WELL CONTROL

WELL CONTROL: It is a technique used to control the pressure, inside the oil
and gas well; during drilling, well intervention, workover, production and well
abandonment.

The main goal is to prevent kick or unwanted flow of formation fluid from
entering wellbore.

It is essential for drilling and well-servicing rig crew to understand proper well
control methods while drilling well control and well
intervention pressure control operations.
Why the well control is important in the hydrocarbon production industry?

• higher drilling costs,

• waste of natural resources and damage to the environment

• and the possible loss of human life when kicks and blowouts occur

One of the most pervasive problems with well control is the "kick."

Understanding Pressures

1. Hydrostatic Pressure

All vertical columns of fluid exert hydrostatic pressure. The magnitude of the
hydrostatic pressure is determined by the height of the column of fluid and the
density of the fluid. It should be remembered that both liquids and gases could
exert hydrostatic pressure. The hydrostatic pressure exerted by a column of
fluid can be calculated using Equation 1. While drilling ahead, the hydrostatic
pressure exerted by the drilling mud is our number one defense against taking
kicks.

2. Pressure Gradient

When comparing fluid densities and hydrostatic pressures, it is often useful to

think in terms of a pressure gradient. The pressure gradient associated with a
given fluid is simply the hydrostatic pressure per vertical foot of that fluid.
Heavier (more dense) fluids have higher-pressure gradients than lighter fluids.
The pressure gradient of a given fluid can be calculated with the formula given
in Equation 2.

As you can see from the above equation, the pressure gradient can be
thought of as an alternate way of describing a fluid’s density. This is useful
because other parameters, such as reservoir pressure, are often expressed in
terms of pressure gradients as well.
3. Formation Pressure

Formation pressure is the pressure contained inside the rock pore spaces.
Knowledge of formation pressure is important because it will dictate the mud
hydrostatic pressure and therefore the mud weight required in the well. If the
formation pressure is greater than the hydrostatic pressure of the mud
column, fluids (gas, oil or salt water) can flow into the well from permeable
formations.
Consider a formation located at a vertical depth of 5000’ and with a reservoir
pressure of 2325 psi. The pressure gradient of this formation can be easily
figured with the following formula:

In order to keep this formation from flowing into the well, the mud in the hole
must also have a pressure gradient of at least 0.465 psi/ft.

4. Surface Pressure

We use the term surface pressure to describe any pressure that is exerted at
the top of a column of fluid. Most often we refer to surface pressure as the
pressure, which is observed at the top of a well. Surface pressure may be
generated from a variety of sources including downhole formation pressures,
surface-pumping equipment, or surface chokes.
5. Bottom hole Pressure

Bottom hole pressure is equal to the sum of all pressures acting in a well.
Generally speaking, bottom hole pressure is the sum of the hydrostatic
pressure of the fluid column above the point of interest, plus any surface
pressure, which may be exerted on top of the fluid column, plus any annular
friction pressure. This concept is expressed mathematically in Equation 5

BHP = Bottom hole Pressure (psi)

= Hydrostatic Pressure (psi)
SP = Surface Pressure (psi)
FP = Friction Pressure (psi)

When the hole is full and the mud column is at rest with no surface pressure,
the bottom hole pressure is the same as the mud hydrostatic pressure.
However, if circulating through a choke or separator at the surface, the
annular surface pressure and friction pressure (back pressures) will be
conveyed down hole and must be added to the mud hydrostatic pressure to
obtain the total bottom hole pressure.

6. Equivalent Circulating Density

When fluid is circulating in a wellbore, frictional pressures occur in the surface

system, drill pipe, bit and in the annulus, which in turn are reflected in the
standpipe pressure. As also discussed, these frictional pressures always act
opposite to the direction of flow. When circulating conventionally, all the
frictional pressures, including annular friction, act against the pump. The
annular friction, or annular pressure loss as it is sometimes referred to, acts
against the bottom of the wellbore, which results in an increase in bottom hole
pressure. This is known as Equivalent Circulating Density, or ECD. ECD is
normally expressed as a pound per cubic foot equivalent mud weight and is
shown mathematically in Equation 5.

ECD is a result of annular friction and is affected by such items as:

• Clearance between large OD tools and the ID of the wellbore

• Circulating rates (or annular velocity)

• Viscosity of the mud

Overbalance and underbalance:

Underbalance is the term used when at a particular depth the formation

pressure exceeds the hydrostatic pressure exerted by the drilling fluid column.
In this situation there is a risk that fluid from the formation will intrude into the
wellbore and begin to displace the drilling fluid.

Overbalance in the well is present when the drilling fluid hydrostatic pressure
exerts a higher pressure than the formation pressure. In this situation
formation fluids cannot intrude into the wellbore.

Example:
What overbalance pressure would be in a hole drilling at depth of 7000 ft if the mud
weight is 9.5 ppg and the formation pressure is 3225 psi?
Sol:
Δp= 0.052*9.5*7000-3225= 203 psi

What is the Kick?

A kick is a well control problem in which the pressure found within the drilled

rock is higher than the mud hydrostatic pressure acting on the borehole or

rock face. When this occurs, the greater formation pressure has a tendency to

force formation fluids into the wellbore. This forced fluid flow is called a kick.

If the flow is successfully controlled, the kick is considered to have been

killed. An uncontrolled kick that increases in severity may result in what is

known as a "blowout.
Causes of Kicks:
There are many situations, which can produce this unfavorable downhole
condition. Among the most likely and recurring are:
• Low Density Drilling Fluid
• Abnormal Reservoir Pressure
• Swabbing
• Not Keeping the Hole Full on Trips
• Lost Circulation

1. Low Density Drilling Fluid

The density of the drilling fluid is normally monitored and adjusted to provide
the hydrostatic pressure necessary to balance or slightly exceed the formation
pressure.
Accidental dilution of the drilling fluid with water in the surface pits or the
addition of drilled-up, low density formation fluids into the mud column are
possible sources of a density reduction which could initiate a kick. Diligence
on the mud pits is the best way to insure that the required fluid density is
maintained in the fluids we pump down hole.
Most wells are drilled with sufficient overbalance so that a slight reduction in
the density of the mud returns will not be sufficient to cause a kick. However,
any reduction in mud weight during circulation must be investigated and
corrective action taken. A major distinction must be drawn between density
reductions caused by gas cutting and those caused by oil or saltwater cutting.
1.1 Gas Cutting
The presence of large volumes of gas in the returns can cause a drop in the
average density and hydrostatic pressure of the drilling fluid.
1.2 Oil or Saltwater Cutting
Oil and/or salt water can also invade the wellbore from cuttings, reduce the
average mud column density, and cause a drop in mud hydrostatic pressure
large enough to initiate a kick.
2. Abnormal Reservoir Pressure
Abnormal Pressure is defined as any pore pressure that is greater than
hydrostatic pressure of the formation water occupying the pore space.
Abnormal Pressure is sometimes called overpessure or geopressure.
Abnormal Pressure can be thought of as being made up of a normal
hydrostatic component plus an extra amount of pressure.
Salt water is a common formation fluid and averages about 0.465 psi/ft.
Therefore, 0.465 psi/ft is considered the normal formation pressure gradient.

3. Swabbing
Swabbing is a condition, which arises when pipe is pulled from the well and
produces a temporary bottomhole pressure reduction. In many cases, the
bottomhole pressure reduction may be large enough to cause the well to go
underbalanced and allow formation fluids to enter the wellbore. By strict
definition, every time the well is swabbed in, it means that a kick has been
taken. While the swab may not necessarily cause the well to flow or cause a
pit gain increase, the well has produced formation fluids into the annulus,
which have almost certainly lowered the hydrostatic pressure of the mud
column.
If a length of drillpipe composed of five barrels of metal volume is pulled from
the well and the hole fill-up is only four barrels, a barrel of gas, oil, or salt
water has possibly been swabbed into the wellbore.

5. Lost Circulation
An important cause of well kicks is the loss of whole mud to natural and/or
induced fractures and to depleted reservoirs. A drop in fluid level in the
wellbore can lower the mud hydrostatic pressure across permeable zones
sufficiently to cause flow from the formation. Some of the more common
causes of lost circulation include:

5.1 High Mud Weight

If the bottomhole pressure exceeds the fracture gradient of the weakest
exposed formation, circulation is lost and the fluid level in the hole drops. This
reduces the effective hydrostatic head acting against the formations that did
not break down. If the mud level falls
far enough to reduce the BHP below the formation pressure, the well will
begin flowing. Thus, it is important to avoid losing circulation.
Should returns cease, loss of hydrostatic pressure can be minimized by
immediately pumping measured volumes of water into the hole.
Measuring the volumes will enable the drilling supervisor to calculate what
weight of mud the formation will support without fracturing.
Upon gaining returns, verify that the well is not flowing on its own.
5.2 Going into Hole Too Fast
Loss of circulation can also result from too rapid lowering of the drill pipe and
bottom assembly (drill collars, reamers, and bit). This is similar to swabbing,
only in reverse; the piston action forces the drilling fluid into the weakest
formation. This problem is compounded
if the string has a float in it and the pipe is large compared to the hole.
Particular care is required when running pipe into a hole having exposed
weaker formations and heavy mud to counter high formation pressure.
5.3 Pressure Due to Annular Circulating Friction
Another item to be considered when drilling with a heavy mud near the
fracture gradient of the formation is the pressure added by circulating friction.
This can be quite large, particularly in small holes with large drill pipes, or
stabilizers inside the protective casing.
It is sometimes necessary to reduce the pumping rate to lower the circulating
pressure. This problem can become acute when trying to break circulation
with high gel fluids.
5.4 Sloughing or Balled-Up Tools
Partial plugging of the annulus by sloughing shale can restrict the flow of
fluids in the annulus. This imposes a back pressure on the formations below
and can quickly cause a breakdown if pumping continues. Annular plugging is
most common around the larger drillstring components such as stabilizers, so
efforts to reduce balling will also diminish the chances of this type of lost
circulation.

Factors Affecting Kick Severity

 Permeability of rock, which is known as the ability of the rock to allow

fluid to move through it.

 Porosity is the amount of space in the rock containing fluids. A rock

with high permeability and high porosity has greater potential for a

severe kick than a rock with low permeability and low porosity. For

example, sandstone is considered to have greater kick potential than

shale because sandstone, in general, has greater permeability and

greater porosity than shale.

 Pressure differentia involved. Pressure differential is the difference

between the formation fluid pressure and the mud hydrostatic

pressure. If the formation pressure is much greater than the

hydrostatic pressure a large negative differential pressure exists.

Kick types
A kick can be labeled in several ways, including one that depends on the type

of formation fluid that entered the borehole. Known kick fluids include gas, oil,

salt water, magnesium chloride water, hydrogen sulfide (sour) gas, and

carbon dioxide. For example, if gas enters the borehole, the kick is called a

"gas kick."
Well Control Principles
There are basically two ways in which fluids can be prevented from flowing,

from the formation, into the borehole:

Primary Control
Primary control over the well is maintained by ensuring that the pressure due
to the colom of mud in the borehole is greater than the pressure in the
formations being drilled i.e. maintaining a positive differential pressure or
overbalance on the formation pressures.

Primary Control - Pressure due to mud colom exceeds Pore Pressure

Secondary Control
Secondary control is required when primary control has failed (e.g. an

unexpectedly high pressure formation has been entered) and formation fluids

are flowing into the wellbore. The aim of secondary control is to stop the flow

of fluids into the wellbore and eventually allow the influx to be circulated to

surface and safely discharged, while preventing further influx downhole. The

first step in this process is to close the annulus space off at surface, with the
BOP valves, to prevent further influx of formation fluids (Figure 2). The next

step is to circulate heavy mud down the drillstring and up the annulus, to

displace the influx and replace the original mud (which allowed the influx in

the first place).

Secondary Control -Influx Controlled by Closing BOP's

Ways in which the mudweight and/or the height of the colom of mud can
fall:

** Reduction in Mudweight
The mudweight is generally designed around 200-300 psi greater than the

formation pore pressure. This pressure differential is known as the

overbalance. If the mud weight is reduced, the overbalance becomes less and

the risk of taking a kick becomes greater. It is therefore essential that the
mudweight is continuously monitored to ensure that the mud that is being

pumped into the well.

The mudweight will fall during normal operations because of the

following:

• Solids removal

• Dilution of the mud (due to watering-back)

• Gas cutting of the mud.

**Reduced Height of Mud Colom

During normal drilling operations the volume of fluid pumped into the borehole

should be equal to the volume of mud returned. When the pumps are

stopped, the fluid should continue to flow from the well (this would indicate

that a kick was taking place) or should the level of the mud fall below the mud

flow line.

The mud colom height may be reduced by;

• T ripping

• Swabbing

• Lost circulation

Indicators of a kick: