdown required?

Yes

Stop Pump

Maintain constant BOP Pressure. Let a small additional influx in, rather than risk overpressuring the well

No
Isolate well and flush Choke & Kill Line and BOP cavity with mud / glycol mixture. Fix problem With gas at surface, monitor MGS pressure. Be prepared to route overboard if MGS pressure rises to alarm levels
Warning The Choke and Kill Line contents will cool down to seabed temperature in about 15 minutes. Unless you act these areas will be within the Hydrate Formation Zone

With gas out, shut down & confirm SIDPP & SICP

SICP should = SIDPP & also equal original SIDPP at initial shut in. If not, then further circulation required (check for trapped pressures).

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7.5.13.

Kill Procedure Drillers Method: 2nd Circulation

Objectives: Return well to hydrostatic control

SICP=SIDPP=Initial SIDPP? Continue 1 Circ.@ constant pump rate and pressure
st

Bring Pump Up To Speed

Maintain constant BOP Pressure. Let a small additional influx in, rather than risk overpressuring the well

Maintain pump speed and constant choke/BOP pressure while circulating Kill Weight Mud down the drill pipe to the bit

Monitor pump pressure and compare to predetermined pump pressure schedule (W&W). If different, stop & think

Shut-down required?

Yes

Stop Pump

Maintain constant BOP Pressure. Let a small additional influx in, rather than risk overpressuring the well

No Maintain pump speed and constant drill pipe pressure while circulating gas from the well (one complete circulation plus excess) Isolate well, flush Choke & Kill lines and BOP cavity with Mud / glycol mix. Fix problem

Shut-down required?

Yes

Stop Pump

Maintain constant BOP Pressure. Let a small additional influx in, rather than risk overpressuring the well

No

Isolate well, flush Choke & Kill lines and BOP cavity with Mud / glycol mix. Fix problem

With KW mud above BOP, monitor pump pressure. If this is rising (with choke wide open) be prepared to slow kill down (OR shut down, isolate well and flush kill weight mud through choke & kill lines to avoid overpressuring casing shoe

Maintain constant BOP pressure while you slow the pumps down. This will maintain the proper BHP

With kill mud all the way round, shut down and confirm SIDPP &SICP=0 If >0 continue circulation increase MW etc.

With SIDPP & SICP=0, open choke to mini trip tank and perform flow check. If no flow then well is dead. If flow then review, raise MW, circulate etc.

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7.5.14.

Kill Procedure Wait and Weight

Objectives: Return well to hydrostatic control in the most efficient manner

Well Shut In on Annular Or Hung Off Based on: Surface Gas Rate Choke operation Choke & Kill Line friction Hang off Bad Weather

Select kill rate and use of Kill line or Choke and Kill lines

Bring Pump up to speed

Maintain constant BOP Pressure. Let a small additional influx in, rather than risk overpressuring the well

Maintain pump speed and pressure following established pump pressure schedule (adjust based on measures pump pressure with pump up to speed). When kill weight mud reaches bit, maintain constant pump pressure

Shut-down required?

Yes Stop Pump

No With gas at surface, monitor MGS pressure. Be prepared to shut down / go overboard if MGS pressure rises to alarm level

Isolate well, flush Choke & Kill lines and BOP cavity with Mud / glycol mix. Fix problem

Maintain BOP pressure constant while slowing pumps

With KW mud above BOP, monitor pump pressure. If this is rising (with choke wide open) be prepared to slow kill down (OR shut down, isolate well and flush kill weight mud through choke & kill lines to avoid over pressuring casing shoe

Warning The Choke and Kill Line contents will cool down to seabed temperature in about 15 minutes. Unless you act these areas will be within the Hydrate Formation Zone

With kill mud all the way round, shut down and confirm SIDPP & SICP=0 If >0 continue circulation increase MW etc.

With SIDPP & SICP=0, open choke to mini trip tank and perform flow check. If no flow then well is dead. If flow then review, raise MW, circulate etc.

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7.5.15.

Choke Adjustment Considerations

When using the Drillers or Wait & Weight methods, it may be necessary to make adjustments to the Drill Pipe Pressure by manipulating the choke. The correct method is: 1. When a change is desired on the Drill Pipe Pressure, note the amount of pressure change required For example, if the current Drill Pipe Pressure is 850 psi and the desired Drill Pipe Pressure is 1000 psi, the amount of change is an additional 150 psi 2. Note the current Choke Pressure and by manipulating the choke, change the Choke Pressure by the amount of change desired on the Drill Pipe Pressure. For example, continuing from the example in 1 above, if the current Choke Pressure is 1050 psi, the choke operator should close the choke to increase the Choke Pressure by 150 psi to 1200 psi. 3. Wait at least two seconds for every 1000 ft of measured depth of the well for the pressure change to come from the Choke to the Drill Pipe Pressure gauge. (this delay time may be confirmed by using a choke reaction test, which would be performed before drilling out of casing)

The Drill Pipe Pressure should now change (after 20 seconds or so) to the desired reading (1000 psi). If it only comes up to 980 psi, the procedure is repeated (the Choke Pressure raised by 20 psi etc.). The key to success is to allow a time lag between choke adjustment and the change at the Drill Pipe Pressure gauge. 7.5.16. Preventing Hydrate Formation within the BOP Stack Use of WBM

Gas hydrates, which are solid, ice-like crystals, can form when a mixture of gas (methane, ethane etc..) and water is cooled below a hydrate formation temperature. The higher the pressure, the more likely that hydrates will form. Conditions at the BOP are such that hydrates could form. In particular the seabed temperature is close to 0 deg C. Hydrates do not form at the instant that conditions fall below the formation temperature. It can take some time while nucleation sites become available. Once hydrates have formed, they will be very difficult and time consuming to remove. There is a 3-part process to preventing hydrate formation within the BOP, consisting of: 1. Inhibiting the mud system. Salt and glycol when added to the mud system are effective in lowering the hydrate formation temperature. It may not be possible (or economic) to inhibit the mud system to the extent that hydrates will not form under any potential temperature/pressure combination. Note: The computer program WHYP (partly developed by Shell) can be used to determine the level of inhibition that is appropriate. Removing the gas from the wellbore as soon as possible The Drillers method has been selected in preference to the Wait & Weight method in order to achieve this objective It is always best to maintain a constant circulation. However, if a shut down is required for any length of time (more than 10 minutes), the well should be isolated using the lower pipe rams and inhibited fresh mud (at the same weight as is in the choke and kill lines) should be circulated down the choke line and up the kill line. This will ensure that hydrates do not form and block the BOP and choke lines. If the

2.

3.

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shutdown is to be for an extended period, the choke and kill line should be displaced to inhibited glycol/seawater mixture as per normal drilling practice. This action will also prevent the settling of drill solids and subsequent blockage of the choke and kill lines. When SOBM is in use, the hydrates will not form unless water has been introduced to the system. 7.5.17. Sweeping the Stack & Clearing the Riser- General Issues

Following a well control circulation there are three types of potential situation where gas may be trapped in the BOP stack. These are: a) b) Very small amount of potential trapped gas (< barrel) at the BOP stack.. Able to pump down choke/kill line and flush trapped gas up kill/choke line. Although there is the potential for a larger volume of gas to be trapped under the BOP, this potential larger volume can be (and must be) flushed up the choke/kill line once the kill circulation is finished and with the well isolated using the lower pipe rams. Large volume of trapped gas poor BOP configuration/valving inoperable. Here the potential for a significant amount of trapped gas dictates that the BOP must be swept.

c)

These options are shown below

(A) Very small trapped volume

CLEAR GAS
(B) Able to flush trapped volume

FLUSH BOP between Pipe Rams & (Upper) Annular

FROM RISER

(C) Large volume of trapped gas

SWEEP THE STACK

Details of the approach to be taken are dependent on the BOP configuration. The examples given below are based on the configuration shown in Figure 7.5.3. 7.5.18. Clearing the Riser of Gas

The key to performing this operation safely is to allow time for any gas to disperse. Dispersion will occur for gas in WBM it is not the case for gas in OBM. FOR OBM IT IS ESSENTIAL THAT THE REMAINING GAS/OBM VOLUME IS LESS THAN BARREL With the well still isolated lower pipe rams closed 1. 2. Displace the riser to kill weight mud through the booster line. When complete open the annular preventer.

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3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.

Pump 3 to 4 barrels kill weight mud down the kill line (choke line if UPR used) to displace any remaining gas above the BOP. Check for flow (15 minutes) Line up and pump kill weight mud down both choke and kill lines & displace 1/4 of the riser with kill weight mud. Check for flow (15 minutes) Pump kill weight mud through the choke and kill lines and displace another 1/4 of the riser volume. Check for flow (15 minutes) Pump kill weight mud through the choke and kill lines and displace another 1/4 of the riser volume. Check for flow (15 minutes) Pump kill weight mud through the choke and kill lines and displace another 1/4 of the riser volume. Check for flow (15 minutes). Confirm kill weight mud throughout riser (mud weight check at flowline plus BOP pressure gauge) Circulate and condition kill weight mud in riser. Close the upper choke line valves on the BOP. Line up the choke line to a closed choke and open the lower choke line valves to check for any pressure build up below the closed lower pipe rams. If no pressure proceed with step 15. Close the lower choke valves on the BOP. Line up and displace the kill line and choke line to unweighted inhibited mud. Close the fail safe valves on the BOP. Open the lowermost pipe rams and condition the mud in the hole.

15.

If at any time during this procedure, gas migration is indicated by an increasing flowrate from the riser, shut the well in using the annular and close the surface diverter. Investigate the cause of the flow and take the necessary steps (e.g. additional Drillers method, clearing the riser of gas) to regain control. 7.5.19. Flushing the BOP

In this case there is potential trapped gas between the Pipe Rams and the (Upper) Annular, but the (Upper) Annular has remained operable throughout the kill. 1. Isolate the well using the Lower Pipe Rams. This is done by: a) Open the Upper Pipe Rams (if they were closed for the kill). Check the riser to confirm that there is no flow. Reduce the upper annular pressure sufficiently to allow free travel of the drill string. Pick up until a TJ tags the annular preventer and confirm space out. Close the Lower Pipe Rams. Reduce the operating pressure as required. Lower the drill string and the TJ onto the Lower Pipe Rams. Hang the drill string off on the Lower Pipe Rams. Increase the ram operating pressure to normal.

b) 2.

Line up to the mini trip tank and flowcheck the well.

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3.

Circulate (at least one volume of the combined choke and kill lines) kill weight mud down the choke line, taking returns from the kill line through the variable choke, until no more gas returns. Leave the fail safe valves on the kill line open (all other fail safes closed) and line up to a closed choke. Monitor BOP and choke pressures (should be constant).

4.

At this point there should be a minimum of gas at the BOP. The riser can now be displaced to kill weight mud and cleared of gas.

Flushing The BOP: Typical Subsea BOP Arrangement

(Potential Location of Trapped Gas)
CHOKE LINE KILL LINE

Original Weight Mud

P/T Upper Annular

Pressure/Temperature Gauge at LMRP Package

Upper Connector
Lower Annular
POTENTIAL GAS

LMRP BOP

Lower Annular

Blind/Shear
Spacer Spool

#1
Pressure/ Temperature Gauge at BOP P/T

Upper Pipe
(Hang Off Ram)

#2 #3 #4

VBRs

Lower Pipe

Kill Weight Mud

Figure 7.5.3: Flushing the BOP

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7.5.20. 1. a)

Sweeping the Stack Open the (Upper) Pipe Rams (if they were closed for the kill). Check the riser to confirm that there is no flow. Reduce the upper annular pressure sufficiently to allow free travel of the drill string. Pick up until a TJ tags the annular preventer and confirm space out. Close the Lower Pipe Rams. Reduce the operating pressure as required. Lower the drill string and the TJ onto the Lower Pipe Rams. Hang the drill string off on the Lower Pipe Rams. Increase the ram operating pressure to normal.

Isolate the well using the Lower Pipe Rams. This is done by:

b)

2.

Circulate (inhibited) seawater down the upper choke line taking returns from the upper kill line through the variable choke with a backpressure to maintain the pressure at the BOP equal to a kill line full of kill weight mud. The BOP pressure gauge will confirm this. Stop when the choke line has been displaced with (inhibited) seawater. There may have been some gas that was flushed to surface during this step. Isolate the choke and kill lines against closed chokes. Confirm the displacement of the kill line using the choke and BOP pressure gauges. (The choke manifold gauge (choke side) should read the difference in hydrostatic between a column of kill weight mud and a column of inhibited seawater - the BOP gauges should read the hydrostatic of a column of kill weight mud.) Close the kill line valves at the BOP. Line up the choke on the choke line side to take returns to the mud gas separator. Open the choke, and allow any inhibited seawater and trapped gas to blow back (AND OVERBOARD) through the mud gas separator. Allow this process to occur until no more fluid or gas comes through the choke. Close the diverter and line up to the riser degasser. Open the lower annular preventer and the choke. Because the fluid in the riser is heavier than the inhibited seawater, U-tubing will occur from the riser into the choke line. Continuously fill the riser (with mud) and using the riser boost pump during this operation. If there is no flow from the riser, open the diverter. Check the riser for flow (15 minutes).

3.

4.

5. 6.

7.

During this period close the lower annular preventer and circulate kill weight mud down the kill line and up the choke line, and through the choke and mud gas separator to completely displace the choke and kill lines with kill weight mud. At this point there should be a minimum of gas at the BOP. The riser can now be displaced to kill weight mud and cleared of gas. 7.5.21. Kick Off Bottom

The best chance of controlling the well is if the string can be stripped back to bottom through closed preventers. Once the drill string has been stripped to bottom, standard well control procedures can be employed.

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Under no circumstances if the well is flowing, may the pipe be run back in the well without stripping. For a subsea BOP, annular stripping only will be considered. The decision on whether to strip to bottom or not will depend on surface pressures, distance from bottom and available equipment. In general for surface pressures less than 1000 psi, it should be possible to strip to bottom. For higher pressures, stripping should also be considered as long as it can be accomplished without additional hazard to personnel. If stripping in is not possible due to high surface pressures, then for gas and WBM combinations the preferred method is to use the Volumetric Method (see section 5.17) to allow the expanding bubble to rise to surface. Bullheading of heavy mud into the annulus may also be considered where the influx is likely to contain H2S or where surface pressures are approaching 80% of casing yield strength. It may also be very effective for OBM, where the bullhead injection rate can be quite slow. Circulation off bottom should only be considered if it is known that the influx is 100% liquid which will not release gas as it comes to surface or if all the influx is above the bit. DO NOT circulate off bottom if there is a risk that there is any gas below the bit. Because of the complicated nature of these types of operations, the rigsite supervisory personnel should take the time to carefully think through the process and agree upon a plan before beginning. If time permits, the plan should also be discussed with the Shore based team. Be aware that (for gas and WBM) if the kill operation is not started shortly after the kick is taken the gas will begin to migrate up the well.

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