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Bullheading is one of the well control methods that involve pumping formation fluids back into
formation into a shut-in well. You can read the basic details about bullheading from this link:
http://www.drillingformulas.com/bullheading-well-control-method/.
For this time, this article will be focused on a calculation example for bullheading operation.
For the bullheading operation, pumping pressure on surface is equal to summation of all frictional
pressure and formation pressure minus hydrostatic pressure (Figure 1). The equation below shows
this relationship in a mathematical term.
Pump Pressure =
Formation Pressure
The pump pressure concept will be utilized for the bull heading calculation.
Figure 1 Pump Pressure Components
Calculations
For the bull heading calculation, reference points for calculation formation pressure, fracture
pressure, kill weight mud are based on top of perforation because it gives the most conservative
fracture pressure value.
Formation Pressure (psi) = Pressure Gradient (psi/ft) x Top of Perforation TVD (ft)
Fracture Pressure (psi) = Fracture Gradient (psi/ft) x Top of Perforation TVD (ft)
Initial Hydrostatic Pressure (psi) = Formation Pressure (psi) Shut In Tubing Head Pressure
(psi)
Initial Average Fluid Density (ppg) = 2,095 (0.052 x 11,000) = 3.66 ppg
Kill Weight Mud (ppg) = Initial Average Fluid Density + (Shut In Tubing Pressure (psi)
0.052 Top of Perforation TVD (ft))
Kill Weight Mud (ppg) = 3.66 + (2800 0.052 11,000) = 8.6 ppg
Maximum Initial Surface Pressure (psi) = Formation Fracture Pressure (psi) Initial
Hydrostatic Pressure (psi)
Maximum End of Tubing Pressure (psi) = Fracture Pressure (psi) (Kill Weight Mud (ppg) x
0.052 x End of Tubing TVD (ft)) Initial Average Fluid Density (ppg) x 0.052 x (Top of
Perforation TVD (ft) End of Tubing TVD (ft))
Maximum End of Tubing Pressure (psi) = 7,095 (8.6 x 0.052 x 10,500) (3.66 x 0.052 x
(11,000 10,500)) = 2,304 psi
Maximum Final Pressure (psi) = Formation Fracture Pressure @ top of perforation (psi)
(Kill Weight Mud (ppg) x 0.052 x Top of Perforation TVD (ft))
Maximum Final Pressure (psi) = Formation Fracture Pressure @ bottom of perforation (psi)
(Kill Weight Mud (ppg) x 0.052 x Bottom of Perforation TVD (ft))
The most conservative figure for the maximum final pressure is 2,176 psi.
As you can see, the figure reference to the top of perforation gives the most conservative figure.
This is the reason why top of perforation is selected for the calculation.
Volume Pumped in Tubing (bbl) = Tubing Capacity Factor (bbl/ft) x Length of Tubing (ft)
Stroke Pumped in Tubing (stk) = Volume Pumped in Tubing (bbl) Pump Output (bbl/strk)
Volume Pumped From End of Tubing to Top of Perforation (bbl) = Casing Capacity Factor
(bbl/ft) x (Top of Perforation TVD (ft) End of Tubing TVD (ft))
Stroke Pumped From End of Tubing to Top of Perforation (stk) = Volume Pumped in Casing
(bbl) Pump Output (bbl/strk)
Volume Pumped From Top of Perforation to End of Perforation (bbl) = Casing Capacity
Factor (bbl/ft) x (End of Perforation TVD (ft) Top of Perforation TVD (ft))
Stroke Pumped From Top of Perforation to End of Perforation (bbl)) = Volume Pumped in
Casing (bbl) Pump Output (bbl/strk)
In order to push all formation fluid back to formation, it is required that the pumping volume must
be at least volume from surface to end of perforation.
This is the same concept as pressure schedule in wait and weight well control method.
Pressure Decreasing in Tubing (psi/required stks) = (Maximum Initial Surface Pressure (psi)
Maximum End of Tubing Pressure (psi)) X Required strokes (stks) Tubing volume (stk)
For this calculation, 100-strokes is selected.
Pressure Decreasing in Tubing (psi/required stks) = (5,000 2,304) x 100 914 = 295 psi / 100 stks
Pressure Decreasing in Casing (psi/required stks) = (Maximum Initial End of Tubing Pressure
(psi) Maximum Final Pressure (psi)) X Required strokes (stks) Volume from End of
Tubing to Top of Perforation (stk)
Pressure Decreasing in Casing (psi/required stks) = (2,304 2,176) X 100 186 = 96psi / 100 stks
The red line is the maximum pressure. If pressure exceeds the red line, a formation will be broken
down (fracture zone). The blue line represents a shut in condition. Pressure below the blue line
means that the well is in an underbalanced condition (flow zone). The area between the red line and
blue line is the safe zone for bullheading operation (Figure 3).
The formations may be fractured if pumping pressure exceeds the fracture line (Figure 5).
Figure 5 -Bullheading Operation Exceeding Fracture Pressure
Note: this chart is constructed without accounting for friction pressure. It is the most conservative
pressure to prevent fracturing formation.