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9. 9.1.

WELL CONTROL TRAINING AND DRILLS Training and Organisation

Well control drills provide an opportunity to assess the effectiveness of training and to identify and make good any inadequacies. 9.1.1. Competency

All Company and Contractor supervisory staff should hold a valid IWCF or equivalent well control certificate at the appropriate level. Well control drills shall be performed under the supervision of an appropriately qualified representative onsite and shall be initiated at unscheduled times when operations and hole conditions permit. The simulated events shall be instigated by the Company drilling representative, or by anyone authorised by him. For each well control operation, all crew members should have a pre-assigned task appropriate to their function in the crew. Every effort must be made to ensure that the drill is carried out in the most realistic manner possible. Where practical, there should be no difference between the drill and actual control procedures. 9.1.2. Task Assignments

The tasks of each individual shall be included in a complete well control drill procedure to be posted on the rig's bulletin boards. Circumstances at the rig site may dictate that these responsibilities be modified in the event of an incident. The full details of the Roles and Responsibilities of the Well Site Team during well control situations are presented in Section 2.1, however the following reiterates the role of key personnel. The Person In Charge (PIC) Once the well has been shut in and is being correctly monitored the PIC will organise a pre-kill meeting for all those involved in the supervision of the well control operation. This should be conducted to provide specific well control procedures. It is the responsibility of the PIC to monitor and supervise the implementation of these procedures and to be present on the rig floor at the start of the kill operation. (See Section 2.1) Either the Toolpusher or the Company Representative (CR) should be present at all times on the rig floor during the operation. It is also the responsibility of the CR to maintain communication with the Operations base and to assign the responsibility of keeping a diary of events. 9.1.3. Communication

A pre-kill meeting will be organised once the well has been shut in. The purpose of this meeting is to ensure that all those involved in the supervision and implementation of the well control operation are familiar with the procedures that will be used to kill the well. This meeting is also the first stage in the process of communication during the well control operation.

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Proper communication during all stages of well control operations is essential. The objectives of a suitable system of communication are:

9.1.4.

To ensure that all information relevant to the well control operation is quickly and accurately relayed to the Company Representative. To ensure that those involved in the supervision of the operation are at all times in communication with the Company Representative. To ensure that all those involved in the operation are aware of the line and method of communication that they should use. To ensure that communication equipment on the rig is adequate and is used during the well control operation in the most effective manner possible Drill Frequency

It may be necessary to repeat the drills each shift until the Company drilling representative is convinced that the crews are adequately trained and responsive. Thereafter, the frequency of the drills can be reduced to once a week with each crew, in order to maintain their alertness and competence. The timing of the drills should be selected so that each crew can practice the following drills:

9.1.5.

Pit drill on bottom Pit drill while tripping Diverter drill Choke control drill Stripping drill Pit drill for floating rigs Reaction Times The type of drill i.e. what type of situation and how was it simulated (such as a kick while drilling indicated by a pit gain) The reaction time from the moment the kick is simulated until the designated crew member is ready to start the closing procedure; The total time it takes to complete the entire drill.

The following shall be recorded in the tour report and the morning report:

The PIC must be in a position to judge the performance of the crew & the equipment and to take the necessary steps for improvement. Experience has indicated that well trained crews can perform well control drills in 3 to 4 minutes. Drills shall be carried out to achieve and maintain this performance standard.

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Notes: The objective of a drill is to increase responsiveness and highlight areas for improvement. It is not a precursor to a blame-storming exercise. Drills must not be so frequent that they are perceived as routine. As they must be conducted under real conditions, it must be ensured that the Team becomes neither apathetic or shell-shocked. A drill must NEVER be conducted during critical activities such as drilling reservoir, coring or POOH with reservoir in open hole. The purpose of drills held during the course of the well is to train the Team for optimum response prior to critical sections of the programme being implemented. 9.2. Well Control Drills

This section discusses drills simulating well control incidents covering a number of scenarios. The role played OR NOT by the mudlogging crew in each drill is discussed here. 9.2.1. Overview

One of the major factors that influence the well-bore pressures after a kick is taken is the volume of the influx. The smaller the influx, the less severe will be the pressures during the well kill operation. In this respect, it is important that the drill crew react quickly to any sign that an influx may have occurred and promptly execute the prescribed control procedure. Drills should be designed to reduce the time that the crews take to implement these procedures. The relevant drills should be carried out as often as is necessary, and as hole conditions permit, until the Company Representative and the contractor Toolpusher are satisfied that every member of the drill crew is familiar with the entire operation. A mudlogging crew should be the eyes & ears of a drilling operation. The sensor array, particularly on a hi-spec rig-up will make a convincing influx simulation difficult. Therefore, on operations utilising the services of a mudlogging contractor, individual drills must be targeted at either

The Drill Crew (mudloggers pre-warned) The mudloggers (Drill crew pre-warned) The Team (Drill Crew and mudloggers) to assess synergy

Every effort must be made to ensure that the drill is carried out in the most realistic manner possible. Where practical, there should be no difference between the drill and actual control procedures. Once satisfactory standards have been achieved, the Drills should be held at least once per week, alternating between crews. If standards fall unacceptably, the Company Representative should stipulate that the drills are conducted more frequently. It is important that returning drill crews have frequent drills. 9.2.2. Pit Drill On Bottom

The purpose of this drill is to familiarise the crew with the control procedure that will be implemented in the event of a kick whilst drilling. This Drill may be conducted either in open or cased hole. However, if the drill is conducted when the drill string is in open hole,

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the well will not be shut in. When the pipe is on bottom, the following procedure can be used as a guideline for the drill: A. Without prior notice, the Shell Representative and Senior Contractor Representative gradually increase the apparent pit level by manually raising the float. With sonic/ultra sonic levelling systems this may be done using a board held above the mud level (this must be done carefully to simulate a realistic gain and may be difficult if the pit level is low) The mudlogger (if included in the drill ) is expected to detect the pit gain within a reasonable influx volume (say 5 bbls or 3bbls during slow drilling) and do the following:

B.

Contact the Driller and report pit gain volume and rate Contact the Shell Representative and report pit gain volume / rate and depth Mark chart recorders and re-set stroke counters to lag returns
C. The Driller is expected to detect the pit gain or increase in return flow and together with the crew take the following steps routinely to secure the well:

Recognise the 'kick' and alert the crew. Pick up the kelly (or top drive) until the tool joint clears the BOPs and the kelly cock is just above the rotary table, at the same time slow down the pumps. Shut down the pumps. Check the well for flow. Open the pressure-operated valve in the side outlet from the BOP stack to the choke manifold (the inner valve is always open under normal conditions) and close in the well. Take readings of the closed-in annulus and drillpipe pressures. Measure the 'gain' in the active mud tank(s). Report to the Company Representative. Record the time required for the crew to react and conduct the drill on the IADC Drilling Report.
9.2.3. Diverter Drill

If shallow gas is encountered and the well kicks, blow-out conditions may develop very quickly. It is therefore important that crew initiate control procedures as soon as possible in the event of a shallow gas kick. Diverter drills should therefore be carried out to minimise the reaction time of the crews. A further objective of the drill is to check that all diverter equipment is functioning correctly. The time taken for each diverter function to operate should be recorded. A drill should be carried out prior to drilling out of the conductor casing. The procedures that should be implemented in the event of a shallow gas kick are covered in Section 5.3. Drills should be designed in line with the specific procedure that will be adopted in the event of a shallow gas kick.

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The contractor Toolpusher must ensure that the drill crew and marine staff (offshore) are correctly deployed during the drill and that each individual understands their responsibilities. The time recorded in the log should be the time elapsed from initiation of the drill until the rig crew (and marine staff) are ready to initiate emergency procedures. 9.2.4. Choke Control Drill

The objective of this drill is to give drill crews the most realistic type of well control training and a feel for the equipment and procedures that they would use to kill a well. This drill should be carried out prior to drilling out the intermediate and production strings. It should never be carried out when open-hole sections are exposed. The following procedure is recommended:

Run in hole, wash down and tag the top of cement. Pull back one stand and install the kelly (or install top drive). Break circulation and establish slow circulating rate pressures. (Consider circulating bottoms up prior to this if the annulus may contain contaminated mud.) Carry out standard BOP Drill, resulting in the well being shut in. Consider applying low pressure to the casing (typically 200 to 300psi), bring the pump up to kill speed, controlling the drill pipe pressure according to a predetermined schedule. Circulate well over the choke.

It is important that this opportunity to circulate across a choke is used to maximum effect. A drill pipe pressure schedule should be drawn up and carefully adhered to. It is important that the choke operator develops a feel for the lag time between manipulation of the choke and its subsequent effect on the drill pipe pressure. The lag time should be recorded, so that it can be used for reference should a kick be taken in the next hole section. Although principally an exercise for the Drill Crew, the mudloggers should be involved in these drills by:

9.2.5.

Running well control software to suit current conditions. Produce step-down / displacement graphs. Monitor influx and kill-mud during displacement etc. Pit Drill While Tripping

The purpose of this drill is to familiarise the crew with the shut-in and kill procedures that will be implemented in the event of a kick during a trip. General These drills should only be conducted when the Bottom Hole Assembly (BHA) is inside the last casing string.

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Before the trip is started, the Standing Orders to the Driller will have been posted. This will be intended as an action item. This will detail the action that the crew should take in the event a kick is detected. When directed by the Company Representative, the contractor Toolpusher will instruct the Driller to assume that a positive flow check has been conducted, and to implement the prescribed control procedure as detailed in the Standing Orders. Procedures These drills can cover both awareness/reaction and the implementation of procedures. On ALL trips both in and out of the hole, the Drill Crew (usually Assistant Driller) and the mudloggers will monitor hole fill or pipe displacement. Simulation of an influx will therefore be a gain in the trip tank (or in the active pit if displacing direct). Clandestine mud-movements may be difficult if the mudloggers have a full suite of pit sensors however due to the small volumes required for a gain in the trip tank (+/-1bbl), a water hose will suffice if WBM or a base-oil line if OBM. On some rigs, if the trip tank is out of sight of the drill floor, the Company Representative and Senior Contractor Representative may start the drill by manually raising the trip tank float to indicate a rapid pit gain. Shut-in procedures to be adopted in the event of a kick whilst tripping are detailed in Section 3.5.5. However, as a guideline the following procedure should be initiated: A. B. The contractor Toolpusher must ensure that the crew are correctly deployed and that each individual completely understands their responsibilities. The Driller in-conjunction with the crew are expected to take the following steps routinely to secure the well:

Recognise the 'kick' and alert the crew. Stop other operations. Lower the stand, install a kelly cock in open position and then close. Close in the well Install a Gray-type inside BOP (if stripping planned) or install circulating head, kelly or top drive. Open the pressure-operated valve in the side outlet from the BOP stack to the choke manifold. Take readings of the closed-in annulus and drill pipe pressures (IBOP may have to be pumped open to read drill pipe pressure). Measure the 'gain' in the trip tank (or active pit if displacing). Notify the Company Representative that the well is shut in. Record the time taken for the drill on the IADC Drilling Report.
The time taken for the crew to shut in the well should be recorded. Having shut in the well, preparations should be made to strip pipe. These preparations should include lining up the equipment as required and assigning individual responsibilities.

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C.

Mudloggers (if on contract) will:

Report and confirm the influx / anomaly with the Driller Report the influx / anomaly with bit depth and stand number to the Shell Representative. Mark chart recorders and zero stroke counters, load well control software.
9.2.6. Stripping Drill

A stripping drill is recommended and should be performed prior to drilling out of the casing shoe after the BOP has been installed and tested. It will only be done with the joint agreement of the Toolpusher and the Company Representative. A pre-stripping meeting should be held with a minimum of the Company Representative, Rig Toolpusher, on-shift Driller, AD and Derrickman in attendance. Mudloggers would not normally be involved in a stripping drill unless mud was being bled to the trip tank. If the trip tank is used then Mudloggers can participate using their own sensors. The recommended procedure for stripping is as follows: (a) Run in hole with the drilling assembly until the drill-bit is +/- 10 stands above the float-collar or at a pre-agreed depth. (In the case of a floater in deep water ensure that drillpipe is below the BOP.) Install the full opening drill-pipe safety valve (kelly cock/TIW valve). Close the valve. Open the choke-line valves to a closed choke, close the (upper) annular preventer. The well is now shut in. This is the same procedure as used for trip drills. Make up the top drive (kelly) or circulating head and open the drill-pipe safety valve. This would be for the purpose of recording the shut-in drill-pipe pressure. Simulate also the installation of the dart, if it was required to drop it. This would be as follows:

(b) (c) (d)

Close the drill-pipe safety valve. Bleed off pressure above. Break off the top drive (kelly) and install the dart. Make up the top drive (kelly). Pressure up through the top drive to equalise the pressure. Open the drill-pipe safety valve to allow the dart to fall.
If a Gray valve is in use, it would be made up above the full opening drill pipe safety valve and the safety valve then opened slowly to ensure that the Gray valve was holding. (e) Open the choke and circulate until returns are seen in the trip tank. This ensures that you have a correct line up and all the lines are full from the choke manifold to the trip tank. Close the choke. Pressure up the well to a value as agreed between the Toolpusher and Company representative. This will normally be 400 to 500psi. Close the drill pipe safety valve. Bleed off above to ensure it is holding, then remove the top drive (kelly). Alternately, you may pressure up the well via the kill line, keeping the full opening safety valve

(f)

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closed. This will eliminate the need for breaking a connection with pressure below the valve. The Toolpusher and Driller are to ensure that a stripping worksheet is completed with bit depth, pressure and trip tank level recorded. Assign responsibilities. (g) Agree an increase in the annulus pressure for the following:

Choke handling safety factor (for example 350kPa/50psi) A working pressure increase for gas expansion (for example 350kPa/50psi) An allowance for drill-string entering influx (for example 175kPa/25psi). These will be added to the initial shut-in annulus pressure when stripping commences
(h) (i) Reduce annular closing pressure to a minimum to prevent leakage as directed by the Toolpusher. Open surge bottle, if fitted. Commence stripping in the drill pipe at a lowering speed of approximately 30ft/min. The operator on the choke is to allow the pressure to increase to the initial calculated value. Once this value has been reached the choke operator is to bleed off fluid to maintain this value as the Driller lowers each stand. As the slips are set, the choke operator will close in the choke, maintaining the calculated value.

NOTE: The Driller to note string weight loss to strip the pipe through the annular, also string weight loss for tool-joints to pass the annular. This is useful information to have in the case of an actual stripping operation. (j) Strip two or three more stands in the hole with the choke operator bleeding off fluid to maintain the calculated pressure as the Driller is lowering the stand. Consider stripping additional stands if required for the rig crew to establish a routine pattern when stripping. Enter the relevant data on the stripping worksheet after each stand has been run. Bleed off all annulus pressure and open annular preventer. Pull back and remove the grey valve/dart and drill-pipe safety valve. Line up all well control equipment back to normal set up for drilling. Have a post-stripping meeting with all concerned discussing all aspects of the drill. Pit Drill For Floating Rigs

(k) (l) (m) 9.2.7.

Kick detection and response drills are essentially the same regardless of rig-type, however floating rigs require additional drills to train crews in spacing out the string in the BOP. 1. With the pump ON, unlock rotary bushing and raise the kelly or top drive to the predetermined position for landing the string on the rams (with the lower kelly cock above the rotary table, allowing for tidal condition). Stop the pump. Open the outer fail-safe valve of the choke line (the rest of the choke line to the closed choke is always open under normal conditions). Close in the well on the upper annular preventer.(This could be simulated) Close the valve upstream of the adjustable choke if it is a non-sealing choke. Do not close valves that isolate pressure sensors.

2. 3. 4. 5.

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6.

Observe closed-in drillpipe pressure (Pdp) and closed-in annulus pressure (Pa).

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