Lecture 11: Well Control Leak-Off Test & Kick Circulation Methods

Arun S Chandel
Assistant Professor aschandel@ddn upes ac in aschandel@ddn.upes.ac.in 09997200339

Leak-Off Test
Leak Off Test is conducted in order to find the fracture gradient of certain formation. The results of the leak off test also dictate the maximum equivalent mud weight that should be applied to the well during drilling operations.

LOT Procedure P d

Leak Off Test (LOT) guide line procedures are as follows: 1) Drill out new formation few feet, circulate bottom up and collect sample to confirm that new formation is drilled to and then pull string into the casing. 2) Close annular preventer or pipe rams, line up a pump, normally a cement ement pump, p mp and nd circulate i l te through th o gh an n open choke hoke line to ensure en e that th t surface line is fully filled with drilling fluid.

3) ) Gradually y p pump p small amount of drilling g fluid into well with constant pump stroke. Record total pump strokes, drill pipe pressure and casing pressure. Drill pipe pressure and casing pressure will increase continually while pumping mud in hole. When plot a graph between strokes pumped and pressure, pressure if formation is not broken, broken a graph will demonstrate straight line relationship. When pressure exceeds formation strength, formation will be broken and let drilling fluid permeate into formation, therefore a trend of drill pipe/casing pressure will deviate from straight line that mean formation is broken and is injected by drilling fluid. We may call pressure when deviated from straight line as leak off test pressure. 4) Bleed off pressure and open up the well. Then proceed drilling operation.

Leak-Off Test Calculations

Leak off test pressure can be calculated into equivalent mud weight in ppg as formula below: Leak off test in equivalent mud weight (ppg) {(Leak off test pressure in psi) 0.052 (Casing Shoe TVD in ft)} (current mud weight in ppg)

= +

Pressure gradient in psi/ft (Leak off test pressure in psi)

(Casing Shoe TVD in ft)

Example:
Leak off test pressure = 1600 psi Casing shoe TVD = 4000 ft Mud weight = 9.2 ppg Leak off test in equivalent mud weight (ppg) = 1600 psi 0.052 4000 ft + 9.2ppg ppg = 16.9 Pressure gradient = 1600 4000 = 0.4 psi/ft

Question

Solution

Normal Procedure followed when a Kick is Encountered

1) Pick up the kelly and note the position of tool joints in relation elation to the drilling d illing spools. spools 2) Stop the pumps. 3) Open the choke line. 4) ) Close l the h annular l preventer or ram preventers. 5) Close the choke. 6) Record the pit gain. 7) Record the SIDP and SICP when they stabilize.
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Circulating out a Kick

For a well to be killed successfully, the pressure in the formation must be kept under control during the entire kill operation. The only exception is in cases when the maximum allowable annular pressure will be exceeded. The simplest method of doing this is to control the drillpipe pressure by running the kill pump at a constant rate and controlling the pressure by regulating the choke on the choke line.

Two basic techniques are The Drillers method - 2 circulations; The Engineers or Wait and Weight method - 1 circulation; The Engineers method results in lower annular pressure, particularly at the shoe. q called as Concurrent method One more technique is also used.
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Drillers Method (2 Circulations)

The Drillers Method requires two circulations.
The first Th fi t circulation i l ti of f the th Drillers D ill Method M th d is i performed f d using i th the original mud. Constant BHP is maintained by holding circulating drill pipe pressure constant through the first circulation. The choke is opened slightly, at the same time the pumps are started up to the kill rate. When the pumps have reached kill rate, the choke is manipulated to maintain the Initial Circulating Pressure (ICP) on the drillpipe. As the kick fluids approach the surface, surface the annular pressure will rise drastically if the kick is gas. If the kick is saltwater the annular pressure will drop slightly. When the influx has been circulated out, , the p pumps p are stopped pp and the choke closed. At this time, the two surface pressures (SIDP & SICP) should be the same. During the first circulation, the influx is circulated out with the original mud weight. weight If the original mud weight is insufficient to balance the formation pressure, the well is killed by circulating a heavier mud (kill mud) in a second circulation.
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The First Circulation

The Second Circulation

Step 1: The Kill mud is pumped in the drillpipe. As with the first f circulation, the choke is opened and the pump speed increased to the kill rate (with the annulus pressure kept constant). The annular pressure is kept constant by manipulating the choke until the kill mud has reached the bit. As kill mud begins to fill the system, the drillpipe pressure will decrease from the initial circulating pressure to the final circulating pressure. Step 2: When kill mud reaches the bit, it is good practice to shutin the well. The drillpipe pressure should fall to zero; if it doesn't, a few more barrels should be p pumped p to ensure that the kill mud has reached the bit. If the drillpipe pressure is still greater than zero when the pump is stopped and the choke closed, the kick control figures should be rechecked. When satisfied, pumping is restarted, but now the drillpipe pressure is kept constant as the kill mud displaces the mud in the annulus. When the kick fluids and original mud have been displaced, the choke should be wide open. The pump should be shut down and both SIDP & SICP should read zero. If so, the well should then be observed for flow.
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To hold constant BHP during the second circulation, one of t two procedures d i is employed. l d Casing C i pressure is i h ld held constant while pumping kill mud from surface to bit, and drill pipe pressure is held constant thereafter until kill mud is observed returning g to the surface. Alternately, during second circulation, a drill pipe pressure schedule can be calculated and followed while pumping kill mud from surface to bit, bit and drill pipe pressure is held constant thereafter. The kick is now killed and mud should be circulated to condition the hole, and at the same time the trip margin (if any) should be added.

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Engineers or Wait and Weight Method

This is usually a more effective method of killing a kick than the driller's method, if time is not a prime concern. Kill mud is pumped into the drillpipe as soon as it is ready, which tends to reduce the high annular pressures associated i t d with ith gas kicks. ki k The Th same shut-in h t i procedures d are used as outlined in the previous section. Step p 1:When all the calculations have been p performed, , the mud density is raised immediately to the calculated kill mud density. When the kill mud volume is ready, the pumps are started and the choke slowly opened, while keeping the annular pressure constant until the pump has reached kill rate. rate The choke is then regulated in such a way as to decrease the drillpipe pressure until the kill mud reaches the bit, at which point the final circulating pressure is reached. Step 2: Pumping is continued, holding the drillpipe pressure constant by adjusting the choke. When the kick fluids have been displaced, and further volume has been displaced equal to the pipe volume, the SIDP should be zero. zero The kick should be killed and the well checked for flow. flow The kick is now killed and further circulations can be performed to condition the hole and to add any trip margin.
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Figure shows diagrammatically the displacement of the original mud with kill mud, mud with example pressures, pressures using the engineers method.
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Drillers Method Vs W&W Method

1. Drillers method is preferred in wells where hole stability is a problemNon-circulating well is minimized. i i i d 2. Drillers method is preferred for Old rigs which have limited fluid mixing capability-continuous mixing to make kill mud may result in excessive surface and shoe pressures due to gas expansion. 3. Easier to response to complications occurring during well kill operation if using Drillers method bit nozzle plugging. 4 Time required to kill the well may be lower in W&W 4. method if kill mud is prepared at a faster rate. 5. W&W method results in lower annular pressure, particularly at shoe- depends on location of gas bubble and drill string volume.
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Dynamic Kick Control

[Kill well ll on the th fly] fl ]

For use in controlling shallow gas kicks

No competent casing seat No surface casing - only conductor Use diverter (not BOP BOPs) s) Do not shut well in!
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Dynamic Kick Control

1. Keep pumping. Increase rate! (higher ECD) y 2. Increase mud density 0.3 #/gal per circulation 3. Check for flow after each complete circulation 4. If still flowing, repeat 2 2-4. 4.

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Conventional Kick Control {Surface Casing and BOP Stack are in place}

Shut in well for pressure readings. (a) Remove kick fluid from wellbore; (b) Replace old mud m d with ith kill weight eight mud m d Use choke to keep BHP constant. constant

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Drillers Method - Constant Geometry

Information required:
Well Data: Depth = 10,000 ft. Hole size = 12.415 in. (constant) Drill ll Pipe = 4 1/2 /2 O O.D., 16.60 6 60 lb/ft lb/f Surface Csg.: 4,000 ft. of 13 3/8 O.D. 68 lb/ft (12 415 in I.D.) (12.415 ID)

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Drillers Method - Constant Geometry

Additional Information required: q

Kick Data: Original mud weight = 10.0 #/gal Shut-in annulus press. = 600 psi Shut-in drill pipe press. = 500 psi Kick size = 30 bbl (pit gain)

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Constant Annular Geometry. Initial I iti l conditions: Kick has j just entered the wellbore Pressures have stabilized

SIDPP = 500 psi SICP = 600 psi DP OD = 4.5 in Hole dia = 12.415 in Annular Capacity = 0.13006 bbl/ft

4,000 ft

231 ft 10 000 ft 10,000 BHP = 5,700 psig

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Successful Well Control

1. At no time during g the p process of removing the kick fluid from the wellbore will the pressure exceed the pressure capability of

the formation 4 the casing 4 the wellhead equipment

4

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Successful Well Control

2. When the process is complete the wellbore is completely l t l fill filled d with ith a fl fluid id of f sufficient density (kill mud) to control the formation pressure. p Under these conditions the well will not flow when the BOPs BOP s are opened. opened 3. Keep the BHP constant throughout. throughout

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Calculations
From the initial shut shut-in in data we can calculate:

Bottom hole pressure Casing seat pressure Height H i ht of f ki kick k Density of kick fluid

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Calculate New Bottom Hole Pressure

PB = SIDPP + Hydrostatic Pressure in DP

= 500 + 0.052 * 10.0 * 10,000 = 500 + 5 5,200 200 PB = 5,700 psig

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Calculate Pressure at Casing Seat

P4,000 4 000 = P0 + PHYDR. HYDR ANN ANN. 0-4 0-4,000 000 = SICP + 0.052 * 10 * 4,000 = 600 + 2,080

P4,000 = 2,680 psig

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Calculate EMW at Casing Seat

This corresponds to a pressure gradient of

Equivalent Mud Weight (EMW) =

2,680 psi = 0.670 psi/ft 4,000 ft

0.670 psi/ ft = 12.88 lb/gal 0.052 (psi/ ft)(lb / gal)

( mud = 10.0 lb/gal )
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Calculate Initial Height of Kick Annular capacity p y per p ft of hole: 2 2

4 (D H D P )L
2

vx =

gal bbl = (12 .415 4.5 ) * 12 in * 4 231 in 3 42 gal

2 3

= 0.13006 bbls/ft
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Calculate Height of Kick

Height of kick at bottom of hole, hole

VB 30 bbl hB = = = 230 .7 ft vx 0.13006 bbl/ft
hB

= 231 ft
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Calculate Density of Kick Fluid

The bottom hole pressure is the pressure at the surface plus the total hydrostatic pressure between the surface and the bottom: Annulus Drill String

PB = SICP + PMA + PKB = SIDPP + PMD

600 + 0052 . *10 *(10,000-231) + PKB = 500 + (0.052*10*10,000)

600 + 5,080 5 080 + PKB = 500 + 5,200 5 200

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Density of Kick Fluid

PKB = 20 psi i
KB 20 = 1 .67 lb/gal 0 .052 * 231
(must be primarily gas!)
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Circulate Kick Out of Hole

NOTE: The bottom hole pressure is kept constant while the kick fluid is circulated out of the hole! In this I hi case BHP = 5,700 psig

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Constant Annular Geometry

Drillers Method. Conditions When Top of Kick Fluid Reaches the Surface

BHP = const.

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Top of Kick at Surface

As the A h kick ki k fluid fl id moves up the h annulus, l it i expands. d If the expansion follows the gas law, then

P0 V 0 PB VB = Z 0 n 0 RT 0 Z B n B RT B [ surface ] [bottom]
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Top of Kick at Surface

Ignoring g g changes g due to compressibility p y factor ( (Z) ) and temperature, we get:

P0 V 0 = PB V B P0 v 0h 0 = PB v B h B i. e . P0h 0 = PB h B (v = v B = const .)
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Since cross-sectional area = constant

0

Top of Kick at Surface

We are now dealing two unknowns, P0 and h0. We have one equation, and need a second one.

BHP = Surface Pressure + Hydrostatic Head 5 700 = Po + PKO + PMA 5,700 5,700 = Po + 20 + 0.052 * 10 * ( (10,000 - hO )

PB hB 5 700 - 20 - 5,200 5,700 5 200 = Po - 0.52 0 52 * Po

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Top of Kick at Surface

480 P 0 = P 0 P0
2 2

0 . 52 * 5700 = 0

* 231

480 P 0 684684 480 480

2

P0 =

+ 4 * 684 , 684 2

P 0 = 240 862 = 1,102 psi i

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Finally The Important Principles Finally,

A kick is NOT a blowout. Most blowouts are due to human error in handling a kick. The h fundamental f d l principle l in well ll control l is CONSTANT BOTTOM HOLE PRESSURE Shut Sh t the th well ll in i using i the th HARD or FAST SHUT IN using the annular BOP.
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Important p Principles p
continued

Control a kick with the bit on bottom. Use True Vertical Depth (TVD) for calculating pressures. Use Measured Depth (MD) for volumes and di l displacements. t Establish pore pressure by recording the shut in pipe p p pressure. drill p

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Important p Principles p
continued

Maintain constant bottom hole pressure by controlling the drill pipe pressure - do not us the casing pressure. Assume and design for a gas kick unless the reservoir fluid is known. Gas is more difficult to handle - primarily d due to l large expansion d during circulating l out a kick. (Boyles Law: P1V1 = P2V2)
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If You Get it Wrong!

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