Well Control Manual

Well Control Manual
Document No. K-CW-OP-MA-0001 / Version 1.01

Well Control Manual Rev 1.01, June 2010
FOREWORD
This Well Control Manual has been prepared to document the requirements of KCA DEUTAG with
respect to Well Control Management and assist in the implementation of proper Well Control
practices and procedures.
This document is not a Training Manual (for which the reader is referred to the KCA D EUTAG DART
Well Control Training Manual) and assumes the user has Well Control knowledge to the level of
IWCF or WellCAP. However, where appropriate, some theory and additional information has been
included such that all appropriate background information is included in one reference document.
The Manual has been based on the input from many sources, and has been agreed by
representatives of each Area and the E&M Function and therefore expressly documents KCA
DEUTAG’s mandatory requirements with respect to Well Control, together with additional
recommendations which should be considered for implementation on a local basis.
The manual is not intended to cover all possible well control eventualities and cannot replace sound
judgement based upon a thorough knowledge of well control principles or local knowledge of a
particular set of circumstances.
The custodian of this Manual is Training Department. Any recommendations for changes can be
made via the relevant General Manager to the Head of Training.
Brian Taylor
COO
Foreword and Contents Page 2 of 142

CONTENTS
1 Responsibilities & Summary of Well Control Requirements .......................................... 6
1.1 Responsibilities ......................................................................................................... 6
1.2 Training Requirements.............................................................................................. 7
1.3 Compliance & Exemption Process ........................................................................... 8
1.4 Summary of Well Control Requirements .................................................................. 8
2 Well and Operational Planning ......................................................................................... 12
2.1 Well Planning .......................................................................................................... 12
2.1.1 General Considerations............................................................................................. 12
2.1.2 Bridging Documents .................................................................................................. 12
2.1.3 H2S Contingency Planning ........................................................................................ 12
2.1.4 Minimum Stock Levels .............................................................................................. 12
2.1.5 Formation Considerations ......................................................................................... 13
2.1.6 Shallow Gas .............................................................................................................. 16
3 Hardware Requirements ................................................................................................... 17
3.1 Kick Detection (Hardware) ...................................................................................... 17
3.2 Diverter Equipment Requirements.......................................................................... 18
3.2.1 Diverter Selection Criteria ......................................................................................... 18
3.2.2 Diverter Line Requirements....................................................................................... 18
3.2.3 Diverter Equipment Specifications ............................................................................ 19
3.3 Diverter Arrangements ............................................................................................ 19
3.4 BOP Equipment Classification and Selection ......................................................... 21
3.5 BOP Arrangements ................................................................................................. 23
3.5.1 BOP 13800 kPa 2000 psi without a Casing Spool .................................................... 23
3.5.2 BOP 20700 kPa 3000 psi 34500 kPa /5000 psi without a Casing Spool ................... 24
3.5.3 BOP 34500 kPa 5000 psi with a Casing Spool (Dual Ram option) ........................... 25
3.5.4 BOP 34500 kPa 5000 psi and/or 69000 kPa 10000 psi with Casing Spool ............... 26
3.5.5 BOP 103500 kPa 15000 psi. ..................................................................................... 27
3.6 Control System Requirements for Surface BOP Stacks ......................................... 28
3.7 BOP Testing requirements ..................................................................................... 28
3.7.1 Pressure Test Criteria. .............................................................................................. 28
3.7.2 Frequency of Testing ................................................................................................ 28
3.7.3 Accumulator and Control System Tests .................................................................... 29
3.8 General Maintenance Requirements for Wellhead and BOP Equipment ............... 29
4 Well Control Principles ..................................................................................................... 31
4.1 Barrier Policy........................................................................................................... 31
4.2 Primary Well Control ............................................................................................... 31
4.3 Secondary Well Control .......................................................................................... 31
4.4 Tertiary Well Control ............................................................................................... 32

4.5 Causes of kicks ....................................................................................................... 32

5 Preparation for, Prevention and Detection of Kicks ...................................................... 38
5.1 General Preparation Requirements in order to be prepared to handle a kick ........ 38
5.1.1 Equipment Checks and availability ............................................................................ 38
5.1.2 Flow Checking........................................................................................................... 38
5.1.3 Determining the Maximum Allowable Annular Surface Pressure (MAASP) .............. 39
5.1.4 Slow Circulation Rate Friction Losses (SCR) ............................................................ 39
5.1.5 Establishing the Barite Mixing Capacity of the Rig .................................................... 39
5.1.6 Capacities and Strokes for Drillstring and for Annulus .............................................. 39
5.1.7 Pre-kick sheets.......................................................................................................... 40
5.2 Indications that a Kick may be in Progress While Drilling....................................... 40
5.3 Indications that a Kick may be in Progress While Tripping..................................... 44
5.4 Kick Drills ................................................................................................................ 45
5.4.1 Kick Drill Recommended Procedures ........................................................................ 45
5.5 Casing & Cementing ............................................................................................... 46
5.6 Stripping Drills ......................................................................................................... 47
6 Shut-in Procedures............................................................................................................ 48
6.1 Responsibilities for implementing Well Control Procedures ................................... 48
6.2 General Shut-in Procedures ................................................................................... 48
6.3 Post Shut-in actions ................................................................................................ 51
7 Well Killing Procedures..................................................................................................... 53
7.1 Killing Considerations & Preparation ...................................................................... 53
7.1.1 Calculation of Reservoir Pressure (& Kill Mud Weight) ............................................. 53
7.1.2 Choice of Kill Method ................................................................................................ 53
7.1.3 Initial Preparation ...................................................................................................... 54
7.1.4 Establishing (or re-establishing) the initial circulating pressure ................................. 54
7.2 Drillers Method ........................................................................................................ 55
7.2.1 Kill Procedure ............................................................................................................ 55
7.2.2 First step (circulation). ............................................................................................... 55
7.2.3 Second step (kill circulation)...................................................................................... 58
7.3 Wait and Weight Method ........................................................................................ 60
7.3.1 Preparation to kill ...................................................................................................... 61
7.3.2 Circulating the Influx Out and Killing the Well ............................................................ 61
7.4 Other Kick Killing Methods ...................................................................................... 64
7.4.1 Concurrent Method ................................................................................................... 64
7.4.2 Volumetric Method .................................................................................................... 64
7.4.3 String Out of the Hole ................................................................................................ 72
7.4.4 Killing by Bullhead Squeezing ................................................................................... 73
7.4.5 Kick Control in Deviated and Horizontal Wells .......................................................... 74

7.5 Stripping Operations ............................................................................................... 76

7.5.1 Preparation for Stripping ........................................................................................... 76
7.6 Potential problems while well killing ........................................................................ 81
7.6.1 MAASP is reached .................................................................................................... 81
7.6.2 Equipment Failure ..................................................................................................... 81
7.6.3 Hydrates .................................................................................................................... 82
7.6.4 Well Kill Problem - Quick Check List & Trouble Shooting Charts .............................. 82
8 Appendix 1: Forms, Calculations, Worked Examples ................................................... 88
8.1 Kick Drill Sheets: Pit/Kick Drill Report – Hard/Fast Shut In .................................... 89
8.2 Kick Drill Sheets: Pit/Kick Drill Report – Soft Shut .................................................. 90
8.3 Kick Killing Worksheets (IWCF Forms)................................................................... 91
8.4 Stripping Form ...................................................................................................... 100
8.5 Stripping Check Sheet .......................................................................................... 101
8.6 Form for Completing a Leak off Test .................................................................... 103
8.7 Calculation of Reservoir Pressure (& Kill Mud Weight) ........................................ 105
8.8 Kick Behaviour ...................................................................................................... 107
8.9 Influx Gradient ....................................................................................................... 108
8.10 Gradients of some common wellbore Fluids......................................................... 109
8.11 Gas Migration, Boyles Law, .................................................................................. 109
8.12 Hydrates ................................................................................................................ 112
8.13 Worked Examples ................................................................................................. 113
8.13.1 Example Calculations – Kick Tolerance .................................................................. 113
8.13.2 Example Calculations: Barite Addition .................................................................... 115
8.14 Field Worked Example – Drillers method ............................................................. 117
8.15 Field Worked Example – Wait & Weight method .................................................. 121
9 Appendix 2: Shallow Gas Requirements....................................................................... 124
9.1 Introduction ........................................................................................................... 124
9.2 Risk and implications of encountering shallow gas. ............................................. 124
9.3 Shallow Gas Kick Prevention ................................................................................ 125
9.4 Equipment Selection ............................................................................................. 126
9.5 Shallow Gas Drilling Practices .............................................................................. 126
9.6 Actions to be taken in the event of a Shallow Gas Kick ....................................... 129
10 Appendix 3: Conversions Factors and Formulae ........................................................ 132
10.1 Conversion Factors ............................................................................................... 132
10.2 Formulae - SI ....................................................................................................... 133
10.3 Formulae - Field Units.......................................................................................... 136
10.4 Formulae - Bar Litre ............................................................................................. 139

1 Responsibilities & Summary of Well Control Requirements

1.1 Responsibilities
On all operations it is the responsibility of the senior onsite KCA DEUTAG representative (normally the
Rig Superintendent, Toolpusher or OIM), to ensure the implementation of proper well control
practices and procedures.
Prior to spud it is the responsibility of the Rig Manager to ensure that all the appropriate issues have
been addressed in conjunction with the Client in order that the risk of a well control incident is as low
as reasonably practicable.
Where the Drilling Programme or Client instructions (whether written or verbal) conflict with
requirements of this Manual or good oilfield practice the issue must immediately be raised through
line supervision and, if not resolved, raised to the Rig Manager, Operations Manager or Country
Manager as required.
Responsibilities during a well control event

It is the responsibility of the senior onsite KCA DEUTAG representative to ensure that the required
responsibilities are allocated and appropriately disseminated to those involved
These responsibilities include:
 safeguarding personnel
 protecting the environment and
 protecting KCA DEUTAG drilling rig and its associated equipment
Some generic key responsibilities for the drill crew are summarised below. However dependent upon
the specific crew make-up and competencies etc., these may be reallocated as long as
responsibilities are clear and documented.
Mud Tester / Shakerman:
To inform the Driller if any variances in mud returns and / or gas cut, water or oil contaminated mud
is coming over the shakers.
Derrickman (or competent assigned crew member):
To monitor the active mud volume in the tanks at all time and inform the Driller of any variances.
During killing operations to manage the density up the kill mud according to Mud Eng. instructions.
Assistant Driller:
Line up and when necessary start the degasser and assist the Derrickman or the Driller during
killing operations according to Driller's instruction.
Driller:
To monitor his instrumentation and evaluate any changes and information given to him by the Mud
Tester and Derrickman. Perform flow checks* and if well is flowing, shut in the well and inform the
Toolpusher.
*Note: The well is not to be flow checked when drilling in formations containing H2S.
Prepare a Company approved Surface BOP Kill Sheet and compare it with Toolpusher's Kill Sheet,
to avoid mistakes.
To verify at his pre tour inspection that both the Koomey unit and the BOP are ready to operate.
To carry out any BOP test with his crew in accordance with the Toolpusher's instructions, the Drilling
Program, and KCA DEUTAG procedures.
Responsibilities & Summary Page 6 of 142

During killing operation, follow the pumping schedule in accordance with the approved Surface BOP
Kill Sheet and Toolpusher's instructions. Record pressures; pump rate, volume pumped, and time.
Compare the actual parameters with the kill graph and if any significant changes alert the
Toolpusher.
Rig Superintendent or Toolpusher:
To maintain full control over the behaviour of the well to prevent blowout from happening. Notify the
Company Representative, the Mud Engineer, the Drilling Engineer and Rig Manager.
Evaluate borehole situation upon presumed influx. Select the most appropriate killing procedure
depending on the type of kick and hole size. Calculate his Surface BOP Kill Sheet and compare it
with the Driller's, the Company Representative's, and / or the Drilling Engineer's to avoid any
mistakes. Be in charge of the killing operation, controlling backpressure and timing.
To communicate with the Company Representative the BOP testing schedule, and the pressures
and intervals.
To instruct the Driller to which pressures the BOP must be tested according to the Drilling Program
and as agreed with the client.
Ensure the BOP manufacturer's engineering data for the specific equipment is readily available.
To be aware of the annular preventer closing pressures to retain wellbore pressure in order to
minimize excessive wear on the packer element particular when reciprocating the drillstring.
Drilling Engineer:
To assist the Toolpusher in evaluating borehole situation, calculate independently IWCF or WellCAP
Surface BOP Kill Sheet and compare same with the Toolpusher's. Assist the Toolpusher during
killing operations.
Rig Manager:
To approve the killing procedure proposed by the Toolpusher and Client.
Country & General Managers:
To assure themselves and the Company that the procedures outlined in this manual are adhered to
for all KCA DEUTAG rigs in his Country/Area.
1.2 Training Requirements
Formal Training & Certification
KCA DEUTAG requires that all personnel are to meet any statutory or contractual requirements
regarding Well Control Training. Where statutory or contractual requirements do not exist, or where
these are lower than KCA DEUTAG’s minimum standards, the KCA DEUTAG minimum training
requirements are as follows:
The following personnel must complete a Company approved Well Control training course (either
IWCF or WellCAP), in accordance with the KCA DEUTAG Training Matrices, and pass the associated
examination at least every 2 years:
 Rig Managers
 Rig Superintendents (Toolpushers)
 Asst Rig Superintendents (Night Toolpushers)
 Drillers
For MODU operations the OIM must also have appropriate Well Control Certification.
In many cases Client Contractual requirements will also require Assistant Drillers (and potentially
Derrickmen) to have Well Control certification.
Anybody operating the brake when formation pressures are in communication with the wellbore must
have current well control certification. Anybody operating the brake without well control certification

(only allowable when formation pressures isolated from the wellbore) must be directly supervised by
somebody with current well control certification.
Additional training may be required dependent upon the types of well to be drilled and any local
legislation or contractual requirements.
All crews must be trained ‘on the job’ through the regular use of kick drills which are to be conducted
in accordance with section 5.4 of this document.
1.3 Compliance & Exemption Process
The practices and procedures included in this Manual are minimum requirements and are not to be
reduced to comply with any governmental or Client requirements. The well control practices must,
however, be adjusted accordingly to comply with any more rigorous local regulations of either the
relevant local authorities or the Operator. Any changes or selection of alternatives to be used in a
well control situation must be documented in the Bridging Document.
Whilst the Manual dictates certain mandatory requirements, in other areas options or a preferred
procedure may be mentioned. In these cases the detailed local knowledge and expertise is to be
taken into account in determining which course of action will be instigated.
In this document the following terms are used to express a course of action:
 “May” indicates one possible cause of action
 “Should” indicates a preferred course of action
 “Must” indicates a mandatory course of action (and is the equivalent of “shall”)
It is a requirement that all relevant KCA DEUTAG personnel must know of and comply with the
Company’s approved well control Standard and Procedures as included in this manual. It is the
responsibility of the Senior KCA DEUTAG Representative to assure implementation of the appropriate
Well Control practices and procedures.
If, for any reason, a mandatory requirement of this manual is deemed not appropriate for particular
circumstances a dispensation in accordance with the Operations Standards Dispensation Process
(CW-ALL00-DW-OP-ST-0002), is required from the Country Manager, after appropriate risk analysis
and justification.
1.4 Summary of Well Control Requirements

Whilst all aspects of this manual are critical in maintaining good well control practices, certain
aspects are extremely important and have therefore been highlighted within the text of the manual
with grey shading. These requirements are also summarised in this section and are also reproduced
in the KCA DEUTAG Well Control Standard.
Well Control Standard Section

Reference
Management & Client Interfacing

The applicable procedures that are to apply (i.e, Operator’s or KCA 2.1.2
DEUTAG’s) should a well control event occur must be documented in a
Bridging or Interface document, with the procedures/requirements reconciled
against those in this manual before operations commence.
Where the Drilling Programme or Client instructions (whether written or 1.1
verbal) conflict with requirements of this Manual or good oilfield practice the
issue must immediately be raised through line supervision and, if not
resolved, raised to the Rig Manager, Operations Manager or Country
Manager as required.

Competency & Supervision

The following personnel must have current well control certification; Rig 1.2
Managers, Rig Superintendents (Toolpushers), Asst Rig Superintendents
(Night Toolpushers), Drillers, OIMs.
Compliance:
All requirements (“musts”) included in this manual are mandatory. 1.3
Dispensations can only be granted after suitable risk analysis and approval
by the Country Manager
Chemical Stocks
Sufficient stocks of barite, chemicals and associated additives must be on 2.1.4
location to allow for the weighting up of the mud system by 0.5 ppg (60
3 3
kg/m ) on development wells or 1 ppg (120 kg/m ) for exploration wells.
For offshore rigs and land rigs where logistics preclude a readily available
supply of cement, enough cement must be onsite to enable the setting of a
500 ft (150 m) cement plug in open hole.
Kick Tolerance
3 3
For kick tolerances of between 25 bbl (4m ) and 50 bbl (8m ) the Operations 2.1.5.6
Manager must be informed and any additional precautions implemented as
3
advised. For kick tolerances of below 25 bbl (4m ) the Country Manager
must be advised.
Kick Detection Hardware

The following Kick detection hardware must be installed on each rig: 3.1
 Flowline Recorder
 Pit Volume Totaliser
 Trip Tanks (on wells capable of natural flow) 4.5.1
Diverter, BOP Equipment and Control System Specifications

All BOPs, choke manifolds, diverters, valves, risers, adapters and spools, 3
hoses and flexible piping, and associated equipment must have valid
certification available at the rig site with copies being held in the office.
Well Control Equipment standards must never be lower than API 3.2/3.4
specifications or Recommended Practices or than as stated in this document
BOP Arrangements
Adequate redundancy must be in place in keeping with the equipment 3.5
specifications, the well programme and emergency contingencies.
Shear rams installed must be capable of shearing the pipe in use. If they 3.4, 3.5, 3.8
cannot they must only be used as blind rams with a notice to that effect
posted on the drillfloor and the Country Manager must also be informed.
Correct BOP equipment must always be installed on the well, be operational 3.5
and in an arrangement suitable for the specific application
Automatic MAASP controls must be disabled. 2.1.5.5
BOP Testing
BOP Testing must be undertaken under the direct supervision of the Rig 3.7.1

Superintendent or Asst Rig Superintendent (Toolpusher or Night Toolpusher)

BOP Testing is to take place with water and charts maintained. A low and
high pressure test must be undertaken with suitably calibrated gauges.
Acceptance is a stabilised (zero) pressure drop.
All gauges are to be calibrated at least yearly
Each rig is to have its own detailed testing procedure and referenced valve
schematic
BOP Testing Frequency

All BOP and related equipment must be pressure tested every 14 days or 3.7.2
st
during the 1 trip thereafter but never exceed 21 days
All BOP equipment is to be function tested upon installation and every 7
days or during the subsequent trip and must never exceed 14 days
The accumulators precharge pressures are to be checked prior to the 3.7.3
commencement of drilling each well or at a frequency not exceeding 3
months, or after any repair of the system. The operating lines to the BOP
components shall be pressure tested to rated working pressure at least
every 3 months
BOP Maintenance
Routine BOP maintenance must be undertaken in accordance with this 3.8
manual, approved PMRs, and at the specified frequency of the approved
PMRs
All BOP equipment is to be overhauled every 5 years
Manufacturers BOP manual requirements are to be followed. No
modifications, welding or cutting of any BOP equipment is to be made
without Manufacturers and/or E&Ms written consent. OEM spares must be
used unless a dispensation has been agreed with E&M function
Barrier Policy
During any well operations after surface casing is set a minimum of two 4.1
independent barriers must be in place. If the primary barrier is lost then a
second barrier must be in place,. When only one barrier remains, normal
operations will cease until a second barrier can be re-established.
Drilling Procedures
The hole must be kept full of mud of the agreed density at all times 4
The relevant personnel must understand and be experienced in the use of 4,
the rig’s specific equipment.
All drilling personnel must be constantly alert and able to respond quickly 4, 4.5.6,
should danger signs occur
A drillpipe back pressure valve must be installed while drilling and opening 4.2
hole until the first 1000ft (300m) of hole has been cased
The Rig Supt or Asst Rig Supt (Toolpusher or Night Toolpusher) must be on 4.5.2
the drillfloor for the first 10 stands of any trip to witness the commencement
of tripping operations and until he is confident that the hole is taking the
correct volume of fluid.
During drilling operations a fully opening string valve, plus a non-return valve 5.1.1

and suitable crossovers must be available on the drillfloor

Relevant information (pre-kicksheets) must be available and up to date at the 5.1.1, 5.1.4,
wellsite at all times 5.1.6, 5.1.7
Flowchecks must be held: 5.1.2
 Prior to a trip
 Prior to pumping a slug
 During a trip when:
o Collars are at the shoe,
o Collars are at the BOP
o Improper hole fill is observed
 During drilling when:
o Mud weight changes
o When a change in flowrate is observed
o When a change in pit level is observed
o When a drilling break is observed (unless the area is
known to be trouble free)
o When there are signs of water or gas cut mud
Kick Drills:
Kick drills are to be conducted with each crew on a weekly basis. All 5.4
drills are to be reported on the Daily Drilling Report
Drillcrew are to be made aware of the preferred kill method and shut- 6.1, 6.2.1
in procedure
Kick Tolerance
Rig crews are to know the kick tolerance for the section and how
this relates to the abilities of the crew and equipment to detect a kick 2.1.5.6
and close in the well
5.5
Cementing
When running casing, self fill shoes must not be used over
hydrocarbon zones.
Well Control Operations

During well kill operations constant bottom hole pressure must be maintained 7.2,7.3
regardless of kill method used
Shallow Gas Requirements Appendix 2

To minimise the loss of primary well control, each rig must prepare shallow 9.3
gas procedures specific to each rig.
During top hole drilling all wellsite personnel must be prepared to cope with a
shallow gas kick. All personnel involved in the drilling operation are to be
trained on the subject of shallow gas and its associated hazards
Prior to commencing operations the plans are to be developed and drills 9.5.1
conducted.
Drills:
Shallow Gas drills must be performed at the start of each shift when the 9.5.2
possibility of shallow gas has been identified in the Drilling Programme.

2 Well and Operational Planning

Preventing a kick will always be the best well control method and therefore certain planning activities
are to be implemented on all KCA DEUTAG operations.
2.1 Well Planning
Whilst KCA DEUTAG is not normally responsible for preparing the Well Programmes there are a
number of actions that KCA DEUTAG personnel can take at the planning stages to reduce the
likelihood of a well control event. Ultimately the Senior Wellsite Representative (normally Rig
Superintendent or Toolpusher) and Rig Manager are responsible for the overall safety of the
operation and are therefore encouraged to participate in pre-spud meetings and required to review
the Client’s drilling programme.
Such a review may well highlight areas where extra vigilance may be required with respect to Well
Control.
2.1.1 General Considerations

It is common practice for the Operator to hold a pre-spud meeting with Operator, Drilling Contractor
and Service Contractor personnel. At these meetings each step of the well programme is normally
reviewed and due consideration given to any specific aspects.
At this meeting the following points should be addressed:
 Previous field experience regarding lost circulation experiences, magnitudes and depths of
any anticipated abnormally pressurised formations
 Possible shallow gas sources
 The accuracy of the geological prognosis
 The anticipated formation pressures to be expected during drilling
 Procedures to be followed in case of kick or lost circulation
If a prespud meeting is not held then a separate meeting should be convened by the Rig Manager to
allow for adequate discussion on the above issues.
If specific issues have been identified these should be discussed with the Client’s representative to
establish whether additional training, precautions or extra vigilance is needed at particular phases of
the operation. If issues are identified early enough additional training, such as the benefits of using
DART (Drilling Advanced Rig Training) for Drill Well on Simulator (DWOS) sessions can be explored.
2.1.2 Bridging Documents

To ensure there is clarity of which procedures (Client or KCA DEUTAG’s will be applied should a
Well Control event occur, these issues are to be documented in a Bridging (or Interface) document.
If a Client’s procedures are to apply these must be reconciled against the requirements of this
manual (and other Operations Standards) prior to operations commencing
2.1.3 H2S Contingency Planning

When drilling a well where H2S is suspected all relevant personnel must be trained in special
procedures relative to well control and appropriate Company standards applied. Prior to
commencement of drilling all Well Control equipment must be deemed suitable for service (as per
section 3 of this manual). Bullheading a kick must be considered as the preferred method of
handling if H2S is suspected.
2.1.4 Minimum Stock Levels

Sufficient stocks of barite, chemicals and associated additives must be on location to allow for the
3
weighting up of the mud system by 0.5 ppg (60 kg/m ) on development wells or 1 ppg (120 kg/m3)
for exploration wells.
For offshore rigs and land rigs where logistics preclude a readily available supply of cement, enough
cement must be onsite to enable the setting of a 500 ft (150m) cement plug in open hole.

2.1.5 Formation Considerations

The Rig Manager and Senior onsite Representative must be aware of the expected formation
pressures and whether normally or abnormally pressured formations are to be expected during the
drilling operations. These issues are to be discussed at the pre-spud meeting and documented
within the drilling programme.
2.1.5.1 Normally Pressured Formations

The average figure for normal formation pressure gradient is 0.465 psi/ft (or 0.108 bar/m or 10.8
kPa/m). This is the pressure gradient produced by a column of water of 100,000 ppm chlorides as
opposed to a typical value for seawater as 23,000 ppm. Unless other information is available via the
Operator regarding the specific well, this average figure can be used for estimating the formation
pressure.
2.1.5.2 Abnormally Pressured (or surcharged) Formations

Abnormal formation fluid pressures can arise from a number of reasons:
 Differential fluid pressure
 Surcharged shallow formations
 Sediment compression
 Salt beds
 Mineralisation
The pressures that can result in overpressured or abnormally pressured formations will depend upon
a number of factors and should therefore be subject to discussion at the Client’s pre-spud meeting.
Further background information regarding the causes of abnormally pressured formations can be
found in the DART Well Control Training Manual.
2.1.5.3 Formation Strength

Formation fracture or breakdown pressure is the pressure required to rupture a formation in order
the mud will freely flow into it. The formation breakdown pressure is usually determined for
formations just below the casing shoe by means of a leak-off test.
2.1.5.4 Leak-off Tests & Procedures

Leak-off tests are to be performed on all wells below the casing shoe when drilling has to be
continued below the casing string. This also includes the conductor string if a BOP or diverter has to
be installed.
Data obtained from leak-off tests is important and must be taken with care as the data obtained is
used for well killing procedures. Calibrated pressure gauges must be used, covering various
pressure ranges and preferably mounted on a special manifold. Mud pump or rig gauges are not
accurate enough for these measurements and rig pumps are not suitable for conducting leak-off
tests. Rig pumps must be isolated from the wellbore pressures with the Lower Kelly Cock or the
IBOP during the conducting of a Leak-of test.
The leak-off test is to be carried out under the direct supervision of the Rig Superintendent
(Toolpusher), or the Driller and the Company Representative as follows:
Leak of Test procedure:
The following sequence should be adhered to when conducting leak-off tests:
1. Drill out the cement, cement plug and casing shoe plus 5m (or 15 ft) of formation.
2. Circulate and condition the mud until the mud properties (density, viscosity, etc.) are the
same, going in and out of the well.
3. Pull the bit back into the casing shoe.
4. Ensure the hole is full, then line up the test pump on the drillstring,

5. Pump mud slowly using a high pressure, low volume pump until the pressure builds up to
approximately half the anticipated maximum surface pressure.
a. Pump small volume to flush out all the lines and circulate mud all the way around;
b. Open the HCR valve on the choke line and close the valve directly upstream of the
choke,
c. Close the remote controlled choke,
d. Close the pipe rams around the drillpipe, and then
e. Close in the lower kelly cock.
f. Open the annulus between the current and the previous casing strings, where
applicable.
6. Pump uniform increments of 0.1 to 0.25 bbl. (15 Litres to 40 Litres) and wait for 2 minutes
or the time required for the pressure to stabilise. Note where low pressures are expected
and the volume is small, i.e. shallow weak formations, plot the pump strokes against the
pressure, this is a far more accurate method than using the displacement tanks which at best
are accurate to 0.25 bbls (40 ltrs).
7. Note and record the cumulative mud volume pumped (strokes), the final pumping and final
static pressure on the Leak-Off Test report as per section 8.6 of this manual.
8. Repeat items (5) and (6) and plot pressure versus cumulative mud volume (strokes) curves
for each increment of pumped volume.
9. Continue this procedure until the trend of the final pumping pressure curve deviates from that
of the final static pressure curve after an appropriate waiting time, or until a predetermined
pressure has been reached.
10. Keep the well closed in for a sufficient time (15 minutes) to verify that a constant pressure
has been obtained.
11. Bleed off the pressure back to the tank of the high pressure pump unit and note and record
the volume of any mud lost to the formation.
12. Check the casing pressure gauge and if zero, open the valve immediately upstream from the
choke and open the choke.
13. If the BHA contains a restriction, such as, mud motor, MWD or a bit with small nozzles, bleed
the well pressure back to the tank of the high pressure pump unit via the annulus, with the
HCR open, through the choke to avoid plugging the small flow areas. Measure the volume of
mud recovered.
14. Open the pipe rams, close the HCR and realign the choke manifold.
2.1.5.5 Maximum Allowable Annular Surface Pressure (MAASP)

For practical purposes, the maximum borehole fluid pressure that can be withstood at the casing
shoe is translated into a measurable pressure at the surface known as the Maximum Allowable
Annular Surface Pressure, (MAASP) and is determined from the leak-off test as described in section
2.1.5.4.
During a well control situation the highest pressure exposed to the formation just below the casing
shoe is when the influx is gas, and is just below the shoe.
If the MAASP is exceeded there is a risk of an internal Blow Out under the shoe. When the top of the
influx reaches the choke, the MAASP will reach its maximum value and may exceed the casing burst
pressure or the pressure rating on the blowout preventer equipment.
If the MAASP exceeds the casing burst pressure or the pressure rating of the BOP equipment,
whichever is the lower, will become the limiting factor for surface pressures.

Some control panels of remote controlled chokes have an automatic MAASP control which keeps
the MAASP constant as soon it is reached. It is a KCA DEUTAG requirement that such devices
must be disabled.
The maximum casing shoe, or weakest formation pressure, must be used to calculate the MAASP
before any well killing starts.
During well control operations and the influx is below the last casing shoe if the pressures indicate
that MAASP will be exceeded the following options should be considered:
1. Reduce circulation rates to reduce annular pressure losses (and adjust drillpipe pressure
accordingly)
2. Continue with kill procedures and exceed MAASP (in which case there is a risk of formation
breakdown)
3. Continue kill procedures but open choke as needed to limit casing pressure to MAASP (in
which case there is a high risk of an additional influx)
The choice between these options will depend upon the data available regarding formation
permeability, shoe strength etc.
Once the influx has passed the shoe the MAASP will be based on the allowable pressure ratings of
the following:
 The Casing burst pressure
 Wellhead rating
 BOP rating
It is therefore important to know the position of the influx at all times such that the appropriate
analysis can be conducted.
Unless there is a strong reason for not exceeding MAASP and risking breakdown at the shoe,
exceeding MAASP is the preferred option to opening up the well and allowing a further influx.
Prior to considering opening the choke, in order to not exceed MAASP, the following hidden safety
factors should be taken into account:
 The formation intake pressure obtained during the leak-off test is usually lower than the
formation breakdown pressure.
 The influx is dispersed in the mud and the actual position of the top of the gas is much
higher than the theoretical top of the gas when well killing commences. This means that the
influx will not reach the shoe as one bubble, but part of the influx is already inside the casing
shoe when the theoretical top of the influx should be at the shoe. The actual shoe pressure
is therefore lower than the calculated shoe pressure using the MAASP.
 Normally, after closing in a well on a gas kick, the shut in pressures will start to rise (for
nearly the same amount) with a certain speed due to the migration of the gas kick. When
starting to pump the viscosity of the mud mostly is decreasing and the speed of the gas
bubble is, besides the speed of pumping, increasing. This means that the gas bubble can
reach the casing shoe earlier than calculated.
 Leak-off tests are usually done in virgin hole. In principle, higher leak-off test results are
obtained with time due to the plastering effect of mud.
2.1.5.6 Kick Tolerance

Kick Tolerance is the maximum kick volume that can be taken into the wellbore and circulated out
without fracturing the formation at the weak point (normally the shoe).
The kick tolerance can be calculated as per the examples in section 8.13.1 of this manual.
The amount of influx volume that enters a well depends on:

 the reaction time of the crew to a well control situation

 the difference between mud weight and pore pressure
 the reservoir porosity and permeability
 the influx type
 the reliability and sensitivity of the detection equipment
 the well shut in procedure used
 the time of BOP closure
Although wells may have the same kick tolerance, this does not necessarily mean that the risks are
equal.
It is a requirement that the rig crew know what the kick tolerance is for the section being drilled and
how that relates to the abilities of the crew and equipment to detect a kick and close in the well.
3
If kick tolerances are above 50 bbl (4m ) no specific additional precautions are required. For kick
3 3
tolerances of between 25 bbl (4m ) and 50 bbl (8m ) the Operations Manager must be informed and
any additional precautions implemented as advised. For kick tolerances of below 25 bbl the Country
Manager must be advised.
2.1.6 Shallow Gas

Shallow Gas kicks have to be handled in a substantially different manner than Conventional kicks as
primary well control is the only means to protect the well from blowing out, with secondary well
control techniques not normally applicable in top hole drilling operations. All Shallow Gas aspects of
well control are therefore included in a separate Appendix 2 (Section 9) to this Manual.

3 Hardware Requirements
This section provides KCA DEUTAG’s selection, configuration, testing and maintenance
requirements and recommendations with respect to Kick Detection, Diverter, BOPs and associated
equipment. Only with adequately selected, configured and maintained equipment can well control
situations be adequately mitigated.
If any of the equipment categorised as “must” is inoperable and drilling with BOPs is under way the
Rig Manager must be informed.
All BOPs, choke manifolds, diverters, valves, risers, adapters and spools, hoses and flexible piping,
and associated equipment must have valid certification available at the rig site with copies being held
in the office.
3.1 Kick Detection (Hardware)
The following kick detection equipment is either mandatory or recommended in order to be able to
detect kicks as efficiently as possible.
3.1.1 Flowline Recorder

The flow line recorder is the best kick indicator because the flow line is the first point at which an
increase in flow from the well can be detected. When out of the hole, the flow recorder also makes it
impossible for the well to unload without warning.
All KCAD rigs (owned or managed) rigs must therefore be fitted with a Flowline Recorder.
3.1.2 Pit Volume Totaliser

After the Flow Line Recorder, the Pit Volume Totaliser (PVT) is usually the next significant kick
indicator since it gives warning of a change in the active mud pit level during drilling.
All KCAD rigs (owned or managed) must be fitted with a Pit Volume Totaliser with a means of
monitoring tank levels (including during trips) and transmitting this information to the driller.
3.1.3 Gas Detector

The gas detector used on most rigs extracts a continuous sample of mud from the ditch. The sample
is agitated to enable the gas to separate out and it then passes through armoured tubing to an
instrument in the on-site laboratory where it is analysed, measured and recorded.
All KCAD rigs (owned or managed) should be fitted with gas detection equipment.
3.1.4 Mud Density Recorder

The continuous mud density or Specific Density (SD) recorder is not an instrument which will give an
early warning of a kick as its first indication would be when the gas or salt-water cut mud reached the
surface. By that time, other instruments should have indicated earlier warning signs.
The SD recorder does, however, provide assistance during the subsequent killing operation by
recording the time of arrival of the kick at the surface, the extent to which the mud is gas - or fluid -
cut and the duration of the kick.
KCAD rigs may therefore be fitted with a Mud Density Recorder.
3.1.5 Mud Density or SD Recorder/Multi Function Recorder

In order to record appropriate information relating to well control planning or well killing operations a
Multi function recorder should be installed on all KCAD owned or managed rigs.
The recorder located in the dog house should be capable of recording up to six or more functions
simultaneously on a single strip chart. Typically, these include:
(a) Rate of Penetration
Preparation for, Prevention and Detection of Kicks Page 17 of 142

(b) Mud volume in pits

(c) Pressure on the annulus (or choke)
(d) Pump pressure or pressure on the drillpipe (or standpipe).
(e) Pump speed
(f) Rate of Circulation
(g) String weight
(h) Weight on bit
3.2 Diverter Equipment Requirements

Diverter Systems and their control systems are to be in accordance with API specifications or
recommended practices (currently API 16D latest revision, and API RP 53 latest revision).
3.2.1 Diverter Selection Criteria

The decision to install a BOP or Diverter on the conductor string depends on the expected formation
strength at the conductor shoe and the rig's capability to detect and handle an influx successfully.
The rig should be equipped with a diverter system instead of a BOP if circulating out such influx
would result in formation breakdown and subsequent cratering of the well.
All wells to be drilled where there is a possibility of shallow gas and a BOP cannot be installed for the
above reasons, must be equipped with a diverter system in an attempt to preserve wellbore integrity
and to enhance the safety of personnel.
If the decision has been made to drill for the conductor string with a diverter system installed on the
stove pipe, the diverter equipment to be used should be specified in the well programme together
with specific shallow gas procedures applicable for that particular hole section.
In development drilling where there is sufficient geological information available from surrounding
wells to determine that there is no shallow gas, a dispensation may be granted to avoid the use of
diverter equipment. However a diverter system is still recommended if there is a chance of colliding
with another well or if there is a possibility of penetrating charged sands from leaking or poorly
cemented casing strings.
3.2.2 Diverter Line Requirements

Flow restrictions in diverter systems must be avoided. Any restrictions, such as elbows and turns,
may lead to formation breakdown and cratering of the well in case of a shallow gas blowout.
Diverter studies have illustrated that well flows, during a shallow gas blowout diverted through a 12"
nominal ID diverter line, will not cause excessive diverter backpressures. Increasing the size of the
diverter outlet further will not reduce the diverter backpressure significantly. The minimum
recommended nominal ID of diverter outlets / lines is therefore considered to be 12".
The friction pressure loss across diverter lines is mainly determined by the size of the lines, not so
much by the length of the lines, unless small diverter lines are used. However, diverter lines should
be as short as possible, but long enough to conduct flow away from any obstacle in land operations.
Diverter lines should be straight, properly anchored (especially at the end of the lines), and sloping
down to avoid blockage of the lines with cuttings, etc. Where temporary diverter lines are run these
must be tied down with turfers or similar every 15ft to prevent movement if the diverter system is
used. Rig structure and/or cellar design may have to be modified to accommodate straight diverter
lines.
In principle two outlets are required on the diverter spool. They should face opposite directions to be
able to vent flow downwind of the rig. However, one outlet only may be considered, in case there is a
prevailing wind direction and the vent line extends a sufficient distance from the rig to permit safe
venting.

3.2.3 Diverter Equipment Specifications

The following must be considered when selecting diverter equipment:
1. The equipment must be selected to withstand the maximum anticipated surface pressures
and in accordance with API specifications or recommended practices.
2. The minimum rated working pressure of diverter equipment is based on the anticipated
backpressure during a shallow gas blowout and therefore largely depends on the size of the
diverter lines. The minimum rated working pressure of the recommended large bore diverter
line system is 500 psi (3450 kPa) WP. It should be noted that the dynamic forces are much
higher in the initial stage of diverting a well, when the expanding gas is forcing the mud out
of the diverter system.
3. Welded flange or hub connections must be used on diverter systems. Quick connections in
diverter lines are not allowed.
4. A diverter system can be a BOP stack system with a diverter spool, or a specifically
designed and developed diverter system. A faster closing diverter unit is preferred over a
large and slowly closing annular preventer.
5. The diverter and mud return lines should be separate lines, not partially integrated lines, to
avoid gas entering the rig system in case the separating valve between both lines fails to
operate properly.
6. Diverter valves must be full opening valves with an actuator (pneumatic or hydraulic). The
bore of the diverter valves must be equal to the bore of the diverter lines.
7. Each diverter system should incorporate a facility (including a check valve) to be able to
pressure and function test the system and to be able to pump water through the diverter
system.
8. The diverter control system should preferably be self-contained or may be an integral part of
the BOP accumulator unit and control system. If so it must be located in a safe area away
from the drilling floor and have the control functions clearly identified.
9. The diverter control system should contain the minimum of functions. Preferably, a one-
button or lever-activated function to operate the entire diverter system.
10. A 1-1/2" hydraulic operating line should be used for diverter systems with a 1-1/2" NPT
closing chamber port side. The hydraulic line for the opening chamber port may be 1".
11. All spare operating lines of the control system and connections which are not used should be
properly plugged off.
12. Control systems of diverters / annular preventers and BOPs should be capable of closing the
diverter and annular preventers within the following elapsed time specifications:
a. smaller than 508 mm (20") within 30 seconds, and
b. annular preventers of 508 mm (20") or larger within 45 seconds.
13. Diverter valves must be fully opened before the diverter element is completely closed;
Note that the installation requirements for wellhead and BOP equipment also apply to diverter
equipment.
3.3 Diverter Arrangements

If a stove pipe has been driven, or run and cemented into a pre-drilled hole, and a diverter has to be
installed for the next section, the recommended stove pipe diverter set-up is shown Figure 3-1
below.
The Stove pipe diverter system is only meant to divert flow away from the drill floor in case of a kick.
It should never be completely closed in and used as a BOP in an attempt to control the well.

29 -1/2 “ Bag type

preventer
Actuator
Diverter spool
Diverter line P P Diverter line
V
NR
e
ll lin
Ki
26“ or 30“ Stove pipe/

Marine conductor
P Valve (pressure operated, remote

controlled, fail safe Open)
Figure 3-1 Stove Pipe Diverter Configuration
Once the Conductor has been set the recommended conductor string diverter set-ups are shown in
Figure 3-2 below.
The minimum requirement of diverter equipment is shown in Option A. This system is usually
installed when it is highly unlikely to encounter shallow gas, but other factors may cause the well to
flow (i.e. colliding with nearby wells, drilling into formations which have been charged-up at a later
stage, etc.).
Option B may be used as an alternative in case there is not enough space underneath the drill floor
to accommodate Option C.
Option C is used for wells with possible shallow gas and is the preferred diverter set-up.

When a pipe-ram type preventer is included in the diverter system, casing rams should be installed
and function tested prior to running and cementing the surface casing string (see Figure 3-2, Option
C).
20“ Bag type

preventer
P Valve (pressure operated, remote

controlled, fail safe Open)
20“ Bag type Pipe Rams
preventer
20“ Bag type P P

preventer BL/SH NRV BL/SH
NRV Choke Kill Choke
Kill Rams Rams line
line line line
Actuator Actuator Actuator

Diverter Diverter Diverter spool
Diverter line P spool Diverter line P spool P Diverter line Diverter line P P Diverter line
P Diverter line
NRV
Kill
line
Conductor Conductor Conductor
Casing Casing Casing
String String String
housing housing housing
Stove pipe / marine Stove pipe / marine Stove pipe / marine

conductor conductor conductor
OPTION A OPTION B OPTION C
Figure 3-2 Recommended Diverter Conductor String Diverter Set-ups
3.4 BOP Equipment Classification and Selection

KCA DEUTAG’s minimum standards for well control equipment and control systems must never be
lower than the relevant API specifications or recommended practices (currently API 16D latest
revision, and API RP 53 latest revision) or the standards included in this document.
Well control equipment falls into five basic working pressure classifications:
1 2000 psi 138 bar 13800 kPa
2 3000 psi 207 bar 20700 kPa
3 5000 psi 345 bar 34500 kPa
4 10000 psi 690 bar 69000 kPa
5 15000 psi 1035 bar 103500 kPa
The following factors are to be considered when selecting Well Control Equipment

1. The equipment must be selected to withstand the maximum anticipated pressures and
temperatures.
2. The BOP stack shall consist of remotely controlled equipment capable to close in the well
with or without pipe in the hole.
3. Welded, flanged or hub connections must be used on all pressure systems, exposed to well
pressure. Threaded connections must not be used for pressures above 2000 psi (13800
kPa) and diameters above 1 inch.
4. When operating in an area where sour service equipment is required the complete high
pressure BOP system must consist of materials resistant to sulphide stress cracking (super
trim).
5. Dedicated kill lines must not be smaller than 2" nominal and should be fitted with two valves
and one NRV (check valve). Choke lines should not be smaller than 3" through bore and the
outer valve of each choke line should be hydraulically operated.
6. During drilling and workover operations the BOP should be equipped with one shear ram
capable of shearing the DP in use and to provide a proper seal. If the shear/blind rams are
unable to shear through the string in the hole then this must be made clear that these rams
are only to be used as blind rams and a notice posted on the drillfloor accordingly. If shear
rams are unable to shear the pipe used the Country Manager must also be informed.
7. As per API 16D, closing systems on surface BOPs must be capable of closing any ram
preventer within 30 seconds. For annular preventers up to 20" the closing time must not
exceed 30 seconds, and 20" and more the time must not exceed 45 seconds.
8. All master and remote operating panel handles should, at all time, be in the full closed or
open position. All four-way valves should be either in the fully open or closed position. They
should not be left in blocked or centre position.
9. All spare operating lines and connections, which are not in use in the system, should be
properly plugged off. The valves should be in open or closed position.
As the requirements vary from different Operating Companies, as does local legislation, a “standard”
BOP configuration does not exist. The BOP configurations shown below illustrate how the five basic
working pressure BOPs should be equipped unless otherwise agreed and documented with the
Operator.

3.5 BOP Arrangements

The following sections show the KCA DEUTAG recommended BOP configurations. Specific
operations and Operator requirements may differ and the actual configurations are to be agreed with
the Operator prior to the commencement of operations. The BOP requirements of each well must be
suitable for the specific application.
Adequate redundancy must be in place in keeping with the equipment specifications, the well
programme and emergency contingencies.
Ensure the shearing capabilities for the blind/shear rams meet the requirement for the drillpipe in use
and if they cannot shear the pipe in use then they must only be used as blind rams. This must be
communicated to all appropriate personnel and a notice to that effect posted on the drillfloor. If the
shear rams cannot shear the pipe in use the Country Manager must be informed
Note on each BOP configuration 2 side outlet valves should be installed on the last casing head
housing. These will allow access below the lowermost rams if required. All other casing annuli
should have a single valve and pressure gauge to allow the annulus pressure to be observed during
well operations.
3.5.1 BOP 13800 kPa 2000 psi without a Casing Spool
Notes:
1. The manual inner valve for the kill and choke line to be open and the outer (working) valve is
to be closed during drilling operation.
2. The valves on the casing head housing must be closed.

3.5.2 BOP 20700 kPa 3000 psi 34500 kPa /5000 psi without a Casing Spool
Notes:
to be closed during drilling operations.
2. The valves on the casing head housing must be closed.

3.5.3 BOP 34500 kPa 5000 psi with a Casing Spool (Dual Ram option)
Notes:
2. The valves on the last set casing spool must be closed.
3. Consideration should, however, be given to deploying a 3 ram stacks as per 3.5.4 below with
a blind or shear rams in the middle cavity. The drilling spool ensures that the tooljoint is
below the shear rams and pipe can be sheared, after being hung of on the lower pipe rams.
Ram to ram stripping can be performed if required between the uppermost and lowermost
rams as it provides sufficient clearance for the tooljoints

3.5.4 BOP 34500 kPa 5000 psi and/or 69000 kPa 10000 psi with Casing Spool
Notes:
3. On 3 ram stacks KCAD’s normal standard is to utilise blind or shear rams in the middle
cavity. The drilling spool ensures that the tooljoint is below the shear rams and pipe can be
sheared, after being hung of on the lower pipe rams and ram to ram stripping can be
performed if required between the uppermost and lowermost rams as it provides sufficient
clearance for the tooljoints.

3.5.5 BOP 103500 kPa 15000 psi.
.
Notes:

3.6 Control System Requirements for Surface BOP Stacks

The minimum requirements for Surface BOP Stack control systems are as per API 16D and as
follows:
1. Control system for BOP stacks shall have one independent automatic accumulator unit rated
for 3000 psi 20700 kPa WP with a control manifold, clearly showing open and closed
positions for preventers and the hydraulic operated kill / choke line valves.
2. The Control Units are to be equipped with a 0- 3000 psi 0 - 20700 kPa regulator valve (TR-5)
which will not fail open causing complete loss of operating pressure.
3. The minimum accumulator capacity must be as per API 16D i.e. without recharging, the
accumulator capacity shall be adequate for closing the annular and all ram preventers and
opening the valves on the side outlet and have enough spare capacity to further close the
annular and a set of rams while still holding the side valves open against full rated BOP
pressure.
4. The control unit must be located in a safe area, and it should be equipped with low level and
low pressure warning alarm.
5. All installations should have one remote control panel, appropriately sited, in addition to the
closing unit, clearly showing open or closed for each function.
6. The operation of the BOP stack functions must be possible within the work area of the driller.
7. Control hoses are to be high pressure fire-resistant with a working pressure of 3000 psi
20700 kPa. Steel swivel joints are also acceptable.
3.7 BOP Testing requirements
3.7.1 Pressure Test Criteria.

All BOP test must be carried out under the direct supervision of the Rig Superintendent or Asst Rig
Superintendent. (Toolpusher or Night Toolpusher).
All BOP tests must be carried out with water, unless the Drilling Programme dictates otherwise and
the Driller must maintain chart recordings of all pressure tests.
A low (200 to 300 psi) (1400 to 2000 kpa) and high pressure test is to be undertaken with the high
pressure test at the maximum anticipated wellhead pressure or 80% of casing burst pressure,
whichever is the lower.
The acceptance criteria for all pressure tests is 5 minute stabilised (i.e. no pressure drop) for the low
pressure test and 10 mins stabilised for the high pressure test. Signed off charts are to be retained.
If any component fails to hold the test pressure, that component will be repaired or replaced, and re-
tested.
Each rig is to have its own detailed pressure testing procedure which is to include the pressure
testing sequence and refer to a rig specific BOP/valve schematic with numbered valves.
All gauges used for pressure testing should have an appropriate working range (i.e. test pressure
should be between 25% and 75% of the range of the gauge) and all gauges used in well control
operations must be calibrated at a minimum of an annual interval.
3.7.2 Frequency of Testing

The BOP, wellhead, choke manifold, and related equipment are to be pressure tested every 14 days
or on the first trip after a 14 day interval with a maximum duration between tests of 21 days.
The BOP and associated equipment are to be function tested upon initial installation and on each trip
after 7 days with the period between function tests to not exceed 14 days.
Each rig is to have its own Function Test procedure.

3.7.3 Accumulator and Control System Tests

The accumulators precharge pressures are to be checked prior to the commencement of drilling
each well or at a frequency not exceeding 3 months, or after any repair of the system. The operating
lines to the BOP components shall be pressure tested to rated working pressure at least every 3
months.
3.8 General Maintenance Requirements for Wellhead and BOP Equipment

Routine BOP maintenance must be undertaken in accordance with this manual, the manufacturers
requirements, approved PMRs, and at the specified frequency of the approved PMRs.
The following minimum maintenance and overhaul requirements apply to all BOP and Control
equipment
1. Every 5 years, all BOPs and related equipment must be overhauled. This also applies to all
valves used in the side outlets and equipment up to and including the choke manifold as well
as any other related equipment such as diverters. After re-assembling, a body test should be
performed and where witnessed by a competent party. The test pressure used must be to at
least the working pressure and, where welded repairs have been undertaken, to the rated
test pressure.
2. Maintenance on a routine basis should include that after each well the BOPs are opened,
rams removed and all cavities and related equipment is checked for wear or damage.
3. After working on BOPs ensure ring grooves are clean and new and clean ring gaskets of the
correct type and pressure rating are installed. Ring gaskets are NOT reusable.
4. Ensure the rams are installed correct way up.
5. All connections, valves, fittings, piping, etc. subject to well pressure, must be flanged,
clamped or welded and have a minimum working pressure equal to the rated WP of the
BOP.
6. Valves must be of a flush through type when in open position. Screwed valves and fittings
are only acceptable up to 2000 psi 13800 kPa WP.
7. When using chiksan piping use welded type.
8. All bolts, nuts, fittings etc. must be installed and tightened to the correct torque. (The use of
torque wrench is recommended) All connections must be pressure tested before drilling
operations are is resumed.
9. All manually operated valves must be equipped with hand wheels, correctly marked/aligned
and be ready for use, including the valves on the wellhead.
10. On exploration wells, ram type preventers on the BOP may be installed with extensions and
hand wheels connected, and are ready for use.
11. Wellhead side outlets must not be used for killing purposes. Side outlets must be closed and
on one side and a pressure gauge must be installed.
12. Kill lines must not be used for routine fill-up operations.
13. All pipelines must be securely anchored and fitted with snub lines across the connection.
14. Choke lines should be as straight as practicable and firmly anchored to prevent excessive
whip or vibrations.
15. When freezing conditions are anticipated ensure the kill and choke lines and the choke
manifold must have all the water drained and replaced with water/glycol mixture sufficient to
prevent ice plugging and damage.
16. Ensure the shearing capabilities for the blind/shear rams meet the requirement for the
drillpipe in use and if they cannot shear the pipe in use then they must only be used as blind

rams. This must be communicated to all appropriate personnel and a notice to that effect
posted on the drillfloor. If the shear rams cannot shear the pipe in use the Country Manager
must be informed. An actual shear test is advised before installation of the BOP stack with
the drillpipe size and grade to be used. To obtain maximum shearing capabilities the
installation of large bore shear bonnets and tandem boosters on the closing side of the BOP
can be considered.
17. Ensure that the manufacturer's BOP manual is followed and no alterations are made without
either Manufacturers or E&M Functional written consent. NEVER weld cut or modify any
BOP equipment.
18. Original Equipment Manufacturer spares must be used unless a dispensation has been
made by E&M Function in accordance with their and GSM relevant Group Standards.
Sufficient consumables and spares stocks are to be held onsite.

4 Well Control Principles

The prevention of a kick (i.e. maintaining Primary Well Control) is always the best well control
method and therefore an understanding of the causes of kicks is essential. For further information
see the KCA DEUTAG DART Well Control Training Manual.
The following conditions must always be met :
(a) The hole must, at all times, be kept full of mud of the agreed mud density.
(b) The correct BOP equipment must always be installed on the well, operational, and be
suited to the specific conditions.
(c) All relevant personnel on site must understand and be experienced in the use of the
installed BOP equipment.
(d) All drilling personnel on site must be constantly alert for the danger signs and be able to act
quickly and correctly when they occur.
This section defines KCA DEUTAG’s Barrier Policy, Primary, Secondary and Tertiary Well Control and
then describes the causes and conditions of kicks in order that the implementation of relevant
operational safety precautions can be fully understood.
4.1 Barrier Policy
During any well operations after surface casing is set a minimum of two independent barriers must
be in place.
A well barrier can be mud hydrostatic (providing there are no losses during drilling and the well is
shown to be overbalanced), a ram-type BOP, an annular BOP, a cement plug, casing, casing float
valve, mechanical plug, subsea safety valve, permanent packer, tubing or kill-weight fluid. (A
mechanical barrier needs to have been tested to qualify as a barrier).
If the primary barrier is lost then a second barrier must be in place, ready to be closed as required.
When only one barrier remains, normal operations will cease until a second barrier can be re-
established.
(Note: In some areas it may not be possible to drill ahead without losses, but techniques have been
developed to allow progress whilst minimising the risks. In these cases a dispensation will be
required, showing an assessment of the risks and the precautions to be taken.)
4.2 Primary Well Control

Prevention of a kick (i.e. maintaining Primary Well Control) is always the best well control method.
Primary well control is maintained through the use of drilling or workover fluid with a specified density
which provides sufficient pressure in order to prevent an influx of formation fluid or gas into the well
bore, without breaking overlaying formations.
Primary well control is the first line of defence and it is therefore most important to ensure that strict
procedures and practices are followed at all times in order to maintain primary well control.
There are seven principal causes which may result in or contribute to the loss of primary well control
and these, together with the associated preventative measures, are described in section 4.5 below.
For top hole drilling (with the associated potential for shallow gas), Primary well control is the only
means to protect the well from blowing out, because secondary well control techniques are not
normally applicable in top hole drilling operations.
A drillpipe back pressure valve must be installed in the drillstring while drilling or opening hole until at
least the first 1000ft (300m) of hole has been cased, unless otherwise agreed with the Client.
4.3 Secondary Well Control
Secondary Well Control relates to the situation where, for whatever reason, pore pressure,
(formation pressure) exceeds BHP resulting in Primary Well Control being lost. Early recognition of

the associated warning signs as described in section 5.2 are critical in effectively controlling the
situation via the Secondary Well Control equipment and appropriate well killing procedures.
When primary well control is lost and an influx may occur (kick) the blowout preventer equipment
(BOPs) must then be used to enable the 'kick' to be controlled by one or more of the 'kill procedures',
outlined in this manual.
4.4 Tertiary Well Control
An emergency well control situation exists when both Primary and Secondary Well Control procedures have
been unable to control the influx of fluids into the well, or another unusual well control situation arises
requiring specialist techniques, expertise and/or equipment.
4.5 Causes of kicks
The main causes of kicks and therefore losing Primary Well Control are the following:
1. Failing to fill the hole by controlling the volumes and going in and out properly when tripping
2. Swabbing in a kick while tripping, (moving string too fast). Particularly in situations with
balled up stabilisers and overpull
3. Insufficient mud density
4. Abnormal formation pressures
5. Lost circulation
6. Shallow gas sands
7. Excessive drilling rates in bearing sands
Note: The most common causes of kicks are attributable to items 1 and 2 above.
The mitigation actions required to reduce the potential for kicks in each of the above scenarios is
described below:
4.5.1 Failing to Fill the Hole Correctly when Tripping

The key word here is “correctly”. Many wells have been lost even though the hole was ‘filled’. A
swabbing pressure is generated when the drillstring is moved. If drilling close to balance, pulling too
fast, the drilling fluid is too viscous, the stabilisers are balled up, or pulling overload in tight sections
of the open hole, these pressures will be large. In slim hole situations all this effects occur faster
(slim hole means everything smaller than 7”).
The formation fluid can be drawn into the wellbore from below the bit whenever the hydrostatic head,
minus the swabbing pressure, falls below the formation pressure, regardless of whether the hole is
topped off (kept full) or not.
The correct procedure is to ensure that a barrel of fluid at least replaces each barrel of steel
removed. On all occasions of tripping, an accurate trip sheet can detect any discrepancy in this hole
fill. Ensure that the trip tank measuring mechanism is working accurately at all times, and especially
prior to any trip. Do not start to pull the first stands, while the trip tank is not ready to use
One reliable method of ensuring the borehole is always filled correctly is through the use of a
calibrated trip tank ("Possum Belly" tank), a tall small diameter tank with a pump which continuously
circulates mud across the wellhead in a closed circuit from the trip tank.
All KCA DEUTAG drilling rigs, and those workover rigs operating on wells capable of natural flow,
must be equipped with trip tanks and these are to be used during tripping of pipe.
4.5.2 Swabbing In a Kick While Tripping

When the drillstring is pulled up out of the hole during a trip, mud has to flow down past it to fill the
space. If pulled too quickly, it acts like a negative 'annular pressure loss' and the total pressure
exerted by the fluid column is reduced slightly.

This reduction in pressure is called a swabbing or suction effect and it is created in a borehole when
the pipe is pulled out too fast. This reduces the bottom hole pressure on the well section below the
bit. Balled up BHA and tight spots in the open hole section will increase this effects.
If the bottom hole pressure (BHP) is reduced to the extent that the overbalance is lost, the formation
contents will enter the wellbore. The chances of this occurring are much greater when the bit is close
to bottom, therefore extra care must be taken in the initial stages of a round trip.
The dangers in this operation are two-fold and cumulative. The very action of swabbing pulls mud
out of the hole. If formation fluids enter the well bore, they will also displace mud out of the hole.
Bottom hole pressure fluctuations, which could cause a kick, are likely to occur whenever the pipe is
moved in the hole.
The swabbed in kick is particularly hazardous since often a brief swabbing episode is followed by
normal tripping practice.
If the small discrepancy in string displacement volume is not noted, it will probably be overlooked. An
overall influx of gas, for instance, swabbed into an open annulus, may only displace a very short
head of mud.
The net decrease in BHP is small and likely to be well below the normal range of 'trip margin'
overbalance. No further flow of gas will occur into the well and, if the well is shut in, no pressures will
show on either DP or casing gauges since the well is still in balance.
However, gas will slowly migrate up the well and expand as it does so. At first the expansion is very
slow and it is unlikely that any significant flow will be seen at the surface unless the influx is very
large, or very close to surface. The possibility to detect a kick by its expansion will be normally first
given when the gas bubble has reached the middle of the well.
In any event, any gas in the hole will reach the surface eventually. Even if the well does not flow
while tripping out it can flow when the bit is returned to bottom and the gas retained in the hole is
then circulated out.
The greatest swabbing action normally occurs when tripping through freshly drilled hole due to the
filter cake being of little substance and liable to wiped clean by the action of the bit. Swabbing can
also occur in the casing (especially with balled up BHA).
The effects of swabbing or surge pressure are made more serious by:
(a) High pipe speed when pulling out (pressure decrease) or when running in (pressure
increase).
(b) Small clearance between the drill pipe/drill collars/bits and the wall of the hole.
(c) Extreme mud properties - density, viscosity, yield point, gel strength, water loss.
(d) Plugging of the bit nozzles.
(e) Balling up of the bottom hole assembly (bit, stabilisers, etc.).
Of the major causes of kicks i.e. failure to keep the borehole full and swabbing, these are most
important because about 70 % of all blow outs have occurred on round trips.
There is also the possibility that most, or all, of the drillstring will be out of the hole when the kick
situation becomes apparent, which complicates and adds to the risk of the killing procedure.
Preventing kicks under these circumstances requires the Driller and his crew to be always ALERT
AND WATCHFUL. They must know at any time during a trip:
(a) What volume of mud should be in the trip tank and mud pits.
(b) Always maintain the mud flow and mud volume indicating and recording instruments in
good working order.
(c) Constantly monitor the flowline, mud pits, trip tank, indicators and recorders.

Whenever there are signs that the borehole is taking less than the calculated volume of mud, (this
decision can normally be made within the first ten stands pulled),
(d) the drillpipe should immediately be run back into the hole - to bottom, if possible,
(e) the hole circulated clean and a flow check made.
The Rig Supt or Asst Rig Supt (Toolpusher or Night Toolpusher) must be on the drillfloor for the first
10 stands of any trip to witness the commencement of tripping operations and until he is confident
that the hole is taking the correct volume of fluid.
4.5.3 Insufficient Mud density

The hydrostatic pressure exerted by the column of mud in the hole is the primary means of
preventing kicks.
Insufficient mud density can result from:
(a) penetration into an unexpected, abnormally high-pressure zone, or
(b) by deliberate balanced or underbalanced drilling methods.
The benefits of keeping the mud density as low as possible include:
(a) Increased rate of penetration.
(b) Minimising the possibility of differential sticking of drillstring.
(c) Creating a small filter cake.
(d) Pumping water pills while stuck in salt formations.
Other circumstances where insufficient mud density is brought about accidentally include:
(a) Contamination of the mud by water from a wash hose, a leaking valve or water pipe.
(b) A leaking valve or wrong switching of tanks in the surface mud system.
These circumstances can only be avoided by the continual alertness of Mud Tester, the Driller and
his crew.
The benefits for the lower mud density outlined above require them to pay special attention if the
relatively small overbalance is to be maintained and kicks avoided.
Note: A kick can be the result of too low a mud density; conversely, a kick can be the cause of too
low a mud density.
4.5.4 Abnormal Formation Pressures

Abnormal pressures and their causes are discussed in section 2.1.5.2 and the DART Well Control
Training Manual. The consequences and what action must be taken depend on what caused the
abnormal pressure, and whether the abnormally pressured formations are permeable with mobile
formation fluids.
If the abnormal pressure was caused by under compaction, and a stable impermeable formation is
penetrated, there is no benefit to weighting up. However, even if the formation is impermeable but it
is also unstable (sloughs into the wellbore) then the mud might be weighted up to reduce drilling
problems.
It is not uncommon, however, for a porous and permeable formation to also be in contact with an
under compacted and over pressured shale. This well will kick unless the hydrostatic pressure of the
mud at least balances the formation pore pressure. In this regard, the tendency to kick is the same
as for all other causes of abnormal pressure listed in section 2.1.5.2
When these formations are penetrated, this almost invariably results in the formation pore pressure
exceeding the bottom hole pressure with a high possibility of a kick occurring. All possible steps
should be taken to anticipate and guard against it.

Drilling personnel rely on the Geologist and/or Drilling Engineer and the Mud Logger or Well Logger
to warn them of possible high-pressured formations. This is done via the Drilling Programme from
offset well records. Once drilling commences, it is done on the basis of evidence accumulated as the
well progresses.
For the under compacted formations, since the transition from normal to high pressure formations
usually occurs via a transition zone of which the thickness may or may not be predictable, the
Engineer or Mud Logger can also assist in forecasting the latter by analysing changes which occur in
the drilling variables and by analysing the shape, character, and volume of formation cuttings
throughout this transition zone.
By gradually increasing the mud density prior to reaching an anticipated high-pressure zone, there is
a greater possibility that primary control can be retained should signs of a kick appear.
Generally, whenever a permeable zone containing fluids is pressured above the normal gradient,
then appropriate mud densities should be run.
4.5.5 Lost Circulation

Loss of circulation is a very serious drilling problem and every effort should be made to prevent its
occurrence. If the loss of mud to natural or artificially induced fractures is sufficiently great, then all
returns from the well can cease.
If the level of mud in the well annulus drops, it will lower the hydrostatic pressure and may lead to an
influx or kick. The influx can be from an upper or a lower formation which will start to flow into the
well, then either down or up to exit into the weaker or broken down formation.
This type of kick may rapidly become very severe since a large influx can occur before any rise in
annulus. Should this occur, and if mud supplies are limited, the annulus must be filled with water or
any other available fluid at maximum rate to maintain the best possible hydrostatic head.
Note: A record of the water pumped is essential in order to estimate the BHP if returns are
regained.
Large losses into one formation combined with high-pressure flow from another usually results in an
underground blow out. If the loss zone is near or can communicate with the surface which could lead
to broaching and possible cratering around the wellbore and the abandonment of the well.
Great care is necessary, where known lost circulation zones exist, to plan the casing string setting
depths to ensure minimum risk.
Signs of lost circulation while drilling must receive immediate attention. Depending on the
seriousness of the losses, circulate LCM, followed if necessary by cement, with the minimum of
delay. An adequate stock level of lost circulation materials must be discussed at the planning stages
and then this level always be maintained on site.
Losses can also occur following high pressure breakdown of a formation while circulating out a kick.
This can be a particularly dangerous situation. Safety Factors when killing a well should therefore be
achieved by additional backpressure rather than additional density as this extra margin can be
manipulated more readily than mud properties.
4.5.6 Shallow Gas Sands

Shallow gas is gas encountered in a well, which cannot be closed in, because well shut in pressure
combined with the hydrostatic head of the fluid in the well bore will probably result in a formation
breakdown and subsequently crating of the well.
If BOP protection and normal well killing procedures can be applied the gas is not considered to be
shallow gas. Normally shallow gas occurs while drilling for the conductor and is normally high-
pressure gas with little volume.
In a shallow well, gas can travel to the surface very rapidly and with little warning. While drilling
shallow hole, the short surface casing string is set in a relatively weak formation and it is normally

necessary to divert the flow rather than to shut the well in and risk fracturing the casing shoe with the
possibility of gas coming up around the outside of the well (broaching).
As bottoms up time are very short, the Driller and crews must be very alert to all the early signs of a
kick.
The flow sensor may be the only piece of equipment to give a warning early enough. Pit level gains,
although positive indication, are generally too late to indicate flow in this situation. Swabbing can
easily reduce hydrostatic head.
Also, there may be just sufficient ‘core’ gas, or gas released from the drill chips of the drilled
permeable gas sand, to reduce the ECD (equivalent circulating density) below the formation pore
pressure as the chips are transported to the surface.
There is only one method of attempting to kill a shallow gas kick and that is dynamic killing, which
means that the hole is filled with mud or water in excess to the production rate of the formation. It is
recommended to speed up the pumps to the maximum possible rate.
At first sign of flow, the following action is required:
(a) Open diverter valve and close diverter element.
(b) Pump mud immediately at maximum pump rate and be prepared to abandon the location
(c) If the well continues to flow, pump heavier mud at maximum pump rate (generally 0.12 Kg/l,
1 ppg, 1.175 kPa/m).
It is recommended when drilling in shallow gas areas to have at least the pilot hole content premixed
and ready for pumping.
If the well continues to flow after the heavy mud has been pumped, carry on pumping mud at a
maximum rate. When running out of mud, change over to water. Do NOT reduce the pump speed.
Depending on the severity and type of flow, condition of the diverter equipment and availability of
water, the location may need to be abandoned at this stage.
Due to the complexities of Shallow gas planning and precautions a separate section (Appendix 2)
has been included in this manual.
4.5.7 Excessive Drilling Rates in Gas Bearing Sands

When a formation containing gas is drilled, the mud becomes gas cut due to the breakout of gas
from the cuttings as they are circulated to the surface.
The extent of gas cutting is related to the total gas content of the rock, the rate of penetration and the
length of time the cuttings are in the whole (bottoms up).
The gas in the hole is subjected to normal hydrostatic pressure. The released gas, as it percolates or
is circulated up, will, under Boyles Gas Law, expand progressively, as the pressure gets lower and
lower.
In turn, the expanding gas pushes mud out of the hole faster than it is being pumped into the hole so
the annular hydrostatic pressure falls.
Small quantities of gas can cause a large reduction in mud density as measured at the flow line at
surface.
Use of a degasser removes gas before the mud is re-circulated around the well, otherwise, the
amount of gas in the mud rises and a progressively greater reduction in hydrostatic head occurs.
4.5.8 Human Failure

Coupled with the previously described causes of kicks is another important one: human failure. This
possibility can never be eliminated. The chances of it happening can be considerably reduced by
ensuring that all wellsite personnel:
(a) know the causes and effects of kicks,

(b) know the steps to be taken to prevent kicks from becoming blowouts,
(c) are properly and regularly trained and tested,
(d) remain constantly alert for all signs of danger, and develop a sense of, or a feel for, the
onset of a "kick".
(e) Competence assurance.
The rig crew will then be able to respond correctly and automatically whenever a positive sign of a
kick occurs.

5 Preparation for, Prevention and Detection of Kicks

5.1 General Preparation Requirements in order to be prepared to handle a kick
In order to limit the likelihood of taking a kick and in order to be prepared to handle a kick efficiently
and effectively, a number of Pre-kick preparation actions are necessary.
Ensure drillfloor personnel know which tool to use to shut-in the drillpipe while tripping, the kelly cock
or the Gray valve.
5.1.1 Equipment Checks and availability

The following equipment checks must be made to ensure that on any sign of a kick the well can
efficiently be closed in:
 Ensure equipment for blowout prevention is always operational and available.
 Ensure an up-to-date pre-kick record (kill-sheet) is available at all times.
 Check the capacity of the Koomey unit is in accordance with API RP 53 and API 16D (i.e. in
accordance with section 3.6 of this manual).
 Check that the following are present:
a. Adequate fluid in the accumulator
b. Kelly cock (in open position) with wrench on the rig floor
c. Crossovers on the kelly cock for tubulars in the drillstring or tubing
d. Gray valve (non return string valve) and matching circulating sub and
crossovers, on the rig floor
e. Back-up circulating equipment (hose and/or chiksan lines) hooked up to
standpipe manifold.
f. Short pup joint (to connect to top drive).
 Ensure the pit level and trip tank level indicators and the flow show are properly adjusted
and functioning. Ensure the audible alarm in the panel by the Driller is working and always
switched on.
 Ensure the well remains filled via the trip tank at all times.
 Place the wrench for closing the kelly cock within hands reach.
 Ensure the valves on the BOP, kill lines; choke lines and choke manifold are correctly lined
up according to the KCA DEUTAG Shut-in Procedure (or procedure agreed between KCA
DEUTAG and the Client).
 Ensure the indicators for monitoring closing / opening of BOP rams is working correctly.
5.1.2 Flow Checking

Flowchecking is one of the main methods of indicating that the well is not flowing. Whilst it is
emphasised that the Driller / Assistant Driller can perform flow check any time they feel this is
necessary, flowchecks must be undertaken at the following times during operations:
 Prior to a trip
 Prior to pumping a slug
 During a trip when:
o Collars are at the shoe,
o Collars are at the BOP
o Improper hole fill is observed

 During drilling when:

o Mud weight changes
o When a change in flowrate is observed
o When a change in pit level is observed
o When a drilling break is observed (unless the area is known to be trouble free)
o When there are signs of water or gas cut mud
Normally a flow check will take around 15 minutes, however in a lot of cases a flow check has taken
much longer time to recognise a flow. A negative flowcheck can be assumed if zero flow is noted for
a period of 10 minutes.
5.1.3 Determining the Maximum Allowable Annular Surface Pressure (MAASP)

During killing operations, the maximum allowable hydrostatic pressure opposite the weakest
formation is a determining factor and must be known at all times (see section 2.1.5.5)
Unless evidence is available to the contrary, the weakest point is taken to be the formation
immediately below the shoe. This pressure is:
MAASP = (formation breakdown strength gradient at shoe, minus hydrostatic mud gradient),
multiplied by (vertical distance from surface to shoe).
The formation strength at the shoe will either have been determined by a Formation Strength Test
(or Borehole Integrity Test, or Leak-off Test, as it is sometimes known) performed after drilling out
the shoe and the cement; or it will be known from previous drilling experience in the area.
The hydrostatic head due to the mud column will vary with the mud gradient. The MAASP must
therefore be re-calculated whenever the mud density changes.
For example calculations regarding calculating the MAASP see Appendix 1
5.1.4 Slow Circulation Rate Friction Losses (SCR)

The slow circulation rate friction losses will change with changes in mud properties, changes in bit
nozzle size, changes in the drillstring configuration, including the ID and OD of tubulars and the total
length.
Before drilling with a new bit, at the beginning of each shift and after every 1000 ft (300m) has been
drilled, the Driller must establish new SCR pump pressures at the following times:
 at the beginning of each shift
 when any of the fluid properties change
 when drillstring or bit characteristics change
 when pump liners are changed
 after each 1000 ft (300m) drilled
These pressures are only used for comparison. For calculating purposes when a kick actually
occurs, the observed Pst (Standpipe pressure) at that time is always used.
5.1.5 Establishing the Barite Mixing Capacity of the Rig

Since time is of the essence during a well control operations, it is essential to know beforehand the
rate at which barite can be added to the mud over a continuous period of perhaps one or two hours,
so that the pump speed for circulation (which should remain constant throughout the operation) will
not be set too high.
5.1.6 Capacities and Strokes for Drillstring and for Annulus

All of the information required regarding well volumes, pipe capacities and strokes required to
circulate various parts of the well must be available and filled in the Surface BOP Kill Sheet.

5.1.7 Pre-kick sheets

In the event of the unexpected loss of Primary Well Control, and order to avoid unnecessary delay in
taking action to control a kick and kill the well, certain relevant information must be kept up to date
and available at the wellsite at all times.
The above information is therefore to be recorded on the International Well Control Forum (IWCF)
Surface BOP Kill Sheet or equivalent form approved by the KCA DEUTAG or the Client. Examples of
the IWCF forms are shown in Appendix 1 and the appropriate forms are available via the BMS.
These Kill Sheets are available for vertical and deviated wells. The units of measurement for both a
vertical and a deviated well kill sheet are available in “Field” (Bar/litre), SI (metric) and “Field” (API)
via the BMS .
The IWCF Surface BOP Kill Sheet must be constantly up-dated during drilling operations to amend
depth and mud-dependent data.
Typically, this update will be done
 at the beginning of each shift
 whenever 1000’ (300m) of hole has been drilled
 if the mud density has been changed
 whenever any change occurs in any relevant parameters such as casing and hole size, mud
properties / gradient, drill string configuration, bit nozzle sizes, formation characteristics etc.
5.2 Indications that a kick may be in Progress while Drilling
In order to reduce the impact of a kick, simplify any well killing procedure and limit the seriousness of
a well control incident , it is necessary to limit the volume of any influx to as small a volume as
possible. It is therefore necessary for the well to be shut in as soon as possible after the signs of a
kick become evident. All relevant drillcrew personnel must therefore be familiar with the signs of a
kick and advise the driller accordingly.
General signs that a kick has been taken are individually discussed in detail below. By definition
many of the signs of a kick into the well relate to identifying that there is a fluid flow into the well.
Whilst taking the appropriate action the crew should also ensure that there is no leaking or wrongly
positioned valve on the surface equipment which may indicate a kick when there is not one.
Extra care should be taken during the following situations as these can mask a kick:
(a) Making a connection.
(b) Mud density adjustments while drilling.
(c) Partial lost circulation.
(d) Solids control equipment and degassing mud.
(e) Spills and leakages in surface equipment.
(f) Drain back.
(g) Pump start-up and shut down.
(h) Transfer of mud between the active tanks and mix/reserve tanks.
It should be emphasised that the Driller / Assistant Driller can perform flow check any time they feel
this is necessary. However, there are many cases and situations where a flow check can be
negative while still having a kick in the well.
3
During drilling, the crews are generally able to recognise a 10 bbls (1.5m ) kick or less. If, during
kick drills such results cannot be achieved then additional kick drills or detection equipment should
be considered.

5.2.1 Flow Rate Increase

An increase in the return flow rate indicates that more mud is flowing from the well than is being
pumped in. This can only be due to fluid from the formation entering the well bore and displacing the
circulation mud. This is a certain sign of a kick.
When the Driller observes an increase in the return flow rate, drilling and pumping must cease and
the well closed in immediately and observed for pressure build-up. The man at the mud pit mustalso
inform the Driller at once when the increase in return flow is observed.
A flow sensor provides a means for measuring quite small variations in flow. However, if a kick is
coming from a relatively low permeability formation, it is unlikely that this slow bleed in will make an
observable variation in flow rate. A very small flow also can occur in situations using oil based mud
and having a gas kick.
If a flowrate increase is observed the well should be closed in immediately and observed for
pressure build-up.
5.2.2 Well Flows with the Pump Stopped

If, after stopping the pump, the well continues to flow, the well must be closed in immediately and
observed for pressure build-up.
The explanation of the cause is the same as for 5.2.1, Flow Rate Increase. The exception to this rule
is when a pill of heavy mud was spotted in the drillpipe prior to pulling out; in which case the flow is
from a temporary imbalance or U-Tubing and it would soon stop. A drillstring consisting of 5” and 3
1/2” drillpipe will indicate a second imbalance when heavy mud was spotted in the drillpipe prior to
pulling out
5.2.3 Pit Volume Increase

Any influx into the borehole usually results in the expulsion of mud from the well (oil based muds
excepted) and this shows up as an increase in surface volume.
Any surface additions, movements of mud, or dumping of a portion of the mud system must be done
with the Driller’s knowledge.
The addition of significant amounts of barite also changes the total mud volume. The Driller should
again be informed of the pre-calculated increases and over what period this should occur.
The continuous use of centrifuges, for example, can result in gradual losses that can be estimated at
the rig site and avoid masking any gains that might occur. Any variation to pre-calculated should be
brought to the attention of the Driller.
5.2.4 Pump Pressure Decrease and Pump Stroke Increase

An influx of gas, or other fluid of lower density than the mud, generally reduces the total hydrostatic
head of fluid in the annulus.
These lighter fluids also need less force to make them flow so the annular friction loss might also be
slightly less (unless the influx, such as a salt water, may contaminate the mud). In the slim hole
situations in a drop of pump pressure will be higher.
As the head of mud in the drillpipe is not affected, there is a tendency for the fluid in the drillpipe to U
tube into the annulus. As the pump does not have to provide so much energy and this is usually
seen as a pump pressure reduction. On some rigs, a small increase in pump rate may also be noted.
A similar effect is seen if a drillstring washout occurs, or if a seat or a plunger were washing out in
the pump. However, a sudden pressure drop might be more indicative of a twist-off in the drillstring,
or the loss of one or more bit nozzles.
A good practice is to always confirm what is happening by flow checking the well, and by a physical
inspection of the surface equipment. If no flow occurs, reasons other than a kick should be
investigated.

The opposite signs (pump pressure increase) may be observed if the mud used is normally
weighted, 9.5 ppg (1140 kg/m3), and a saturated magnesium chloride salt water of 12.5 ppg (1500
kg/m3) is encountered.
5.2.5 Drilling Break

One common sign that an abnormally high-pressure formation has been penetrated is a sudden
increase in the rate of penetration.
A gradual penetration increase may signal an increase in permeability and a loss of pressure
overbalance.
It is rare for the drilling break to indicate a kick is in progress though it is an indicator that conditions
are changing and perhaps formation pressure is raising. These "drilling breaks" should always be
regarded as an indication of a possible kick. Always check what the torque is doing when the drilling
break took place –was there an increase or decrease? Was this change steady or erratic?
The difference between the pressure exerted on the bottom of the hole by the column of mud (the
Bottom Hole Pressure) and the formation pore pressure has a considerable influence on the rate of
penetration. The greater the difference, the lower the rate of penetration. This pressure difference
causes the Chip Hold-down Effect.
When a new formation is penetrated in which the pore pressure is higher than previously, the
pressure difference or overbalance is reduced and the bit will penetrate faster. If the formation pore
pressure is so high that the overbalance is lost, then the well will kick.
A continuous increase in penetration rate is a fairly reliable sign, if confirmed by the lithology, that a
transition zone above an abnormal pressure formation is being drilled.
On the other hand, some formations are just softer and easier to drill than others. In these cases an
increase in penetration rate might not signify a higher pore pressure.
A “drilling break” should always be investigated by a flow check, unless known from experience that
the area is trouble-free.
5.2.6 Steady Increase in Penetration Rate

A continuous increase in penetration rate is a fairly reliable sign, if confirmed by the lithology, that a
transition zone is above an abnormal pressure formation and that is what is being drilled.
Since the rate of increase in penetration is in general small and therefore difficult to detect, it is
necessary to maintain all the drilling variables and mud properties as constant as possible over as
long a drilling interval as possible.
A Drilling Engineer should co-operate with the Driller to collect and analyse the data concerned and
perform the necessary calculations.
5.2.7 Hole Stability

Provided that the bit bearings are in good shape and there is no junk in the hole, a change in torque
on the drill string is generally an indication of impending formation change from impermeable shale
to an abnormally pressured permeable formation.
The increased torque can be caused by the shales expanding due to internal pressure and tending
to slough into the hole.
Note that a similar condition could arise by a high water loss non-inhibitive mud causing gumbo clays
or soft shales to swell. Control in this case requires chemical treatment (inhibition) of the mud
system, rather than an increase in density.
Other warning signs of hole instability are:
 evidence of overpull at the start of a round trip, and
 a necessity to ream when the bit approaches bottom at the end of a trip.

5.2.8 Decrease in Values of Shale Density with Depth

Abnormal pressures can sometimes be forecast by measuring the density of shale cuttings, since
undercompacted shales have a lower density than when normally compacted.
Very accurate measurements, which are seldom possible on site, are necessary and many other
factors, which could affect the density, should be expertly considered. The value of this warning sign
is marginal.
5.2.9 Increase in Mud Temperature

The increase implied is in addition to that normally found with increasing depth, and could be
associated with undercompacted clays/shales above an abnormally pressured permeable zone.
There are, however, so many variables affecting flow line temperature that this sign only has some
degree of reliability in areas where extensive drilling has already provided adequate data.
5.2.10 Gas, Oil or Salt Water Cut Mud

Gas, oil or salt water cut mud as a sign of a possible kick. This can be caused by:
 cuttings entering the borehole or
 influx from the formation.
At any sign of gas or water cut mud the Driller must investigate by flow checking the well.
If the Mud Logger detects small quantities of gas influx at intervals this may correspond with
connections (pumps stopped) which is known as “Connection Gas”. While drilling with connection
gas the times when making connection with pump off should be as short as possible. Before making
a new connection in this situation be sure that the bubble from last connection has reached surface.
Gas and oil cut mud can also appear at the surface, even if the formation pressure is less than the
bottom hole pressure. This is when gas or oil from the formation cuttings is absorbed into the mud as
it rises in the annulus.
If in doubt, circulate well once round, and if all signs of cut ceased to appear, it will be safe to
continue drilling.
If a flow continues, the well must be shut in and precautions to deal with a kick taken immediately. A
kick is more likely to have occurred if the show was observed while drilling.
5.2.11 Increase in Salinity

An increase in salinity, which sometimes occurs in formations above high pressure zones only have
a small degree of reliability.
A considerable amount of information should already be at hand from a number of adjacent wells to
properly correlate increase in salinity.
5.2.12 Change of cuttings in size, form, shape and amount

Changes in the shape of shale cuttings can occur as an underbalanced situation is developing. The
particles are often larger and may be sharp and angular in the transition zone. Extra fill on bottom
may coincide with the trend change. Severe sloughing will often cause changes in pressure and
stroke relationship. If changes in cuttings shape are observed the driller must be informed.
Normally pressured shales produce small cuttings with rounded edges and are generally flat, while
cuttings from an over pressured shale are often long and splintery with angular edges. As reduction
of hydrostatic differential between the pore pressure and bottom hole pressure occurs, the hole
cuttings will have a greater tendency to come off bottom. This can also lead to shale expansion
causing cracking and sloughing of the shales into the wellbore. Changes in cuttings shape and
cuttings load over the shakers need to be monitored at surface.

5.2.13 Increased torque and drag.

Increased drag and rotary torque are often noted when drilling into over pressured shale formations
due to the inability of the under balanced mud density to hold back physical encroachment of the
formation into the wellbore.
Drag and rotating torque are both indirect and qualitative indicators of hole instability and other
mechanical problems.
Torque and drag trend increases often indicate to the driller that a transition zone is being drilled. Up
drag and down drag as well as average and torque figures should be recorded on each connection.
These trends are valuable when comparing other trend changes.
5.2.14 Decrease in D-exponent.

The D- exponents will be plotted by the well loggers and maintained current all the times. This value
was introduced in the mid-60s to calculate a normalised penetration rate in relation to certain drilling
parameters and has been used with moderate success in predicting abnormal pressure.
5.3 Indications that a Kick may be in Progress While Tripping

Approximately 40% of all blowouts are the result of kicks taken whilst round tripping.
Flow into the wellbore will cause improper hole fill up, if this is seen a flow check must be performed.
(a) If the flow check is positive then the well must be shut in.
(b) If the flow check is negative the drillstring should be run back to bottom to circulate bottoms
up (stripping may have to be used here).
Normally a flow check will take around 15 minutes, however in a lot of cases a flow check has taken
much longer time to recognise a flow. In a swab kick situation the flow check can be negative, i.e. no
flow.
Trip tanks are recognised to be the safest and most reliable method of monitoring mud volumes on
trips. The hole must be kept full when tripping in the hole with the trip tank being used to ensure the
correct mud displacement is taking place.
On trips, the drill crew should be able to recognise a 5 bbls kick or less.
The size or severity of a kick depends on the volume of foreign fluid allowed to enter the wellbore,
which depends on the degree of underbalanced, the formation permeability, and the length of time it
takes the drilling crew to detect that the well is kicking.
The timing of the increase in pit volume is important in distinguishing between a true kick and gas
expansion only.
The main indications showing that a kick is being taken while tripping are each discussed in further
detail below.
5.3.1 Well Fails To Take Correct Volume of Mud When Tripping Out
While pulling out, the amount of mud used to fill the hole between stands must be measured. If it is
less than the volume of steel in the pipe just pulled, it indicates an influx into the well bore from the
that could develop into a kick.
The well should be observed for flow. If the well flows, close it in and prepare to kill it. If it does not,
run back to bottom and circulate bottoms up. If there is no sign of an influx at bottoms up resume the
round trip but take additional care not to swab.
In situations using oil based mud and having a gas kick the danger to reduce bottom hole pressure
while running back to bottom is not so high. However if circulating bottoms up, the gas will come out
of the solution at the bubble point. It should therefore be considered to circulate up halfway then to
close in the well and circulate the rest by using the choke.

In situations using water based mud and having a gas kick, the decision running back to bottom can
become critical. When through passing the gas kick, the height of the kick will increase significantly
and a great loss in bottom hole pressure can occur. Due to this pressure loss, a new kick could enter
the wellbore. Under this circumstances it is absolute necessarily to control the volumes coming out
when tripping back. If there will be any uncertainty, close in the well and strip back to bottom by
using the volumetric stripping method.
If the well is killed at some distance higher than the TD, a higher mud density is required than it
would take if the well were killed on bottom as the original mud density exists from beneath the bit to
TD. If this is the case, the well may need to be killed in stages.
Alternately, if the rig crew is very familiar with stripping into the borehole, it might be more prudent to
get as close to bottom as possible by stripping, then to kill with the correct mud density.
5.3.2 Well Flows when Running In

It is equally important to check the mud volume in the pits while running in because it is easy not to
notice a kick at this time. Mud is continually being displaced from the well as the pipe is run in and
unless positive measurements are made at the pit and compared with the theoretical displacement
of the string, a flow based on influx from the formation can be missed.
If additional flow is suspected, the well should be observed, and if necessary closed in and steps
taken to kill it.
5.3.3 Hole Keeps Flowing Between Stands

When running into the hole, if the well has not stopped flowing by the time the next stand is ready for
running in, it is probable that flow may be occurring in the well.
Flow check the well and shut in if there is any doubt.
5.4 Kick Drills
Kick drills are designed to familiarise the rig crew with the tools and techniques required to determine
if the well is flowing, and if so, to get it shut-in as quickly as possible. Many kicks that later turned
into blowouts, were often the result of failing to get the well closed in quickly. As well kicks are
seldom encountered, the crew will not be able to close in the well quickly unless these drills are
performed regularly.
Kick drills are to be conducted with each crew on a weekly basis once confident of acceptable crew
reaction times. All drills are to be reported on the Daily Drilling Report
Stripping drills should be conducted prior to drilling out the final casing shoe before entering a
hydrocarbon bearing zone.
5.4.1 Kick Drill Recommended Procedures

The Driller / Assistant operating the drawworks should co-ordinate the initial actions to be taken both
during a kick drill (and of course in the event of an actual kick).
5.4.1.1 During Tripping

1. The Drilling Superintendent / Workover Supervisor (or a designated person) gives a signal
that a kick drill will be carried out by telling the people on the rig floor.
2. The Drilling Superintendent / Workover Supervisor sounds the audible alarm at an
unexpected moment by pulling up the float of the pit level indicator on the mud / trip tank,
and presses a stopwatch as soon as the kick drill starts.
3. When the alarm sounds, the Driller hangs the string suspended in the elevator as quickly as
possible with the top tool joint within hands reach.
4. The Derrick man (if present) must immediately come down from the derrick.
5. The floormen set the slips, and open the elevators.

6. The Driller raises the elevators a few metres and the Floormen stab the kelly cock on the
pipe as quickly as possible and torque up same.
7. Close the kelly cock using the wrench.
8. The Driller opens the H.C.R. valve on the BOP and then closes the appropriate preventer.
The times taken to install and close the kelly cock and to close the BOP (including opening the
H.C.R. valve) should be recorded individually. The total time are to be filled in on the kick drill sheet
(example shown in the Appendix 1).
With the well now shut in:
9. Connect the top drive or kelly.
10. Open the kelly cock.
11. Observe and record SIDPP and SICP.
If it is decided to strip the drill string to bottom continue as follows:
12. Close the kelly cock and bleed off any pressure from top drive.
13. Disconnect the top drive and remove the pup joint from the kelly cock.
14. Install the Gray valve and connect the top drive.
15. Open the kelly cock and test the Gray valve.
Note the above assumes the topdrive kelly cock has an OD that allows it to be stripped into
the well. In many wells the regular 6 5/8” Kelly cock will not pass through 9 5/8” casing. This
aspect should be considered during the well planned phase.
5.4.1.2 During Drilling / Milling

1. The Drilling Superintendent / Workover Supervisor (or a designated person) gives a signal
that a 'kick' drill will be carried out by telling the people on the rig floor.
2. The Drilling Superintendent / Workover Supervisor sounds the audible alarm at an
unexpected moment by pulling up the float of the pit level indicator on the mud tank, and
presses a stopwatch as soon as the kick drill starts.
3. The Driller / Assistant raises the drillstring to a convenient position where no tool joints are at
the pipe rams or annular preventer(s) or, when a kelly is in use, until the lower kelly cock is
above the drill floor.
4. Stop the pumps.
5. Open the hydraulic-operated choke line (H.C.R.) valve and close the appropriate preventer.
6. The well is now shut in. Record the total time and fill in on the kick drill sheet.
7. At the end of the kick drill restore the settings of all preventers and the H.C.R. valve to those,
which existed before the kick drill.
8. Discuss the drill with the Supervisor paying particular attention to the aspects which could
still be improved.
5.5 Casing & Cementing
Many kicks occur during casing and cementing operations. The following precautions are therefore
required.
 Self fill shoes must not be used in hydrocarbon bearing zones
 Casing should be filled at least every 5 joints while running casing
 Cementing programmes should be reviewed to ensure that the preflush and postflush and
cementing densities do not allow the well to become underbalanced at any stage during the
circulation

5.6 Stripping Drills

The purpose of the strip drill is threefold:
 Training of personnel to obtain a level of routine and familiarity, including communication
aspects.
 Check on correct function of equipment (rig’s and contractor’s)
 Determination of the required annular closing pressure and strip in resistance.
The strip drill should be held in casing prior to drilling out the shoe-track. It can be combined with a
pit drill. Prior to conducting a strip drill determine whether there is a risk of drillpipe collapse or
casing burst. Prior to commencing the strip drill refer to the Stripping Checklist in Appendix 1.
5.6.1 Stripping Procedure (based on a Pit Drill alarm)

1. Install the Kelly cock on the drillstring and close the Kelly cock.
2. Open HCR.
3. Close annular preventer.
4. Close the valve before/after the choke.
5. Install the Gray Valve on the Kelly Cock (drillstring).
6. Pressure up the well to 30 bar via the kill line.
7. Reduce the annular closing pressure to the lowest leakage free level.
8. Check the stripping bottle pre-charge pressure (plus/minus 50% of the annular closing
pressure) and open the ball valve to the close line.
9. Open the Kelly cock (slowly) and check the Gray valve for leakage.
10. Install the next stand of drillpipe. Remove tong marks with a file. Lubricate tool joints with
grease (not pipe dope).
11. Ensure choke manifold is lined up to the trip tank. Fill up Poor Boy Degasser.
12. Run in some stands of drillpipe while keeping the well pressure constant.
 Check the correct working of the fill up line on the rig floor
 Record actual values of annular closing pressure and strip-in resistance (= loss of
weight on MD to overcome the friction in the annular preventer) in the drilling
report.
13. Drain the closed end stand volume after each stand into the stripping tank. Without stripping
tank, the level increase in the trip tank is to be recorded accurately.
14. Fill up the string with fresh mud of the correct properties.
15. If every one is satisfied, stop the stripdrill. Release of pressure from the well. Open the
annular preventer. Check for pressure under the Gray valve and then remove Gray Valve
and Kelly Cock. Reset all valves in the normal positions. Adjust annular closing pressure and
stripping bottle pre-charge.
16. Discuss the exercises with the drill crew and Drilling Superintendent.
17. End of stripping exercise.

6 Shut-in Procedures
6.1 Responsibilities for implementing Well Control Procedures
The shut in procedure and the preferred kick killing method to be used, is to be made known to the
crew by the Rig Manager and Operator, not later than the spud meeting. Any agreed procedures and
the methods should be in accordance with the procedures in this Manual.
The Driller is responsible for monitoring his instrumentation, evaluating any changes and information
given to him, performing flow checks and, where there are indications of a kick, shutting in the well
and informing the Rig Superintendent or Toolpusher.
6.2 General Shut-in Procedures
6.2.1 Shut in Procedures whilst drilling

The preferred shut-in procedure must be agreed between KCA DEUTAG and the Operator
before drilling begins and should be discussed at the pre-spud meeting. KCA DEUTAG’s
preferred shut in procedure is the hard (or fast) shut-in (i.e. choke closed) method. The agreed
shut-in procedure shall be clearly posted on the rig floor before drilling begins
Once a kick has been detected, or is suspected, the decision must be made to shut the well in as
quickly and as safely as possible. The success of the well control operation depends upon the
response of the crew at this most critical phase.
When any positive indication of a kick is observed such as a sudden increase in flow or an increase
in pit level, then the well must be shut in immediately even without doing a flow check
The procedures which follow our generalised suggestions and not necessarily applicable to any
specific rig.
The well is now shut in:
 to prevent further formation fluid influx,
 to protect the rig and the crew from an uncontrolled flow, and
 to organise the kill procedure after the stabilised shut in DP and Annulus pressures and the
pit gain are determined.
If Top hole is being drilled and the conductor pipe is not set in a competent formation and a shallow
gas kick is taken then the gas must be diverted.
6.2.1.1 Hard or Fast shut in procedure

KCA DEUTAG’s preference is for the Hard or Fast shut-in where the choke is closed during drilling
operations. With the Fast shut-in (via the annular) there is no need to space out within the rams. If
this procedure is to be followed the close-in process is simplified to the following.
1. Stop rotating the string.
2. Raise the drillstring with pumps on to a convenient position where no tool joints are at the
pipe rams or annular preventer(s). Note this step can be eliminated if using the Fast shut-in
method. (When a kelly is in use, raise the string until the lower kelly cock is above the drill
floor.).
3. Stop pumps and check for flow, if positive continue as per steps 4 through 7 below.
4. Close pipe ram BOP.
5. Open (hydraulic, HCR) choke line valve.
6. Close the choke upstream valve and check the complete system for leaks.
7. Call supervisors and commence plotting a graph of shut in drillpipe and casing pressure.
8. After the shut-in procedure, start reading and recording every two minutes:
Shut-in Procedures Page 48 of 142

a. the shut-in drillpipe pressure - SIDPP

Note: if a back pressure valve or drillpipe float (non-return valve) is installed in the
string, pump very slowly and stop as soon as the pressure increase is noted on the
casing side, then read the drillpipe pressure. Record this as SIDPP
b. the shut-in casing pressure - SICP
c. Measure the pit-level increase.
Record these data on the IWCF Surface BOP Kill Sheet.
The Choke is to be in the closed position while drilling in preparation for a hard shut in.
6.2.1.2 Soft shut in procedure

The soft shut in procedure is not preferred as the well is open via the choke while the rams or
annular is closed. However if this procedure is to be considered then the following steps would
apply.
1. Stop rotating the string.
2. Raise the drillstring with pumps on to a convenient position where no tool joints are at the
pipe rams or annular preventer(s). (When a kelly is in use, raise the string until the lower
kelly cock is above the drill floor.)
3. Stop pumps and check for flow, if positive:
4. Open (hydraulic, HCR) choke line valve.
5. Close annular or pipe ram BOP.
6. Close choke. If the choke is not a positive closing choke than one should close a valve
downstream of choke. Check the system for leaks.
7. Call supervisors and commence plotting a graph of shut in drillpipe and casing pressure.
8. After the shut-in procedure, start reading and recording every two minutes:
a. the shut-in drillpipe pressure - SIDPP
b. the shut-in casing pressure – SICP
Note: If a back pressure valve or drillpipe float (non-return valve) is installed in the
string, pump very slowly and stop as soon as the pressure increase is noted on the
casing side, then read the drillpipe pressure. Record this as SIDPP
9. Record these data on the IWCF Surface BOP Kill Sheet.
In preparation for a soft shut in the Choke is in open position while drilling.
6.2.2 Shut in procedure while tripping
6.2.2.1 Shut in procedures while tripping on drill pipe

If a kick has been caused by swabbing then hydrostatic pressure may still be sufficient to provide an
overbalance and a flow check can be negative. Even the difference in the volume while tripping can
be an indication for a swab kick.
If there is an indication of swabbing and/or the well flows during a flow check proceed as follows.
1. Set the slips.
2. Install a full opening safety valve (kelly cock type).
3. Close the safety valve.
4. Close BOP

5. Open choke line HCR valve.

7. Call supervisor and check pressures.
8. Install inside blowout preventer (Gray valve, non return valve or IBOP).
9. Open safety valve
10. Reduce annular preventer pressure and prepare for stripping drillpipe in the hole
The choke will be in the closed position while tripping
With the swab kick where flow is observed there are mainly four options to consider:
(a) Strip back to as close as bottom as possible.
(b) Perform a volumetric bleed.
(c) Bullhead kick back into formation.
(d) Perform off bottom kill then return to bottom and circulate well to desired mud density.
In any shut in procedure it is prudent to line up the annulus to the trip tank above the annular or
rams. This will assist in double-checking to see if they are leaking.
6.2.2.2 Shut in procedures while tripping on drill collars

If there is an indication of swabbing and well flows during a flow check the recommended option for
closing the well if collars are in the BOP is as follows:
1. Set the slips.
2. Install a drill pipe (single or stand, ready for use when tripping) with an inside blowout
preventer (Gray valve, non return valve or IBOP)
3. Release slips
4. Run in drill pipe
5. Close ram bop
6. Open choke line HCR valve.
8. Call supervisor and check pressures.
9. Reduce annular preventer pressure and start stripping drillpipe in the hole
There can still have been a swab kick where the flow check can show negative. The difference in the
volume while tripping can be an indication for a swab kick.
Note in the event of a significant folw rate the annular can be utilised and the pipe stripped through
the annular after which a ram can be closed on the drillpipe. It should be remembered a relatively
low pressure actinting upon the cross sectional area of the assembly can be sufficient to push the
pipe out of the well hence the preference to utilise the pipe rams.
6.2.3 Special shut-in procedures

When a kick occurs and the rig is not drilling or tripping drillpipe, special shut-in procedures may be
required. For example, some Operators require special procedures when a kick occurs during a trip
and drill collars have reached the BOP stack.
Other operations that require special shut-in procedures include kicks that occur during logging
operations in open hole and kicks that occur when the drillstring is completely removed from the
hole. It is important for every crew member to know the required procedures during all phases of the
drilling operation. Also, it is important for them to notify their supervisor whenever a kick or a
suspected kick occurs. Some of the more common special shut-in procedures are discussed below.

6.2.3.1 Shut-in procedure while running casing

Shutting in a well while running casing is similar to shutting in a well when tripping drillpipe.
The main differences involves a device used to stop potential flow up the casing and whether
to close a bop or a diverter, which depends on the type of casing being run.
When running surface casing, the bop stack is not usually nippled up, since there is no casing
head to nipple onto. In such cases, crew members will have to use a diverter or other
procedures to close in the well.
Because casing is normally run with a float shoe, once the diverter or bops are closed, the
shoe prevents backflow through the casing. A cement circulating head can also be used to
prevent flow up the casing.
Self fill up shoes are not to be used when running casing into productive zones. When
running casing into a productive zone casing rams should be installed or a suitable crossover
system considered. It is important to remember to plan for having to close in around casing,
with ram bops needing to be properly sized to close around the casing. Further, annular
closing pressure may need to be reduced to prevent collapsing the casing.
6.2.3.2 Shut-in procedure while cementing

During cementing operations, it should be remembered that joints of casing shorter than
normal may be run into the well to ensure that the casing shoe hangs at the correct depth near
the bottom. With joints shorter than normal, space out becomes important such that the bops
will be able to close on the casing body and not on a coupling. If a kick is detected, the driller
should first ensure that the casing is properly spaced out prior to the cement pump being shut
down, the bop closed (usually the annular), and the supervisor notified.
6.2.3.3 Shut in procedures during wireline operations

When a kick occurs during wire line operations, usually the drillstring is out of the hole. If a
kick is detected, the annular bop should be closed to shut in the well, since it will seal around
the wire line. Most operators do not recommend shutting in the pipe, line, shear, or blind-shear
rams on wireline. Should the blind or shear rams need to be closed to shut in the well, most
operators recommend having a line cutter accessible during wire line operations that will cut
the line and allow it to fall back into the hole. With the wire line out of the way, the blind or
shear rams can effectively close on the open hole.
6.2.3.4 Shut in procedures with no pipe in hole

When all the drillstring is out of the hole and it becomes necessary to shut in the well, most
operators recommend that the blind or blind shear rams be closed. While an annular preventer
can be used to shut in open hole, doing so places a great deal of wear on the sealing element.
As a result, the element may have to be replaced before it can be used again.
6.3 Post Shut-in actions
6.3.1 Data recording

After the shut-in procedure, start reading and recording every two minutes:
(a) The shut-in drillpipe pressure - SIDPP
(b) The shut-in casing pressure – SICP
If a back pressure valve or drillpipe float (non-return valve) is installed in the string, pump
very slowly and stop as soon as the pressure increase is noted on the casing side, then
read the drillpipe pressure. Record this as SIDPP.
(c) Measure the pit-level increase.
Record these data on the IWCF Surface BOP Kill Sheet.

6.3.2 Verifying shut in

As mentioned earlier, regardless of the procedure used to shut in a well, it is important to
verify that the well is completely shut in. Otherwise formation fluids could continue to enter the
hole, making it difficult or impossible to regain control of the well. To confirm shut in, it is good
practice to use the following procedures.
6.3.2.1 Annulus
To ensure that the annulus is close, check to be sure that the annular bop is completely close
on the well and is holding pressure. Then be sure that no fluids are flowing out of the mud
return (flow) line. It is best practice to line up the trip tank across the top of the BOPs to
confirm the rams or annular is not passing.
6.3.2.2 Drillstring
To confirm that pressure is holding on the drillstring, check to be sure that the mud pumps
pressure relief valves have not popped open and that closing pressure will not exceed the
pressure at which the relief valves will open; then, check the standpipe manifold. Every joint
should be pressure tested with no leaks.
6.3.2.3 Wellhead and BOPs

On surface stacks crew members should ensure that the casing valve on the wellhead is
closed and, once closed, is capable of holding the anticipated annular pressures. Further,
they should check for pressure broaching to the surface outside the wellbore.
6.3.2.4 Choke and choke manifold

Finally, the choke and choke manifold should be checked to ensure that the choke, when
completely close, is holding pressure. If not, then well fluids could be leaking past the choke
and an alternate choke may need to be employed. Crew members should also ensure that all
the fittings and lines in the choke manifold are holding pressure. If not, prompt repairs should
be made.

7 Well Killing Procedures

7.1 Killing Considerations & Preparation
After the shut-in procedure, start reading and recording every two minutes:
a. The shut-in drillpipe pressure – SIDPP
If a back pressure valve or drillpipe float (non-return valve) is installed in the
string, pump very slowly and stop as soon as the pressure increase is noted on
the casing side, then read the drillpipe pressure. Record this as SIDPP.
b. The shut-in casing pressure – SICP
Record these data on the Surface BOP Kill Sheet.
As quickly as possible, using the Surface BOP Kill Sheet make the necessary calculations and
determine:
d. the mud density required to balance the formation pore pressure (see Appendix
1).
e. the pumping speed (unless already determined), based on the pre-established
mixing rate of the barite; but not more than half the speed used in normal drilling
operations.
f. The number of pump strokes required to displace the influx to the casing shoe.
Confirm that all persons involved with the well kill are aware of the proposed kill method and
procedures to be used.
In case the manual operated choke needs to be used, it is convenient to have a means of reading
the drillpipe pressure at the manual choke. Ensure that two gauges are available on each of the
drillpipe and annulus in order to validate pressure readings during the kill.
7.1.1 Calculation of Reservoir Pressure (& Kill Mud Weight)

Once the well is shut in, providing nothing has broken down, the pressure in the well will be in
balance and the reservoir pressure can be calculated as described in section Appendix 1.
7.1.2 Choice of Kill Method

For a conventional well kill the well killing procedure (Drillers method, or Wait and Weight method) is
to be determined taking into account the specific well conditions, crew experience and rig capabilities
at the time of the event.
The advantages of the Wait and Weight method are:
 The surface annulus pressure will mostly be lower than with other methods.
 Depending on the hole and drillstring configuration, the open hole pressures might be lower
(but not higher). This gives the best condition for avoiding formation breakdown.
 The hole and the wellhead equipment is subjected to high pressures for the shortest
possible time.
 Minimum on choke circulating time - less chance of washing out the choke.
The disadvantages of the Wait and Weight method are:
 If large increases in mud weight required, this is difficult to do uniformly in one stage.
There is no advantage to use the Wait and Weight Method in highly deviated and horizontal wells.
The advantages of the Driller's method are:
 Simplicity: Circulation can start without any calculations.
 Minimum waiting around time - can start kill at once. Pumping can begin as soon as the
drillpipe pressure build up is established. This could be important in case of a H2S influx or
Well Killing Procedures Page 53 of 142

in situations with danger of differential sticking (highly deviated and horizontal wells) and/or
plugging of the annulus.
 The well can be controlled, even if weighting material supply is inadequate.
 Easier to use in vertical wells with a taper string, in highly deviated wells and horizontal
wells.
The principal disadvantages of the Driller's Method are:
 The well will be closed in under pressure longer.
 The maximum pressure at the casing shoe and against the formation might be higher if the
influx is gas however this depends on the borehole and the drillstring configuration. The
downhole pressures of both methods will be the same as long as the drillstring - open hole
capacity is the same or less than the internal drillstring capacity.
 The maximum choke pressure when the top of the influx reaches the surface will be higher if
the influx is gas.
In more complex situations the volumetric method or the bull heading can be considered.
All these methods are described in the following sections:
7.1.3 Initial Preparation

Prepare the killing graph according to which well kill method has been chosen, to show the
standpipe pressures to be maintained against the elapsed pump strokes during the killing operation.
While making the above calculations, the well should remain closed in, with the closed-in pressures
being observed and recorded continuously. If gas migration (percolation) occurs, SIDPP and SICP
will continue to rise simultaneously after the initial build-up and, unless remedial action is taken,
there is a danger that formation breakdown can and will occur.
The shut-in drillpipe pressure should therefore not be allowed to increase by more than a few bar. It
if does, the gas must be allowed to expand by bleeding off the annulus at the choke until the
pressure on the drillpipe has fallen to just above the former SIDPP. Depending on the MAASP, 3 to 5
bar (44 to 73 psi, 300 to 500 kPa) is acceptable as safety margin.
Once the influx is inside the casing, there is little danger of formation breakdown. However, this only
applies if the well continues to be killed correctly and in accordance with the Surface BOP Kill Sheet
graph.
Once the appropriate well kill calculations and schedule have been made and checked, and
appropriate kill weight mud is available, the actual well kill operation can commence as follows.
7.1.4 Establishing (or re-establishing) the initial circulating pressure

If no slow circulating rate pressure has been taken, then the initial circulating pressure can be
determined using the start up procedures described in the calculations of the Driller's Method.
Where the casing pressure has been held constant while the pumps are brought up to a kill rate, the
drillpipe pressure reading will be the initial circulating pressure.
If the pump rates during a wel kill need to be adjusted for any reason the following procedure can be
followed:
1. Note the casing pressure reading
2. Adjusting to new kill rate by adjusting the choke to hold casing pressure constant at the
value noted.
3. Once the new pump rate has settled, and taking into account any time delay between the
gauges, return to the drillpipe pressure gauge. This new reading is the circulating pressure
for the new pump rate and should be maintained.
4. Check the choke orifice size in relation to kill rate. (For the kill rate for circulating out a gas
kick, the choke opening position should be about 50% as, due to extension of gas, the
choke will have to be opened more and more during circulating).

5. By a determining the initial circulation pressure in this way the SCR can be re calculated as:
Slow circulation rate = initial circulating pressure - shut in drill pipe pressure
This procedure is satisfactory at any time during a kill providing the mud density in the drillstring is
stable during the process. It is however preferable to maintain pump rate constant as much as
possible. Any decision to change pump rate should be taken early.
7.2 Drillers Method

In this method the well is killed in two steps (circulations).
1. In the first step (circulation) is the influx circulated out, using the original mud and applying
backpressure to the bottom hole, equal to the excessive BHP
2. second step (circulation), when weighted up mud is available, the well is killed.
Before using the Driller's method, it is essential to confirm that exposed formations and casing can
support the higher pressures, which may be developed during the first circulation.
7.2.1 Kill Procedure

Prior to undertaking the following procedure it is assumed that the well is shut in as per the Shut-in
Procedure described in 6 and all pre-kick information is recorded on the pre kick sheet as follows:
Pre-recorded Information items on the Surface BOP Kill Sheet can be noted as follows:
1. Formation Strength Data:
a. Leak-Off Test pressure (A)
b. Drilling fluid density at Leak-Off Test (B)
c. Maximum Allowable Drilling Fluid Density (C)
2. Initial MAASP at current drilling fluid density
3. Pump Data:
a. Pump Rates and corresponding Dynamic Pressure Loss
4. Current Well Data:
a. Drilling fluid data: Density and Gradient in use
b. Casing & shoe data: Size, Measured depth and True Vertical Depth (TVD)
c. Hole Data: Size
d. Pre-recorded Volume Data:
e. Volume of surface equipment (no provision on the sheet )
f. Drill String tubular sizes
g. Length of HWDP and Drill Collars
h. Volume of all tubulars in use
i. Volume between all tubulars in use and open hole/casing
7.2.2 First step (circulation).

1. Inspect the surface BOP equipment and ensure all equipment is holding without leaks.
2. If a slow circulation rate pressure has been taken, then calculate the pressure required on
the drill pipe for the first circulation of the well.
Initial circulation pressure = slow circulation rate pressure + shut in drill pipe pressure
For the Drillers method there is no requirement to complete any kill sheet, the pre-recorded
information is quite enough.

Once well killing procedures have been discussed and agreed the well kill procedure should
commence as follows:
3. Open the choke about one-quarter, start the pump and break circulation; then bring the
pump up to the kill rate (the time to bring up the pumps to kill speed should be one minute no
less no more)
4. While the driller is bringing the pump up to the kill rate, the choke operator should operate
the choke so as to keep the casing pressure at/or near the closed in casing pressure
reading.
5. Once the pump is up to the kill rate, the choke operator should transfer his intention to the
drill pipe pressure gauge and adjust the choke to maintain the initial circulation pressure on
the drill pipe pressure gauge. If there is no slow circulation rate pressure or uncertainty about
it, the pressure reading on the drill pipe gauge, by keeping the casing pressure constant, will
be the established initial circulating pressure (remember the time delay between drill pipe
and casing pressure gauges).
6. The initial circulating pressure is held constant on the drill pipe pressure gauge by adjusting
the choke throughout the whole of the first circulation, until all of the kick fluid has been
circulated out of the well. The pump rate must also be held constant at the kill rate
throughout this period.
7. To confirm that there is no more kick in the well, shut in drill pipe pressure and shut in casing
pressure should be near same (pumps off) and the suction pit level should be nearly the
same like before the kick.
8. Once the kick is out of the hole, shut in the well in and continue to mix up the kill mud density
required as per the following formulae
 SIDPP(ps i) 
Kill mud density(ppg)= original mud density(ppg) +   (ppg)
 TVD(ft) x 0.052 
 SIDPP(bar)x 10.2 
Kill mud density(kg/l)= original mud density(kg/l) +   (kg/l)
 TVD(m) 
 SIDPP(kpa)x102 
3
Kill mud density(kd/m )= original mud density(kg/m ) +
3
  (kg/m3)
 TVD(m) 
Notes:
 This is the kill mud density to balance formation pressure. It is the lowest as possible mud
density which will kill the well. Once the well is dead, it will be necessary to increase the mud
density further to provide a trip margin.
 The heavy mud gradient can include a suitable overbalance margin.
 Some operators prefer to continue circulating the well while kill mud is being mixed. There is
no theoretical reason why this should not be done, though it results in further wear and tear
on equipment under pressure - in particular the choke. In situations of highly deviated or
horizontal wells this will make sense and one can even consider moving and slowly rotating
the string through the closed annular bop.
 At this stage the well is now controlled but not killed.

st
Figure 7-1 Pressure profiles during 1 Circulation of Driller’s Method

7.2.3 Second step (kill circulation)

Having successfully circulated out the initial influx the second step is to circulate the well to kill mud
as follows:
1. Line up suction to kill mud.
2. Open the choke about one-quarter, start the pump and break circulation. Then bring the
pump up to the kill rate.
3. While the driller is bringing the pump up to the kill rate, the choke operator should operate
the choke so as to keep the casing pressure steady at the same pressure as when closed in
after the first step (circulation) .
4. While the drill pipe is being filled with the heavy mud there are two options for keeping BHP
constant, either keep the casing pressure constant or follow a graph going from ICP to FCP.
When killing highly deviated, horizontal wells or vertical wells with a taper string it is
recommended to keep the casing pressure constant.
Notes:
 If the influx was gas and all the gas was not removed during the first step
(circulation), the first option of keeping casing pressure constant could lead to higher
annular pressures and a new kick.
 The drill pipe pressure will go down as the drill pipe is being slugged with the heavier
mud. In practice, if all the kick was properly removed in the first step (circulation), the
choke should not need to be touched once the pumps are steady at the kill rate, until
kill mud reaches the bit.
 Once the kill mud reaches the bit, the pressure held on the drill pipe is just that
required to circulate the kill mud around the well. This is the slow circulating rate
pressure, increased slightly for the extra mud density.
Kill mud density
 Final circulating pressure = slow circulating pressure x
Original mud density
5. Thereafter the drill pipe pressure is held at the final circulating pressure by controlled
opening of the choke, as the kill mud moves up the annulus.
6. When the kill mud reaches surface shut in the well and check for zero shut in pressures. The
preventers should only be opened and normal circulation resumed after flow has ceased
from the choke line for a reasonable flow check time.
7. Set all valves to normal operating position.
8. After circulating the hole clean perform a check trip.
9. Resume drilling ahead.
Because of the possibility that the annular may not be circulated completely clean, during the first
step (circulation), it may be preferable to work out how the drill pipe pressure should vary as kill mud
is pumped around the well. This will allow the drill pipe pressure to be used throughout, so
eliminating the possibility of small gas bubbles in the annulus producing misleading information.
A worked example using the Drillers method is included in Appendix 1 of this manual.

nd
Figure 7-2 Pressure profiles during 2 Circulation of Driller’s Method

7.3 Wait and Weight Method

This method is also known as the “balanced” or “Engineers” method. This method is normally used if
the bit is on bottom, or after the bit has been stripped to the bottom, and if enough barite is on the
location.
With this method the well is killed in one step (circulation). However, at least two circulations are
usually made:
 to circulate and clean the well,
 to fully condition the entire mud system, and
 to add the necessary trip margin to the trip out without swabbing.
Once the well is shut in and pressure still remains, the shut in drillpipe pressure is used to calculate
the kill mud weight. Mud off the required weight is made up in the mud pits. When ready, kill mud is
pumped down the drillpipe. At commencement, enough drillpipe pressure must be held to circulate
the mud, plus a reserve equivalent to the original shut-in drillpipe pressure. This total steady
decreases as the mud goes down to the bit, until with kill mud at the bit, the required pressure is
simply that needed to pump kill mud around the well.
The choke is adjusted to reduce drillpipe pressure while kill mud is pumped down the string. With kill
mud at the bit, the static head of mud in the drillpipe balances formation pressure. For the remainder
of the circulation, as the influx is pumped to the surface, followed by drillpipe contents and the kill
mud, the drillpipe pressure is held at the final circulation pressure by choke adjustment.
Ensure sufficient barite is on location and the mixing capacity is according to the selected pump rate.
The wait and weight method uses the same calculations already described for a drillpipe pressure
schedule. The calculations are:
 SIDPP(ps i) 
Kill mud density(ppg)= original mud density(ppg) +   (ppg)
 TVD(ft)x 0.052 
 SIDPP(bar)x 10.2 
Kill mud density(kg/l)= original mud density(kg/l) +   (kg/l)
 TVD(m) 
 SIDPP(kpa)x102 
3
Kill mud density(kg/m )= original mud density(kg/m ) +
3
  (kg/m3)
 TVD (m) 
Prior to undertaking the following procedure it is assumed that the well is shut in as per the Shut-in
Procedure described in 6 and all pre-kick information is recorded on the pre kick sheet as follows:
Pre-recorded Information items on the Surface BOP Kill Sheet can be noted as follows:
1. Formation Strength Data:
a. Leak-Off Test pressure (A)
b. Drilling fluid density at Leak-Off Test (B)
c. Maximum Allowable Drilling Fluid Density (C)
2. Initial MAASP at current drilling fluid density
3. Pump Data:
a. Pump Rates and corresponding Dynamic Pressure Loss
4. Current Well Data:
a. Drilling fluid data: Density and Gradient in use
b. Casing & shoe data: Size, Measured depth and True Vertical Depth (TVD)

c. Hole Data: Size

d. Pre-recorded Volume Data:
e. Volume of surface equipment (no provision on the sheet )
f. Drill String tubular sizes
g. Length of HWDP and Drill Collars
h. Volume of all tubulars in use
i. Volume between all tubulars in use and open hole/casing
7.3.1 Preparation to kill

1. Inspect the surface BOP equipment and ensure all equipment is holding without leaks.
2. Continue observing and record the SIDPP, (PDP ) and the SICP, (PAn ).
3. Keep the drillpipe pressure constant while mixing up the new mud.
4. Complete the applicable IWCF Surface BOP Kill Sheet and compare it with the Toolpusher
to avoid mistakes.
Set up a graph and the step down chart for the correct situation of the well and drill string for
pumping down the kill mud to the bit.
5. Select pump rate, determine the height and gradient of the influx, and travel times as per the
balanced method above.
6. Calculate the MAASP at casing shoe and on surface. If below critical pressures start killing
the well by using the balanced method.
7. Depending on the hole condition and formation break down pressure, overbalance the kill
mud equal to a minimum of 7 Bar (100 psi, 700 kPa), and increase the overbalance to
between 21 to 28 Bar (300 to 400 psi, 2100 to 2800 kPa) in the second circulation if this
increase was not possible in the first.
8. At the start of the circulation, with kill mud:
Initial Circulating Pressure (ICP) = Slow Circulating Rate Pressure (SCR) + Shut In Drill Pipe
Pressure (SIDPP)
9. Once kill mud is ready, the start-up procedure is as previously described.
7.3.2 Circulating the Influx Out and Killing the Well

10. On the Choke Manifold open the valves immediately upstream from the Remote Choke.
11. Set the pump stroke counter to zero and slowly start pumping and open the choke to prevent
excess annulus pressure build-up.
Note: Reset your stroke counter to zero when the kill mud has reached the goose
neck of your Kelly or top drive.
12. While the driller brings the pump up to the kill rate, the choke operator works the choke so as
to keep the casing pressure at or as near as possible to the closed in casing pressure
readings.
13. When the pump is up to the kill rate, the choke operator transfers to the drillpipe pressure
gauge.
14. At this time, the standpipe pumping pressure should equal the SIDPP plus the slow
circulating pump pressure (SCR), as shown on the IWCF Surface BOP Kill Sheet, this is the
Initial Circulating Pressure (ICP).
15. As the kill mud proceeds down the drillpipe, the drill pipe pressure is allowed to drop steadily
from the initial circulation pressure to the final circulation pressure, by choke adjustment.
Use the standpipe pressure chart on the IWCF Surface BOP Kill Sheet and adjust the choke

in steps according to the IWCF Surface BOP Kill Sheet and the graph until the kill mud has
reached the bit.
As long as the heavy or kill mud interface is still inside the drillstring there should be very
little change in the choke opening position. If the drillpipe pressure must be adjusted to
correspond with the pressure line on the IWCF Surface BOP Kill Sheet , that pressure
change should be made using the annulus pressure gauge.
Allow sufficient time for that pressure transient to work its way back to the drillpipe gauge.
Typically, at the speed of sound in the drilling fluid, or about 1 second per 1000 ft (300 m) for
the travel path.
Where the kick is a small one, at or near the bottom of the hole, the drillpipe pressure tends
to drop of its own accord as the kill mud moves down. Little or no choke adjustment is
required.
Only in cases of diffused gas kicks with gas far up the annulus will significant choke
adjustments be needed during this period.
DO NOT ATTEMPT TO INCREASE THE STANDPIPE PRESSURE BY CHOKE
MANIPULATION AGAINST THE DIRECT READING OF THE STANDPIPE PRESSURE.
This will result in excess pressure build-up and possible formation breakdown.
16. After kill mud has reached the bit, the drillpipe pressure is maintained at the final circulating
pressure, until the kill mud returns to surface. As an option the pump can be stopped and the
well shut in. The shut in drillpipe pressure now should be zero.
The behaviour of the choke pressure is different depending on the type of influx. When the
gas starts to reach the surface there will be big variations in choke pressure due to slugs of
mud and gas, and it will be impossible to adjust the choke accordingly.
As with the driller's Method, this final circulating pressure is held constant as long as pump
rate is held constant at the selected value. If, for any reason, the pump rate is felt to be
wrong, it can be changed using the same procedure described previously. However, pump
rate changes should be avoided, where possible. While the pump rate is adjusted, the
casing pressure is held steady by adjusting the choke. Once the pump is stabilised at its
new speed, the revised circulating pressure is read from the drill pipe gauge. If a gas influx is
very near to the surface, adjusting pump rate by holding a steady casing pressure may
significantly increase the bottom hole pressure. This is due to the rapid expansion of gas
near the surface. Alterations in pump rate have to be made early on.
17. After the kick has been circulated out, stop the pump and perform a flow check over the
open choke and check the mud density.
18. The well should be circulated for at least another WellCAPacity to condition the mud in the
system, and to ensure that the overbalance is adequate. If not, the mud density should be
adjusted to the correct value while circulating to condition the hole and the mud system.
19. The preventers should only be opened and normal circulation resumed after flow has ceased
from the choke line for a reasonable flow check time.
20. Set all valves to normal operating position.
21. After circulating the hole clean perform a check trip.
22. If circulation after the check trip is normal (no excess gas on bottoms up), the next normal
operation can be performed.

Figure
Figure 7-3 Profile of Circulating Pressure while killing by Wait and Weight Method
Figure 7-4 Profile of Circulating Pressure while killing by Wait and Weight Method
A worked example using the Wait and Weight method is included in Appendix 1 of this manual.

7.4 Other Kick Killing Methods
7.4.1 Concurrent Method

This method is also known as the slow weight - up method. This method was used in the past when
the mud mixing facilities were not as efficient as they are today. It is, however, a method which can
be used if circumstances warrant it, therefore an understanding of how the method works is
desirable.
As soon as the shut in pressures have stabilised following a kick, circulation is started immediately
with the current drilling fluid. Bottom hole pressure is kept equal to or slightly above formation
pressure by manipulation of the choke, to keep the casing pressure constant at the shut in value,
while bringing the pump up to the desired slow circulation rate.
The kill mud density, ICP, FCP, strokes and time to displace are calculated and adjusted the same
as for the wait and weight method.
Weight up of the mud is now started by 0.1 ppg (0,012 kg/l, 11,2 kg/m3 ) increments in the suction
pit, while circulating, until such time as the calculated kill mud density is reached.
This means that several different mud densities are in the drill stem between surface and bit, at one
and the same time. It is of prime importance therefore to keep an accurate record of the strokes and
time (and the corresponding drillpipe pressure), at which each incremental weight up is started down
the drill stem and the time and strokes (and corresponding drillpipe pressure), at which each
incremental weight up will reach the bit.
When preparing a pressure schedule, the ICP and FCP have to be recalculated for each increase in
mud density. Calculations have to be made while circulating which is what makes this method rather
complicated and prone to error.
7.4.2 Volumetric Method

If a gas or gaseous liquid influx cannot be circulated out because the string is nearly or completely
out of the hole, it may be necessary to remove the gas from the well by the volumetric method.
The volumetric method can also be used with the bit on bottom but unable to pump, or when
stripping pipe into the hole, or the pipe is stuck, and the well cannot be circulated.
The volumetric method is to be used in such cases when you have only a casing pressure reading.
The principle of this method is to allow the gas influx to expand during its migration to the surface
whilst maintaining the BHP at a level slightly in excess of the formation pore pressure.
Fluid is bled off from the well through the choke. To compensate for this loss of hydrostatic head, the
annulus pressure has to be increased by progressively closing the choke.
This process is continued until the gas reaches the surface, when, as it starts to bleed off, it is
immediately replaced by mud pumped into the well continuously at a low rate through the kill line.
From the start of mud injection, the annulus pressure must be decreased in small steps to
compensate for the gain in hydrostatic head of the increasing mud column.
Once all the gas has been removed from the well bore and it is again full of mud, the subsequent
action will depend on the circumstances, which led to this critical situation.
 If the gas was swabbed in, the wellhead pressure will be zero and normal operations can be
resumed.
 If the kick resulted from too low a mud density, then the well will still be under pressure. In
this case, further action will be required such as stripping in the string or Bullhead
Squeezing.
If the well flows, even slightly, with the bit off bottom, it is normally neither desirable to attempt a kill
with the bit substantially off bottom (which results in excess mud densities), nor to attempt to outrun
the kick by going to bottom with the well open.
The technique requires close monitoring and supervision by trained personnel. A common
occurrence is that excessive fluid volumes are bled off at the surface allowing further influxes.

Although the method is theoretically viable, caution should be exercised during implementation to
avoid further influx gains.
7.4.2.1 Volumetric Method with the Bit Off Bottom

Prior to undertaking a volumetric kill consideration should be given to stripping to bottom and killing
the well conventionally. Should it be deemed necessary to undertake this technique the precedure to
be followed should be as follows:
1. Close in the well, record Pa and determine the volume of the influx (V influx).
2. Make a kill graph and fill in the IWCF Surface BOP Kill Sheet.
Figure 7-5 Volumetric Kill Graph – Bit off Bottom
3. Allow the pressure to build up to Pchoke where:

Pchoke = Pa + Ps + Pw
Pa = Initial closed in annulus pressure before second build up has taken
place.
Ps = Allowance for loss of hydrostatic pressure as the gas rises from below
the bit to around the DC's
Ps = (Vinf  OH/DC cap. –Vinf  OH cap.) x (p1 - pinf) kPa, bar or psi
3
Vinf = Initial influx volume, (litre, m or bbl)
3
OH / DC cap = Open hole / DC annular capacity, (m /m, l/m or bbl/ft
3
OH cap = Open hole capacity, (m /m, l/m or bbl/ft)
P1 = Mud gradient, (kPa/m, bar/m or psi/ft)
Pinf = Estimated influx gradient, (kPa/m, bar/m or psi/ft)
Pw = Working pressure increment.
Note: Convenient values are between 350-700 kPa (50 to 100 psi or 3.5 to 6.5 bar)
depending on scale divisions on the pressure gauges. A safety margin of 700-1400 kPa (100
to 200 psi or 6.5 to 13 bar) is recommended to reduce the chance of the well becoming

underbalanced. The safety margin should be reduced for critical wells; such as where a low
MAASP does not allow for excess pressure to be applied to the well bore.
4. Bleed off mud (V1) from the well, while maintaining Pchoke constant.
V1 = Pw x OH / DC cap  p1
5. When the additional mud volume has accumulated in the trip tank the well is closed in until
Pchoke rises, under the influence of the migrating gas influx, by one increment of Pw.
6. By repeating step (5) and (6) as often as necessary, gas is allowed to migrate upward and
expand while a nearly constant BHP is maintained.
7. When gas is considered to be above the bit (calculated by migration rate), use a
conventional well killing to remove the influx from the well.
8. If conventional well killing is still not possible, the method has to be continued until gas has
reached the surface.
9. Gas has to be replaced with mud by pumping mud into the well intermittently through the kill
line. This procedure is called “Lubricating”.
10. Pump mud V2 = Pw x (CSG/DP cap.)  (pmud in use ) into the annulus.
11. Allow the gas to migrate to the surface again.
12. Bleed off gas ONLY until the choke pressure (the pressure prior to pumping 2 mud) is
reduced by one Pw increment.
13. Repeat the lubricating exercise until all gas has been replaced with mud and the well is
under control noting that this method has not killed the well; it has only removed the influx .
14. Strip back to bottom and kill the well by using the Driller's Method (after solving the initial
circulation problems).
15. Make flow check and if well is static open the BOP.
16. Circulate bottoms up.
17. Perform a check trip.
18. Resume operations.
Proper records should be kept during the well killing operation i.e.:
 Pchoke versus time to identify an increase in the number of pressure build ups, which
is an indication of gas entering annular capacities.
 Pchoke versus V to maintain the correct BHP.
Volumetric Method with the String Out of Hole

Consideration should be given to stripping to bottom prior to conducting a Volumetric Kill. If this is
not possible then proceed as follows:
1. Close in the well, record Pa and determine V influx
2. Make a kill graph and fill in the Surface BOP Kill Sheet.

Figure 7-6 Volumetric Kill Graph
3. Allow the pressure to build up to Pchoke where:

Pchoke = Pa + Pw + safety margin
Pa = Initial closed in annulus pressure before second build up has
taken place.
Vinf = Initial influx volume
Note: Convenient values are between 350-700 kPa (50 to 100 psi or 3.5 to 6.5 bar)
depending on scale divisions on the pressure gauges. A safety margin of 700-1400 kPa (100
to 200 psi or 6.5 to 13 bar) is recommended to reduce the chance of the well becoming
underbalanced. The safety margin should be reduced for critical wells; such as where a low
MAASP does not allow for excess pressure to be applied to the well bore.
4. Bleed off mud (V1) from the well, while maintaining Pchoke constant.
V1 = Pw * (OH cap)  p1
5. When the additional mud volume has accumulated in the trip tank the well is closed in until
Pchoke rises, under the influence of the migrating gas influx, by one increment of Pw.
6. By repeating steps (5) and (6) as often as necessary, gas is allowed to migrate upward and
expand while a nearly constant BHP is maintained.
7. The method has to be continued until gas has reached the surface.
8. Gas has to be replaced with mud by pumping mud into the well intermittently through the kill
line. (Lubricating)
9. Pump mud V2 = Pw x (CSG cap.)  (pmud in use )
10. Allow the gas to migrate to the surface again.
11. Bleed off gas ONLY, until the choke pressure (the pressure prior to pumping V2 mud) is
reduced by one Pw increment.
12. Repeat the lubricating exercise until all gas has been replaced with mud and the well is
under control (The well is NOT dead).

13. Strip back to bottom and kill the well by using the Driller's Method (after solving the initial
circulation problems).
Note: Proper records should be kept during the well killing operation:
 Pchoke versus time to identify an increase in the number of pressure build ups,
which is an indication of gas entering annular capacities.
 Pchoke versus
7.4.2.2 Kick Control by Using Combined Stripping and Volumetric Method

When the drillstring is partly or completely out of the hole, and there is a kick situation, then an
attempt to get the bit as far back to bottom as possible must be made, while, at the same time,
maintaining well control..
The string needs to be stripped back preferably through the annular preventer. This should be a
smooth and efficient operation. It requires knowledge of equipment and procedures used by all rig
crew. Refer to Figure 7-9 “Rig Layout for combined Stripping and Volumetric Method”.
When applying the combined stripping and volumetric method, estimates of worst case pressures
applied to the wellbore can be calculated by using the well control formula in the volumetric method
described previously.
Combined Stripping and Volumetric Procedure

When applying the combined stripping and volumetric method a worst-case estimation of the
pressures acting along the wellbore can be obtained by using the formula above.
Actual pressures during volumetric killing operations will depend on the following:
(a) The influx is fragmented and dispersed in the mud instead of remaining as a single slug.
(b) The influx is probably not on bottom at the time of closing in the well.
The gas migration rate has to be established and depends on variables such as:
(a) Hole size
(b) Difference in density of gas and well fluid
(c) Depth of the gas (shallow, and/or low density gas has faster migration rates)
(d) Viscosity of the well fluid
(e) Single bubble influx or separate smaller bubbles
(f) Type of well fluid
As a rule of thumb, an estimated migration rate is between 150 to 300 m / hr (500 to 1000 ft / hr) in
water based mud. Migration rates in brines are much higher. For estimating migration times see
Appendix 1.
Bit off Bottom

If the bit is off bottom shut-in the well and monitor the pressure and the kick volume. Whenever
possible, make preparation to strip in the hole as indicated below.
Be sure everything is prepared before starting the stripping process. Prepare a form for the pressure
and volume records during stripping “Stripping Form" (see section 8.4) and the “Stripping Check
Sheet” (see section 8.5 ) for the operation in Appendix 1.
Stripping with the Annular Preventer
1. Shut in the well as per the shut-in procedure.
2. Ensure the surge bottle pre-charge pressure been checked on the annular BOP and open
the valve on the surge bottle. Remove the vent plug on the opening chamber on the
Cameron D annular preventer (see Figure 5, also Figure 6).

3. Line up the choke manifold outlet to the trip tank.

4. Calibrate the trip tank and the strip tank.
5. Ensure the annular preventer operating pressure is adjustable between 100 and 3000 psi (7
– 207 bar, 700 – 20700 kPa).
6. Empty the trip tank to approximately 50%, measure the distance top trip tank –top fluid level.
7. Install the inside BOP on the kelly cock, open the kelly cock and ensure the inside BOP is
holding the pressure.
8. Adjust closing pressure on the annular BOP low enough to maintain a seal on the drill pipe
with a slight amount of drilling fluid leakage as the tool joint passes trough the packing. This
fluid leakage indicates optimum seal off for minimum packing unit wear.
9. After stripping back to bottom readjust the closing pressure to the recommended pressure.
10. Close ram type preventer, due to wear on the annular preventer when on bottom.
Stripping with the Annular Preventer and one Ram Preventer

1. If kelly-cock / inside BOP or other string components will not strip through the annular
preventer, try to bring the tool joint to above the annular preventer.
2. Close bottom ram preventer.
3. Bleed off pressure in between annular and ram preventer.
4. Open annular preventer. Remember the vent line in 3.1 step (2).
5. Decrease the closing pressure of the ram preventer.
6. Strip pipe into hole until tagging the closed ram preventer.
7. Close annular preventer again.
8. Pressure up between annular and ram preventer to wellbore pressure.
9. Open ram preventer. Increase ram preventer closing pressure to recommended pressure.
10. Continue stripping through the annular preventer.

Stripping Ram to Ram

1. Are additional preventers and spools installed?
2. Close the top rams, bleed off to approximately 800 psi closing pressure and observe for
leaks.
3. Strip in and tag the top rams. Pick up the string in tension before closing the bottom rams.
4. Close the bottom rams. Check if they are closed.
5. Bleed off all pressure between the rams.
6. Open top rams. Check they are fully open.
7. Strip in and tag bottom rams. Pick up the string in tension before closing top rams.
8. Close top rams. Check if they are fully closed.
9. Pressure up between the rams to the well pressure.
10. Open the lower rams. Check if they are fully open.
11. Continue to strip in the hole by repeating steps (4) through (11) in sequence.
12. Make a kill graph.
Figure 7-7 Kill Graph - Combined Stripping and Volumetric Method

13. Commence stripping. Allow the pressure to build up to Pchoke without bleeding off any mud.
Pchoke = Pa + Ps + Pw
Pa = Initial closed in annulus pressure before second build up has taken
place.
Ps = Allowance for loss of hydrostatic pressure as the gas rises from
below the bit to around the DC's
Ps = (Vinf  OH / DC cap. - Vinf  OH cap.) x (p1 - pinf) [kPa / bar / psi]
Where:

3
Vinf = Initial influx volume, (litre, m or bbl)
3
OH / DC cap = Open hole / DC annular capacity, (m /m, l/m or bbl/ft
3
OH cap = Open hole capacity, (m /m, l/m or bbl/ft)
P1 = Mud gradient, (kPa/m, bar/m or psi/ft)
Pinf = Estimated influx gradient, (kPa/m, bar/m or psi/ft)
Note: Convenient values for working pressure increments are between 350 to 700
kPa (50 to 100 psi or 3.5 to 6.5 bar) depending on scale divisions on the pressure
gauges. In critical cases where a low MAASP does not allow excessive pressures to
be applied to the well bore; a smaller pressure increment could be used until the
influx is above the DCs.
14. Once the required choke pressure is reached, Pchoke is kept constant while the drillpipe is
stripped back in the hole. Excess pressure is bled off via the choke manifold into the trip
tank.
15. The closed-end pipe displacement of each stripped in stand of drillpipe is then drained from
the trip tank into a stripping tank.
16. The string is then stripped into the hole until a volume of ∆V1 has accumulated in the trip
tank.
∆V1 = Pw x OH / DC cap  p1
17. Once the correct mud volume (∆V1) has entered the trip tank, the choke is closed and the
annular pressure is allowed to rise by Pw by means of stripping DP into the hole.
Note: The closed end displacement volume should NOT be bled off from the trip tank
into the stripping tank during this operation.
It is recommended to strip the complete stand in the hole for each phase of the
operation (whilst maintaining Pchoke constant, or when increasing Pchoke by Pw ) to
simplify the bleeding off process from trip tank to stripping tank and to improve the
accuracy of ∆V1 measurements which directly results in improved BHP.
Note: As a result of stripping the complete stand, higher then required choke pressures
will occasionally be obtained which should be taken into account when next Pw
increment needs to be added.
18. Steps (13) through (17) are repeated as often as necessary, until:
a. Bit is on bottom.
b. Gas has reached surface.
c. Stripping is no longer possible due to excessive pressures; BOP stack problems open
hole resistance, etc.
19. Stripping is then stopped and the well is killed conventionally, if the influx is above the bit.
20. When the bit is back on bottom, the well can be killed conventionally (Driller's Method) by
using following procedure:
21. If not already done, fill up the string with mud.
22. By using last SCR, calculate circulation pressure and Pchoke. Add 3,5 bar (50 psi) to the
calculated pressure to compensate for pressure drop in the inside BOP.
23. Circulate the string content, by maintaining a constant BHP.
24. After the string contents has been pumped; close in the well and check for trapped
pressures. Leave about 3,5 bar (50 psi) in standpipe pressure.

25. Continue to kill the well by using the Driller's Method. If it is a swab kick, the normal mud can
be used as it is proven (during drilling) that it was overbalanced.
7.4.3 String Out of the Hole

If the string is out of the hole when an influx is detected and the closed in surface pressure allows
lowering the first stands of DCs or DP into the well, stripping should be started, as it will improve the
well control situation. The kelly or the top drive may have to be used for extra weight on the first
stands.
The maximum surface pressure that can be overcome by the weight of the first stand, ignoring the
friction between the annular preventer and the string is:
Max. surface pressure = ( Weight of first stand in mud )/(Cross sectional area of the stand)
Once calculations have confirmed that the weight of the first stand can overcome the recorded
surface pressure proceed as follows:
1. Install a bit sub with float valve on the first stand of DC (and/or gray valve) or an inside BOP
on the first stand of DP when stripping with DP only.
2. When stripping with DC, make up a bit without nozzles to reduce the chance of plugged
nozzles.
3. Lower the stand to the top of the blind / shear rams and close the annular preventer.
4. Open the blind / shear rams and strip through the annular preventer. Allow the choke
pressure to increase by Pw, and maintain it constant thereafter.
5. Fill the string with mud.
6. If DCs are used instead of DP, Continue stripping the slick BHA and maintain a constant
choke pressure. Do NOT use more than three stands of DCs.
7. Allow the choke pressure to increase to (Pa + Ps + Pw) without bleeding off any mud when
stripping in the first stands.
8. Continue the combined volumetric method as described above.
Note: If it is not possible to strip the string into the hole and gas migration is indicated, the
volumetric method or bullhead squeezing may have to be employed.

7.4.4 Killing by Bullhead Squeezing

WARNING: Bullhead squeezing is not a routine operation and the execution has to be
discussed with the drilling management in detail.
If normal well killing techniques with conventional circulation is not possible or will result in critical
well control situations, bullhead squeezing may be considered.
Bullhead squeezing means that mud and influx are displaced or squeezed back downhole into the
weakest exposed open hole formation.
Bullheading can be a valuable tool for fighting kicks under circumstances such as the following:
 The influx contains more H2S than the operation can tolerate.
 Plugged or parted drillpipe cannot get kill mud to bottom.
 A weak zone below the kick takes mud too fast for a kill by circulation.
Disadvantages of the Bullheading Squeezing Method are:
 In many cases it will be doubtful if the well can be killed by squeezing the influx back into the
formation.
 There is a potential risk of fracturing formations anywhere in the open hole, which can lead
into a underground blow out situation. In the case of shallow casing setting depths this could
lead to cratering.
 The weakest formation may not be the formation from where the influx were coming.
 Bullhead squeezing may require very high pressures to be applied at surface equipment.
 Even if squeezing fluid back into the formation is possible to some extent, it may not be
possible to kill the well completely. Another well control technique will then have to be used.
 The method can only be used if hole conditions permit.
 Potential is created for an underground blowout and/or a surface eruption (cratering)
Considerations for the use of Bullhead Squeezing Method
Formation Permeability: The formation must have a good permeability to allow squeezing. The
actual kick can be used as a permeability indicator. (Inflow prior to closing in the well and speed of
pressure build up after the well is closed in.)
Type of Influx: A gas is easier to squeeze back than a liquid, however, the lighter gas wants to
naturally migrate up the hole, rather than to be forced down. The higher the viscosity, the more
difficult it is to displace.
Contamination Of Influx With Mud: If the influx is contaminated with mud (typical with most kicks),
squeezing will be more difficult because of the plastering qualities of the mud (filter cake build-up)
and the possible presence of cuttings.
Position of Influx: If the influx has migrated, or has been circulated up over a certain distance, mud
below the influx will have to be squeezed ahead of the influx, assuming that the weakest formation is
where the influx came from. The sooner squeezing takes place, the better the chance for a
successful squeezing operation.
Strength of the Formation: Squeezing should be performed with the aim not to fracture any
formation. In principle, the surface squeeze pressure should not exceed the MAASP. If heavier kill
mud is pumped down the annulus the MAASP should be adjusted accordingly.
Note: The minimum pump rate which is needed to force gas back with a fluid if formation
permeability allows squeezing is:
2 2
Vmin = 20 x d ( where is d = OD in inch) [ l per minute]
2 2 3
Vmin = 0,02 x d ( where is d = OD in inch) [m per minute]
2 2
Vmin = 126 x d ( where is d = OD in inch) [ bbls per minute]

Note: These rates obviously assume that the there exists a formation which is able to take this
volume per minute.
7.4.5 Kick Control in Deviated and Horizontal Wells

Most of the well control methods are applicable to deviated and horizontal wells. However, when the
string is off bottom, or when circulation at bottom is not possible, well control options become limited.
The volumetric method or bullhead squeezing are most likely to be unsuccessful or ineffective in the
horizontal section.
All hydrostatic pressure related calculations need to be based upon true vertical depth (TVD) values.
This means the standpipe kill graph of a deviated well has a different curve as compared to the
graph for a vertical well due to the behaviour of Pdp . It applies only for Phase 1 balanced method,
since the standpipe pressure remains constant for the other phases.
When the standpipe kill graph for a deviated hole is constructed, higher than required BHP will occur
in Phase 1 during the well killing. Especially in deep, highly deviated holes, and horizontal wells, this
overbalance can be relatively high and should be taken into account.
Well control formulas used also apply for deviated holes as long as the hydrostatic pressure related
calculations are based upon true vertical depths.
For hydrostatic pressure related calculations the TVD of the deepest part of the horizontal section
should be used. However, a bottom hole angle of 90° cannot be used in the calculations due to
arithmetical reasons. A maximum bottom hole angle of 89° should be used instead.
7.4.5.1 Kick Control Considerations for Horizontal Wells

 When a kick is encountered, the influx will take place over the entire exposed horizontal
reservoir section at once.
 The overbalance at the beginning of the horizontal reservoir is the same as the end of the
reservoir.
 Possible dispersion effect in the horizontal section will take place which may result in long
circulating times to get the mud in the well gas-free and filled with proper weighted mud.
 Lower than expected annulus pressures will occur due to the dispersion effect.
 If well planning is done correctly, the most likely kicks, which may occur, are the swab kicks.
 Normally, well control situations should not be critical since the casing is set directly above
the horizontal section.
 A proper standpipe kill graph must be used to ensure that the correct bottom hole pressure
is applied during the well killing process.
7.4.5.2 Constructing the Standpipe Kill Graph

To construct a proper standpipe graph for a deviated or horizontal hole proceed as follows:
1. Plot the initial standpipe pressure at time, volume or strokes zero (Point A).
2. Calculate and plot the standpipe pressure when the new mud has reached the bit (end of
Phase 1, Point D).
3. Calculate and plot the standpipe pressures which occur at the beginning and end of each
build up and / or drop off section of the hole at the appropriate position in the graph (Point B
and C).

Figure 7-8 Standpipe Kill Graph for Deviated Wells
4. Connect the points A - B - C - D obtained in steps (1), (2), and (3) with straight lines. This
profile represents the standpipe pressure while pumping the new mud from surface to bit.
Note: The standpipe pressure at point of interest is calculated using following formula:
PST’s' = Pst (start) + (Pc2 - Pc1) x {Px (AH)/D (AH)} - Px (TV) x (p2 - p1)
The static Pdp, at point of interest is calculated as follows:
Pdp'X' = Pdp - Dx (TV) x (p2 - p1)
Where:
Pst'X' = Standpipe pressure at point of interest, kPa or psi
Pst(start) = Standpipe pressure observed at start of kill, kPa or psi
Pc2 = Circulating pressure at end of kill, kPa or psi
Pc1 = Circulating pressure at start of kill, kPa or psi
Dx(AH) = Along hole depth at point of interest, m or ft
D(AH) = Along hole total depth, m or ft
Dx(TV) = True vertical depth at point of interest, m or ft
p1 = Original mud gradient, kPa/m or psi/ft
p2 = Kill mud gradient, kPa/m or psi/ft
5. Calculate (or read from the directional drilling map) TVD of along the hole (AH) height of
influx at bottom and at the shoe to obtain equivalent hydrostatic heads for specific influx
volumes and apply "adjusted annular capacities" into the formulas.
Volume of Influx at bottom

An. Cap. btm TV =
Heightof Influx AH at btm x Cos(holeincclination at btm)

Volume of Influx at bottom

An. Cap. shoe TV =
Heightof Influx AH at shoe x Cos(holeincclination at shoe)
6. Proceed with applying standard well control calculations as per vertical wells.
7.5 Stripping Operations
7.5.1 Preparation for Stripping

If the well kick whilst tripping, it is important that decisions are made quickly and that the procedures
to be used are implemented as soon as possible.
If pipe stripping is an alternative, everything is to be arranged to implement the stripping operation
quickly. This means that there must be away of accurately measuring any mud volume bled off,
accurate gauges must be available, pressure regulators on blowout preventers must be in good
working order, and the equipment and procedures to be used mustd be known and practised.
Strip drills in addition to the usual pit drills should be considered to train crews and to evaluate the
stripping characteristics of the preventer in use.
Additionally, even if stripping cannot for some reason be considered, it is essential that well control is
maintained whilst decisions are made concerning the most effective well killing method to be
employed. To this end, it is essential that equipment is rigged up to immediately implement the
volumetric method.
Note: The detailed stripping procedures are covered in section 7.4.2 and are therefore not repeated
in this section which focuses on equipment, preparation and other stripping aspects such as the
effects of running into the influx.

Figure 7-9 Rig Layout for combined Stripping and Volumetric Method
Regardless of the method used to strip pipe into the hole, to enable effective pressure control it is
very important to measure all of the fluid that comes out of the wellbore. Formation fluid that has
entered the well may be gas and during the stripping operation migration may take place. If there is
no migration of fluid, the volume of mud release from the wellbore, as pipe is stripped, should equal
the closed-end pipe displacement and the surface pressure should remain the same.

Figure 7-10 Bleeding off of closed end displacement
If the gas influx migrates, the surface pressure will increase even though the volume of drilling fluid
released at the surface is exactly equal to the closed-end pipe displacement. In this case it is
necessary to bleed off additional fluid to let the gas expand and thus reduced the change out
formation breakdown. This is achieved by maintaining choke pressure constant whilst pipe is
stripped in.

Figure 7-11 Increase in Volume at Surface due to expansion of influx
When the bit and DCs enter the influx, a dramatic loss of hydrostatic head will take place. This loss
of hydrostatic head should be anticipated and additional backpressure must be added at the very
start of the stripping operations.

Figure 7-12 Effective of Running into the Influx
In general, the annular preventer is used for stripping pipe into or out of the hole. The annular
preventer allows the use of one preventer and permits the tool joints to pass through the packing
element. To minimise friction the pipe should be well lubricated with grease and closing pressures
applied to the annular kept to a minimum whilst avoiding leakage. Additionally, drillpipe protectors
should be removed and if possible sharp edges and tong marks on the pipe body and tool joints filed
off.
Figure 7-13 Equipment Requirements for Stripping with an Annular Preventer

7.6 Potential problems while well killing

A number of problems, can arise during a killing operation. Those most likely to be encountered are
discussed below, and are followed by a Quick Check List. Also refer to the Trouble Shooting Charts
in section 7.6.4.
Since there are a number of possible causes of an abnormality during the killing operation, keep in
mind that:
 If in doubt stop the pumps
 Shut in the well
 Observe the pressures
A logical analysis of the evidence available will almost invariably point to the solution required.
Drop in Circulation Pressure
This could be due to loss of a bit nozzle, a leak in a tool joint or a wash-out in the drillpipe, pump
valve or piston, leakage in surface equipment.
As before, suggested action to be taken can be found in the Trouble Shooting Chart, Section 7.6.4.
Lost Circulation
If standpipe pressure Pst and choke pressure do not respond to either opening or closing of the
choke and it is noted that the mud returns have decreased (or ceased). This may mean circulation
has been lost either directly to the formation, or through a bad cement job, or a hole in the casing.
Possible courses of action are given in the Trouble Shooting Chart, Section 11.24.
7.6.1 MAASP is reached

Possible action is limited to two alternatives, both undesirable.
1. Firstly, continue to apply the necessary choke pressure to maintain them correct standpipe
pressure , but this increases the risk of formation breakdown.
2. Secondly, limit choke pressure to the MAASP, thereby allowing the BHP to fall, possibly
inducing a further influx.
Before deciding upon the course of action, consider the hidden safety factors as discussed in section
2.1.5.5. The least damaging course will depend on the specific situation.
Assessment of the possibility and degree of seriousness of formation breakdown involves
consideration of the:
(a) depth of shoe or weak formation,
(b) quality of the primary cement,
(c) characteristics of the formation most likely to fail,
(d) period of time during which weak formation is at risk.
(e) Chances and severity of a second influx depend on:
(f) productivity of the reservoir being controlled,
(g) degree of underbalanced involved,
(h) period of time until acceptable BHP can be restored.
Formation breakdown and losses may develop into an underground blow-out; or perhaps worse,
broach to the surface outside the well and cause a crater. This is the ultimate disaster scenario for a
jack-up or platform rig with only conductor or surface pipe set for that well.
7.6.2 Equipment Failure

This usually involves a partial or complete failure of the pump or its prime mover. In such a case,
pumping should be discontinued and the well closed in until rapid repairs have been carried out or a
second pump brought into service (determine new standpipe pressure ).

Once the well is closed in, SICP and SIDPP must be continuously observed. If both start to show
signs of an increase, it will be due to upward migrating gas.
The gas should be allowed to expand by opening the choke until SIDPP reverts to the closed-in
pressure observed at the time of equipment failure. (If circulation is stopped after the kill fluid
reaches the bit, SIDPP will normally be zero.)
Once repairs have been completed the killing procedure can be restarted.
7.6.3 Hydrates
The formation of hydrates is dependent upon a combination of the following conditions:
a. Presence of free water
b. Gas at or below it's dew point
c. Low temperature
d. High pressure
The hydrate problem is aggravated by pressure drop / gas expansion (through the choke) and
pressure pulsing.
As the gas passes through these restrictions the resulting pressure drop plus the sudden increase in
velocity cause “expansion cooling” of the gas immediately downstream of the choke.
Hydrates can cause severe problems by plugging valves or chokes and completely blocking flow.
Upstream pressure increases and this compounds the problem.
Prevention of hydrates will always be easier and better than the cure. It may be necessary to inject
methanol or glycol to suppress hydrate formation. Ports can be modified into the choke manifold for
this purpose.
The hydrate problem is virtually non-existent in Oil base muds. With Water base muds, maintaining a
high chloride concentration in the mud will lower the freezing point.
If hydrates do form and plug off the choke or kill line they can be very difficult to remove.
Considerable heat is required for decomposition, for example, circulating hot brine solution.
7.6.4 Well Kill Problem - Quick Check List & Trouble Shooting Charts
Unexpected changes in pressures during a well kill could be interpreted by reference to the following
list and tables which should be consulted prior to closing in the well and assessing the situation
further:
(a) A jumping rotary hose or a surging pressure gauge are signs of a pump problem.
(b) If the standpipe pressure and the choke pressure both increase suddenly, the choke or
choke manifold is plugged.
(c) If only the standpipe pressure increases suddenly, a bit nozzle or the annulus is plugged.
(d) If the standpipe pressure drifts downwards, there could be a leak or hole in the drillstring.
(e) If the standpipe pressure and choke pressure do not respond to choke adjustment and the
pit level is falling, loss of circulation is occurring.
A Trouble shooting Chart for other scenarios is presented below:

7.6.4.1 Drillpipe Pressure and Casing Pressure BOTH UP the same amount
Action to Result Problem Solution

take
Check Pump rate too fast. Circulating pressure is too high Slow the pump rate down to the
pump rate. because the pump is running planned rate. If pressure comes
faster than was planned. down, everything is OK. If not,
continue down chart.
Increase Drillpipe pressure Choke opening was too small. If the pressure come down when
choke and casing the choke opening was
opening. pressure will come increased, everything is OK. If
down. not, continue down chart.
Open Drillpipe and casing Either choke opening was to If pressures come down,
choke all pressure will come small or the choke is on way to everything is OK. If not, continue
the way. down. plug. down chart.
Stop the Drillpipe and casing The choke manifold has started Switch to alternate chokeline. If
pump. pressure will come to plug up. pressure come down, go back to
down. kill the well, if not continue down
chart.
Shut the Pressures stay up. Manifold is plugged. Switch to alternate chokeline. if
well in. pressure come down, go back to
kill the well, if not continue down
chart.
Shut the Pressures stay up. Manifold plugged at or above Close the master valve on the
well in. “T”. kill line, release the pressure
from the manifold and clean it
out.

7.6.4.2 Drillpipe pressure UP, and Casing pressure UP just a small amount

take
Check Pump rate too fast. Circulating pressure is too high Slow the pump rate down to the
pump rate. because the pump rate is faster planned rate. If pressures come
than planned. down, everything is OK. If not,
Increase Drillpipe pressure Choke opening was too small. If the pressure come down when
choke and casing pressure the choke opening was
opening. will come down. increased, everything is OK. If
not, continue down chart.
Casing pressure Wait at least 2 minutes to see if Allow for a long time lag with big
comes down, but not there is a long lag between choke gas kicks. If pressure will not
drillpipe pressure. movement and drillpipe pressure. come down, continue down chart.
Drillpipe pressure A mud ring or pack off near the Raise or reciprocate the drillpipe.
does not come bit. If drillpipe pressure comes down,
down. OK. If not, continue down chart.
Plugged jets. Restore casing pressure to where

it was before the trouble started..
Or:
stop the pump and shut in the
well in and bleed the pressure off
the drillpipe until at least one jet
clears. Then start up holding
casing pressure constant until
you reach the new pump rate.
then use the new circulating
pressure as the constant
circulating pressure.

7.6.4.3 Drillpipe pressure changed UP abruptly; Casing pressure NO CHANGE

Excessive Standpipe Pressure
This could be due to plugged bit nozzles, plugged annulus below the influx or a plugged choke.
Evidence of the first two is an increase in standpipe pressure with no increase in choke pressure. If
both standpipe pressure and choke pressure increase, it is an indication of a plugged choke.
Suggested action to be taken in these circumstances can be found in the Trouble Shooting Chart,
below.

take
Check Pump rate too fast. Circulating pressure too Slow the pump to the
pump high because rate is planned rate.
rate. faster than planned.
Increase Casing pressure A mud ring or pack off Raise or reciprocate the
choke gets very low near the bit. drillpipe. If drillpipe
opening. before drillpipe pressure comes down, OK.
pressure comes If not, continue down chart.
down.
Increase Casing pressure Plugged bit. Either: taking the new

choke gets very low drillpipe pressure as the
opening. before drillpipe constant circulation
pressure comes pressure. Or:
down.
Stop the pump and shut the
well in and bleed off the
drillpipe pressure. Then
start up holding casing
pressure constant, until you
reach a new pump rate.
Then use the new
circulating pressure as the
constant circulating
pressure.
Open Drillpipe pressure Plugged bit. Stop the pump and shut the
choke. does not come well in. Try rocking the
down. pump to clear the bit. You
may have too shoot off or
back off the bit.

7.6.4.4 NO CHANGE to Drillpipe pressure; Casing pressure DOWN or NO CHANGE.

take
Increase Pressure does not Lost circulation, bad cement job, Take a new slow
or seem to respond to or a hole in the casing. Check circulating rate. Add
decrease choke movement. pit volume. circulation material.
in choke Add barite plug. Add
opening. cement plug over
barite plug
Check pit Volume OK. Check of the choke for failure. Switch to alternate
volume. choke.
7.6.4.5 Drillpipe pressure DOWN; and Casing pressure DOWN

take
Check Pump rate too Pump rate is lower than planned Increase the pump
pump slow. rate to the planned
rate. rate. If pressures
come up, OK. If not,
Decrease Drillpipe and casing Choke opening was too great. If pressures increase
choke pressure increase. when the choke size
opening. was decreased, OK.
If not, continue down
chart.
No change in Lost circulation, bad cement job, See "drillpipe

drillpipe and casing or a hole in the casing. Check pressure, no
pressure. pit volume. change".
7.6.4.6 Drillpipe pressure DOWN; NO CHANGE in Casing pressure

take
Check Pump rate too Circulating pressure is too Increase the pump
pump rate. slow. low because the pump is rate to the planned
running slower then was rate. If pressures
planned. come up, OK. If not
Decrease Pressures Choke opening was too If pressures increase

choke increase. great. when the choke size
opening. is decreased, OK. If
not, continue down
chart.

Pressures Pump trouble. Change pumps or

increase but Kelly repair pump.
hose jumps and
drillpipe pressure
surges.
Continually Drillpipe pressure Hole in the drillpipe. Stop the pump and
decreasing stays the same, shut in the well in.
choke casing pressure You may have to
opening. goes up. strip out to replace a
joint of pipe.
7.6.4.7 Drillpipe pressure ABRUPTLY DOWN; Casing pressure NO CHANGE

take
Decrease Drillpipe and casing Washout in bit or in drillpipe. Stop the pump and
choke pressure go up. shut in the well in.
opening. You may have to
strip out to replace a
joint of pipe.
7.6.4.8 Re-starting Procedure

If the well has to be closed in before it is killed for any of the reasons described in the Trouble
Shooting Charts, the killing operation should be re-started as follows:
1. When all is ready for re-starting, read and record Pan .
2. Open the choke slowly whilst simultaneously starting the pump and increasing its speed to
the required rate in SPM.
3. While the pump speed is increasing, start adjusting the choke until Pch = Pan .
4. Read Pst .
5. If still in Phase I, calculate average mud density in the drillpipe (Wav ).
6. Calculate Pcav by subtracting the Pdp (when pump was stopped) from the new Pst Pcav =
Pst - Pdp
7. Calculate the new Pc2 = (W2 / Wav ) x Pcav
8. Draw the new killing graph.
9. If the operation has reached Phase II or later, maintain the new Pst by adjusting the choke
until the well is killed.

8 Appendix 1: Forms, Calculations, Worked Examples
Appendix 1 Forms, Calculations, Worked Examples Page 88 of 142

8.1 Kick Drill Sheets: Pit/Kick Drill Report – Hard/Fast Shut In
Pit / Kick Drill Report

HARD/FAST SHUT IN
Location: Date:
Rig: Driller: Time:
Depth: m
Bit depth: m Pit drill during tripping
Duration
Omit not applicable steps
Time to recognize kick sec.
Time to place Kelly cock (and close) sec.
Time to open HCR valve sec.
Time to close annular preventer sec.
Time to close pipe rams sec.
Time to place top drive sec.
Time to open Kelly cock sec.
sec.
Total Time sec..
Depth: m
Bit depth: m Pit drill during drilling
Duration
Time to raise bit from bottom sec.
Time to stop pumps sec.
sec.
Total Time sec.
Remarks:
Driller:___________________ Toolpusher:_________________

8.2 Kick Drill Sheets: Pit/Kick Drill Report – Soft Shut
Pit / Kick Drill Report

SOFT SHUT IN
Location: Date:
Rig: Driller: Time:
Depth: m
Bit depth: m Pit drill during tripping
1
Duration
Time to place Kelly cock (and close) sec.
Time to close choke (close valve in sec.
front)
Time to place top drive sec.
Time to open Kelly cock sec.
Total Time sec.
Depth: m
Bit depth: m Pit drill during drilling
Duration
Time to raise bit from bottom sec.
Time to stop pumps sec.
Time to close choke (close valve in sec.
front)
Total Time sec.
Remarks:
Driller:___________________ Toolpusher:_________________

8.3 Kick Killing Worksheets (IWCF Forms)
8.3.1 IWCF Kill Sheet Vertical Well (Bar/Metric) Page 1 of 2

PAGE 1 OF 2
DATE :
International Well Control Forum
Surface BOP Kill Sheet - Vertical Well (Metric/Bar) NAME :
FORMATION STRENGTH DATA: CURRENT WELL DATA::

SURFACE LEAK -OFF PRESSURE FROM
FORMATION STRENGTH TEST (A) bar
DRILLING FLUID DENSITY AT TEST (B) kg/l
MAX. ALLOWABLE DRILLING FLUID DENSITY =

CURRENT DRILLING FLUID:
(A) x 10.2
(B) + = (C) kg/l DENSITY kg/l
SHOE T.V. DEPTH
INITIAL MAASP =
((C) - Current Density) x Shoe TVD =

10.2 CASING SHOE DATA:
SIZE in
M. DEPTH m
PUMP NO. 1 DISPL. PUMP NO. 2 DISPL. T.V. DEPTH m
l / stroke l / stroke
HOLE DATA:
(PL) DYNAMIC PRESSURE LOSS [bar]
SIZE in
SLOW PUMP
PUMP NO. 1 PUMP NO. 2
RATE DATA: M. DEPTH m
T.V. DEPTH m
SPM
SPM
PRE-RECORDED LENGTH CAPACITY VOLUME PUMP STROKES TIME

VOLUME DATA: m l/m litres stks minutes
DRILL PIPE x =
VOLUME PUMP STROKES
HEAVY WALL DRILL PIPE x = +
PUMP DISPLACEMENT SLOW PUMP RATE
DRILL COLLARS x = +
DRILL STRING VOLUME (D) l (E) stks min
DC x OPEN HOLE x =
DP / HWDP x OPEN HOLE x = +
OPEN HOLE VOLUME (F) l stks min
DP x CASING x = (G) + stks min
TOTAL ANNULUS VOLUME (F+G) = (H) l stks min
TOTAL WELL SYSTEM VOLUME (D+H) = (I) l stks min
ACTIVE SURFACE VOLUME (J) l stks
TOTAL ACTIVE FLUID SYSTEM (I +J) l stks

8.3.2 IWCF Kill Sheet Vertical Well (Bar/Metric) Page 2 of 2

PAGE 2 OF 2
DATE :
KICK DATA :
SIDPP bar SICP bar PIT GAIN litres
KILL FLUID DENSITY SIDPP x 10.2

CURRENT DRILLING FLUID DENSITY +
TVD
................. + =
KMD ................ kg / l
INITIAL CIRCULATING DYNAMIC PRESSURE LOSS + SIDPP

PRESSURE
................. + ................. =
ICP ............... bar
KILL FLUID DENSITY

FINAL CIRCULATING x DYNAMIC PRESSURE LOSS
CURRENT DRILLING FLUID DENSITY
PRESSURE
FCP x ................. =
............... bar
(J) x 100
(J) = ICP - FCP Bar --.--------- = Bar/100 strokes
(E)
STATIC & DYNAMIC DRILL PIPE PRESSURE [bar]
STROKES

8.3.3 IWCF Kill Sheet Vertical Well Field Units) Page 2 of 2

PAGE 2 OF 2

Field Units
Surface BOP Stack - Vertical Well
KICK DATA :
SIDPP psi SICP psi PIT GAIN barrels
KILL FLUID DENSITY SIDPP

................. + =
KMD X 0.052 ppg

PRESSURE
................. + ................. =
ICP
(J) x 100 X 100 psi

(J) = ICP - FCP = ................... - ................... = .............. psi = =
(E) 100 strokes
STATIC & DYNAMIC DRILL PIPE PRESSURE [psi]
STROKES

8.3.4 IWCF Kill Sheet Deviated Well (Bar/Metric) Page 1 of 3

PAGE 1 OF 3
DATE :
Surface BOP Kill Sheet - Deviated Well (Metric/Bar) NAME :
FORMATION STRENGTH DATA: CURRENT WELL DATA:

DRILLING FLUID DATA:
FORMATION STRENGTH TEST (A) bar
DENSITY kg/l
DRILLING FLUID DENS. AT TEST (B) kg/l GRADIENT bar/m

(A) x 10.2 (C) kg/l
(B) + =
SHOE T.V.D DEVIATION DATA:
KOP M.D. m
INITIAL MAASP =
KOP T.V.D. m
((C) - Current Density.) x Shoe T.V.D = bar
10.2
EOB M.D. m
EOB T.V.D. m
PUMP NO. 1 DISPL. PUMP NO. 2 DISPL. CASING SHOE DATA:

SIZE in
l / stroke l / stroke
M. DEPTH m
T.V. DEPTH m
SLOW PUMP (PL) DYNAMIC PRESSURE LOSS HOLE DATA:

RATE DATA: PUMP NO. 1 PUMP NO. 2 SIZE in
M. DEPTH m
SPM bar bar
T.V. DEPTH m
SPM bar bar

VOLUME DATA: m l/m litre stks minutes
DP - SURFACE TO KOP x = (L) stks

DP - KOP TO EOB x = + (M) stks
DP - EOB TO BHA x = + (N1) stks
HEVI WALL DRILL PIPE x = + (N2) stks
DRILL COLLAR x = + (N3) stks
DRILL STRING VOLUME (D) l stks min
DC x OPEN HOLE x =
OPEN HOLE VOLUME (F) l stks min

TOTAL ANNULUS VOLUME (F+G) = (H) l stks min
TOTAL WELL SYSTEM VOLUME (D+H) = (I) l stks min
ACTIVE SURFACE VOLUME (J) l

Dr No SD 01/01
TOTAL ACTIVE FLUID SYSTEM (I+J) l (BAR-102)
27-01-2000

8.3.5 IWCF Kill Sheet Deviated Well (Bar/metric) Page 2 of 3

PAGE 2 OF 3
DATE :
KICK DATA :
SIDPP bar SICP bar PIT GAIN litre

TVD
................. + =
KMD ................ kg / l
INITIAL CIRC. PRESS.

DYNAMIC PRESSURE LOSS + SIDPP ................. + ................. =
ICP ............... bar
KILL FLUID DENSITY

PRESSURE
FCP x ................. =
............... bar
DYNAMIC PRESSURE KOPMD

PL + (FCP-PL) x = .......... + (...........-............) x =
LOSS AT KOP (O) TDMD ............... bar
SIDPP - (KMD - OMD) x KOPTVD

REMAINING SIDPP 10.2
AT KOP (P) = .............. - ( - .) x =
10.2 ............... bar
CIRCULATING PRESS.
(O) + (P) = ............. + ............. =
AT KOP (KOP CP) ............... bar
DYNAMIC PRESS. LOSS EOBMD

PL + (FCP-PL) x = .......... + (...........-............) x =
AT EOB (R) TDMD ............... bar
SIDPP - (KMD - OMD) x EOBTVD = .............. - (..................-...................) x ................. =

REMAINING SIDPP 10.2
10.2
AT EOB (S)
............... bar
CIRCULATING PRESS.
(R) + (S) = ............. + ............. =
AT EOB (EOB CP) ............... bar
(T) x 100 x 100 bar

(T) = ICP - KOP CP = ............... - ............. = ........... bar = = .............
(L) 100 strokes
(U) x 100 x 100 bar

(U) = KOP CP - EOB CP = .......... - .......... = ........... bar = = .............
(M) 100 strokes
(W) x 100 x 100 bar

(W) = EOB CP - FCP = ............ - .............. = ........... bar = = .............
(N1+N2+N3) 100 strokes
Dr No SD 01/02 (BAR-102) 27-01-2000

8.3.6 IWCF Kill Sheet Deviated Well (Bar/metric) Page 3 of 3

PAGE 3 OF 3
DATE :
STROKES
PRESSURE
[bar]
STROKES
Dr No SD 01/03 (BAR-102) 27-01-2000

8.3.7 IWCF Kill Sheet Deviated Well (Field Units) Page 1 of 3

PAGE 1 OF 3
DATE :
SURFACE BOP KILL SHEET NAME :
DEVIATED WELL UNITS : FIELD
FORMATION STRENGTH DATA: CURRENT WELL DATA:

DRILLING FLUID DATA:
FORMATION STRENGTH TEST (A) psi
DENSITY ppg
DRILLING FLUID DENS. AT TEST (B) ppg GRADIENT psi/ft

(A) (C) ppg
(B) + =
SHOE T.V. DEPTH x 0.052 DEVIATION DATA:
KOP M.D. ft
INITIAL MAASP =
KOP T.V.D. ft
((C) - CURR. DENS.) x SHOE T.V. DEPTH x 0.052
= psi EOB M.D. ft

EOB T.V.D. ft
PUMP NO. 1 DISPL. PUMP NO. 2 DISPL. CASING SHOE DATA:

SIZE in
bbl / stroke bbl / stroke
M. DEPTH ft
T.V. DEPTH ft
SLOW PUMP (PL) DYNAMIC PRESSURE LOSS HOLE DATA:

RATE DATA: PUMP NO. 1 PUMP NO. 2 SIZE in
M. DEPTH ft
SPM psi psi
T.V. DEPTH ft
SPM psi psi

VOLUME DATA: ft bbl / ft bbl stks minutes
DP - SURFACE TO KOP x = (L) stks

DP - KOP TO EOB x = + (M) stks
DP - EOB TO BHA x = + (N1) stks
HEVI WALL DRILL PIPE x = + (N2) stks
DRILL COLLAR x = + (N3) stks
DRILL STRING VOLUME (D) bbl stks min
DC x OPEN HOLE x =
OPEN HOLE VOLUME (F) bbl stks min

TOTAL ANNULUS VOLUME (F+G) = (H) bbl stks min
TOTAL WELL SYSTEM VOLUME (D+H) = (I) bbl stks min
ACTIVE SURFACE VOLUME (J) bbl

TOTAL ACTIVE FLUID SYSTEM (I+J) bbl


PAGE 2 OF 3
International Well Control Forum DATE :
KICK DATA :
SIDPP psi SICP psi PIT GAIN bbl
KILL FLUID DENSITY SIDPP

TVD x 0.052
.................................
KMD ................. + =
..................... x 0.052 ................ ppg
INITIAL CIRC. PRESS. DYNAMIC PRESSURE LOSS + SIDPP

ICP ................. + ................. = ............... psi
KILL FLUID DENSITY

PRESSURE
....................
FCP x ................. =
.................... ............... psi
DYNAMIC PRESSURE KOPMD ............

PL + (FCP-PL) x = .......... + (...........-............) x =
LOSS AT KOP (O) TDMD ............ ............... psi
SIDPP - (KMD - OMD) x 0.052 x KOPTVD

REMAINING SIDPP
AT KOP (P) = .............. - (..................-...................) x 0.052 x ................. =
............... psi
CIRCULATING PRESS.
(O) + (P) = ............. + ............. =
AT KOP (KOP CP) ............... psi
DYNAMIC PRESS. LOSS EOBMD ............

PL + (FCP-PL) x = .......... + (...........-............) x =
AT EOB (R) TDMD ............ ............... psi
SIDPP - (KMD - OMD) x 0.052 x EOBTVD

REMAINING SIDPP
AT EOB (S) = .............. - (..................-...................) x 0.052 x ................. =
............... psi
CIRCULATING PRESS.
(R) + (S) = ............. + ............. =
AT EOB (EOB CP) ............... psi
(T) x 100 .......... x 100 psi

(T) = ICP - KOP CP = ............... - ............. = ........... psi = = .............
(L) ........... 100 strokes
(U) x 100 .......... x 100 psi

(U) = KOP CP - EOB CP = .......... - .......... = ........... psi = = .............
(M) ........... 100 strokes
(W) x 100 .......... x 100 psi

(W) = EOB CP - FCP = ............ - .............. = ........... psi = = .............
(N1+N2+N3) ........... 100 strokes


PAGE 3 OF 3
International Well Control Forum DATE :

STATIC & DYNAMIC DRILL PIPE PRESSURE [psi]
STROKES
PRESSURE
[psi]
STROKES

8.4 Stripping Form
Pchoke = Pan + Ps + Pw = ………..
Pan = ………..
F – factor = ………..
Volume influx = ………..
Ps = F x Vi = …………
Pw selected = …………
divisions in triptank
Triptank level with required Pchoke
T. T. Level Pch
T
i
Stand Pchoke Triptank Remarks
m
No. level
e

8.5 Stripping Check Sheet
Step Stripping Check List YES
1 Has one person being designated to supervise the entire stripping operation?
2 Is the bop stack spaced for stripping and are drawings with measurement available?
3 Is shut-in pressure recorded?
4 Was a heavy pill pumped into the hole before they started out of the hole?
5 Has an inside bop been installed in the drillstring?
6 Is there any evidence of gas migration?
7 Is there everything rigged up for the combined stripping and volumetric method?
8 Has the effective string weight being calculated?
9 Has wellbore force being calculated to verify that the string can be stripped back either through
the annular preventer or ram preventer?
10 Has open hole capacity and open hole to DC capacity been calculated?
11 Are spare parts available for a lower kelly cock?
12 Will all the fluid which will be bled off go into the calibrated trip tank?
13 Have arrangements been made to accurately record and calculate all pressures and volumes?
14 Have arrangements been made to fill the pipe with mud?
15 Have pressure gauges been checked and compared?
16 Has the pressure recorder been hooked up?
17 What is the calculated MAASP and casing burst pressure?
18 Has preparation for removal of DP protectors been made, if installed?
19 Has the effect of stripping into the influx been considered?
20 Have specific jobs been assigned to personnel on location and have proper instructions been
given?
21 Has the Kelly cock been opened before the first stand was made up, in order to check the inside
BOP and to confirm that circulation is possible?
22 Has the correct amount of mud to be bleeding off as the pipe is stripped in been calculated?
23 Has all mud been accurately measured?
24 Has trip tank been calibrated?
25 Has the rig been prepared for lubricating the DP when they are stripped back into the hole?
26 Has preparation been made to circulate out when pipe is on bottom?
27 What was the SCR pressure before tripping out?

Stripping Calculations and Formulae

A worst-case estimation of the pressures acting along the wellbore can be obtained by using the
following formula. It is assumed the original influx volume was on bottom when the well was closed
in, after which the BHP is established at (D x p1).
Vinf.x = [(Dh x p1) - Pf ] x (Vinf.o x pop1)  Px

Where:
A= (X x p1 ) - Pf x ( OH.cap  Av.cap.x)
Px = Pressure at the top of the influx at point of interest ( x )
Av.cap.x = Average annular capacity of influx at point x.
pinf.o = Original influx gradient
p1 = Mud gradient
po = Pore pressure gradient
Pf = pinf.o x hinf.o x p1 / po
X= Depth of point of interest.
The measured kick volume at the time the well was closed in will be compensated due to the
increased BHP to:
Vinf.o x (po) / (p1)
Actual pressures during volumetric killing operations are usually lower than calculated P x values
because:
a. The influx is fragmented and dispersed in the mud instead of remaining as a
single slug.
b. The influx is probably not on bottom at the time of closing in the well.
Gas migration rate can be estimated in a water based mud using following formula:
Where:
Pa1 = Closed-in casing pressure at time T1 minutes, (kPa, bar or psi)
Pa2 = Closed-in casing pressure at time T2 minutes without having allowed the
influx to expand, (kPa, bar or psi)
p1 = Mud gradient, (kPa/m, bar/m or psi/ft)

8.6 Form for Completing a Leak off Test
Leak-Off Test Report
Well: Area: Date:
Init. Press Final Press
P
r
e
s
s
u
r
e
Cumulative Volume
Formation: Total Volume Pumped:

Depth, (metre): Back flow:
Mud gradient in use, (Kg / litre):
BHP static, (bar):
Gradient, (bar/m):
Remarks:
Signature

Calculation of MAASP
Calculation of the maximum pressure (at the top of the gas) when the gas influx reaches the shoe
can be done either by calculation or graphically as follows:
Calculation of the maximum pressure (at the top of the gas) when the gas influx reaches the shoe
using the formula:
Px = 0.5A + [ 0.5A + { Po - ( hinf.o X pinf.a )} x p2 x (Vinf.o /AV.cap.x )]1/2

where:
A = Po - (D - X)p2 + D1(p2 - p1) - (hinf.o x pinf.o)
Px = Pressure at the top of the gas point X
Po = Formation pressure
hinf.o = Height of gas column at the bottom of the hole
pinf.o = Original influx gradient
p1 = Original mud gradient
p2 = Kill mud gradient
Vinf.o = Original influx volume
AV.cap.x = Average annular capacity of influx volume at point x
AV.cap.o = Average annular capacity of influx volume at bottom
D = Depth of the hole
X = Depth of point x
D1 = Height of p1 mud in the annulus after it has been displaced from
drillstring
Calculation of the maximum pressure when the gas influx reaches the shoe using the graph.
Make a graph with the depth to the left and the pressures at the bottom. Draw in the casing shoe
setting depth (Figure 1)
Draw a line for the formation break down pressure crossing the casing shoe line at the right FGT
pressure and extend this line to the bottom of the graph.
Draw a line for the actual BHP (Bottom hole pressure) when the kick occurred.

Figure 1: Graphic Determination of MAASP
Draw up the influx height and extend this line to the top, parallel with the BHP line.
If this line is crossing the formation break down line below the shoe line the MAASP will be
exceeded. (Line b in the graph).
If crossing is above the shoe line the pressure at the shoe will be below the MAASP. (Line a in the
graph).
MAASP = FBP - Head of mud in use to shoe.
Note: The MAASP must be re-calculated if:

(a) The mud density is changed.
(b) A weaker formation has been detected.
(c) A hole or leak develops in the casing.
(d) The cement bond around the shoe of the casing fails
Every time the mud density is changed, the MAASP changes and must be recalculated, hence the
equation above can be rewritten as:
MAASP = (Breakdown gradient - Mud gradient) x Shoe TVD
If a Maximum equivalent mud density is being used as formation strength then the above shall
become:
MAASP (psi) = (Max. EMD (ppg) - Current mud dty.(ppg)) x 0.052 x Shoe TVD (ft)
MAASP (bar) = (Max. EMD (kg/l) - Current mud dty.(kg/l)) x 0.0981 x Shoe TVD (m)
3 3
MAASP (kPa) = (Max. EMD (kg/m ) - Current mud dty.(kg/m ) : 102) x Shoe TVD (m)
EMD is the Maximum Allowable Drilling Fluid Density on the IWCF form in the formation strength
data.
8.7 Calculation of Reservoir Pressure (& Kill Mud Weight)

Once the well is shut in, providing nothing has broken down, the pressure in the well will be in
balance and the reservoir pressure can be calculated by the ‘u’ tube method as described in section
Appendix 1.
What is lacking in hydrostatic head of fluid in the well is now being made up by surface pressures on
the annulus (SICP), and drillpipe (SIDPP).
This allows us to determine what the invading formation pressure is and thereafter, what kill mud
density shall be required to achieve balance (Figure 1).
On the DP side of the U tube;
Formation pressure = Hydrostatic pressure of mud in DP + Shut in DP pressure, (SIDPP)
On the casing side of the U tube;
Formation pressure = Hydrostatic pressure of mud in annulus + Hydrostatic pressure of
influx + Shut in casing pressure, (SICP)
The mixture of mud and formation fluid in the annulus makes it impossible to determine formation
pressure using the casing information. The DP however is full of uncontaminated mud of known
density and can be used as a yardstick of what is happening downhole.

Once the formation pressure is known, the mud density required to kill (balance) can be calculated
thus:
Kill mud density (ppg) = Formation press. (psi)  
Kill mud density (kg/l) = Formation press. (bar) 
Kill mud density (kg/m ) = Formation press. (kPa) 
3
SIDPP SICP
Drillpipe Annulus
Figure 8-1 U-tube method to determine reservoir pressure

8.8 Kick Behaviour
8.8.1 A comparison between oil and water base muds.

Due to high temperatures and pressure a small gas kick can turn into a serious well control problem
with oil base muds. Solution gas can become dissolved and miscible. The reason for this is that the
gas remains in the solution until it reaches its bubble point. In the same way that gas in a disposable
lighter remains in its liquid phase until the pressure is relieved.
In the Figure 8-2 three barrels of gas have entered the wellbore at 10.000 ft, but we would see no pit
gain while drilling until the gas has been circulated up to 2600 ft. The gas then expands rapidly and
there is the real danger of blowing out sufficient mud to put the entire well underbalanced. This
problem is easier to detect in water based mud (figure 2) because the original volume of the gas will
expand much earlier as the pressure above the gas is reduced. The problem in oil base muds is that
if a kick has entered the wellbore undetected it is impossible to know where the top of the gas is.
For example if the pump rate is say 80 SPM and the pump output is 0,117 bbls then in an 8.5” hole
section with 5” drill pipe the influx would travel 203 ft for each minute that the kick is undetected. In
extreme cases the gas could be 6000 - 7000 ft away from the surface without the driller realising
anything is wrong.
Under these conditions it may be prudent to count all drilling breaks as primary indicators. Stop
drilling, shut off the pumps and close the well in. The gas can then be circulated through the choke
in a safe manner utilizing the first circulation of the driller's method. Some procedures advised that
the gas should be circulated to 2500 feet (750m) below the bop before the well is shut in and the gas
circulated through the choke. It may be the case that the bubble point is lower and unless this
information is known, even though the first procedure may take a little longer, remember safety is
always our main concern.

Figure 8-2 Expansion of Gas
8.9 Influx Gradient

Note that these calculations only work in vertical wells. In highly deviated and horizontal wells they
are not to be used as the correct vertical height of the kick will be needed. Even when using in
vertical wells 3 parameters must be absolutely correct:
(a) the correct height of the kick ( potential problems if washouts exist )
(b) drillpipe and casing gauges must be working accurately
(c) the influx volume must be known exactly

In any other case the results can become negative or result in an incorrect gradient for the influx.
The solution is for each kick has to be handled as a gas kick.
The relationship between surface pressures, influx height and density is:
Grad. of influx, psi/ft = Grad. of mud, psi/ft - [(SICP - SIDPP) Influx height, ft]
8.9.1 Example Influx gradient Calculations
8.9.1.1 Example using API Field units:

When drilling at 12500 ft with 14 ppg mud we took a pit gain of 20 bbls. When the well was closed in,
the SIDPP read 300 psi, and the SICP read 705 psi. If annular volume around drill collars is 0.03
bbls/ft, calculate the influx gradient.
Influx height = Kick volume  Annular volume = 20 bbls  0.03 bbls/ft = 667 ft Grad. of mud = 14
ppg x 0.052 = 0.728 psi/ft
Grad. of influx = 0.728 psi/ft - [(705 - 300)  667] = 0.728 - 0.607 = 0.12 psi/ft
8.9.1.2 Example using Bar / Litre units:

When drilling at 3810 m with 1,68 kg/l mud we took a pit gain of 3180 litres. When the well was
closed in, the SIDPP read 21 bar, and the SICP read 50 bar. If annular volume around drill collars is
15,14 l/m, calculate the influx gradient.
Influx height = Kick volume  Annular volume = 3180 l  15,14 l/m = 210 m
Grad. of mud = 1,68 kg/l x 0,0981 = 0,165 bar/m
Grad. of influx = 0,165 bar/m - [(50 - 21)  210] = 0,165 - 0,138 = 0,027 bar/m
8.10 Gradients of some common wellbore Fluids
Fluid Column Gradient psi/ft Gradient bar/m Gradient kPa/m
Salt water 0.465 0.1052 10.52
Fresh water 0.433 0.0979 9.79
Water and gas 0.396 0.0896 8.96
Water and oil 0.382 0.0864 8.64
Oil 0.300 0.0679 6.79
Oil and gas 0.250 0.0566 5.66
Gas 0.120 0.0271 2.71
8.11 Gas Migration, Boyles Law,
8.11.1 Boyles Law

Boyles Law is an expression of the relationship between gas pressure and gas volume. Basically, it
states that a given mass of gas, if under a given absolute pressure (measured from an absolute
vacuum), will always occupy a definite and calculable volume.

Further, if that same mass of gas is taken to a different absolute pressure, then it will also occupy a
different calculable volume.
Note: The effects of compressibility and temperature must also be taken into account for
absolute precision but may be neglected for most field determinations.
For a unit of gas we have a unit of pressure, but we can compress that unit of gas to half it's original
size by doubling the pressure upon it. Original pressure x Original volume = New pressure x New
volume, or,
P1 x V1 = P2 x V2
Working this equation will show the extremes that occur with gas kicks.
8.11.1.1 Example Calculation

Examples using API Field Units:
When drilling with 10 ppg mud at 10000’ we take a kick of 30 bbls. If the kick was
allowed to travel to surface and expand freely, the following would be true:
At 10000' the hydrostatic pressure of the mud and the kick (ignoring formation pressure) would be:
10000 ft x 0.052 psi/ft = 5200 psi
As the bubble reaches 5000 ft with a hydrostatic head of 2600 psi, the volume of the gas bubble is
now:
P1 x V1 = P2 x V2
5200 x 30 = 2600 x V2
V2 = (5200 x 30)  2600 or V2 = 60 bbls.
But as the gas bubble breaks out at surface in atmospheric (14.6 psi), the original 30 bbl influx of gas
now becomes:
P1 x V1 = P2 x V2
5200 x 30 = 14.6 x V2
V2 = (5200 x 30) 14.6 or V2 = 10685 bbls.
This is a much greater volume than the entire annular capacity so the well would be blowing wildly.
Examples using Metric Units:

When drilling with 1.2 kg/l mud at 3060 m we take a kick of 4770 litres. If the kick was allowed to
travel to surface and expand freely, the following would be true;
At 3060 m the hydrostatic pressure of the mud and the kick (ignoring formation pressure) would be:
3060m x 1.20 kg/l x 0.0981 = 360 bar

As the bubble reaches 1530 m with a hydrostatic head of 180 bar, the volume of the gas bubble is
now:
P1 x V1 = P2 x V2
360 x 4.77 = 180 x V2
V2 = (360 x 4.77)  180 or V2 = 9.54 m .
3
3
(But as the gas bubble breaks out at surface in atmospheric (1 bar), the original 4.77 m influx of
gas now becomes:
P1 x V1 = P2 x V2
360 x 4.77 = 1 x V2
V2 = (360 x 4.77)  1 or V2 = 1717 m .
3
This is a much greater volume than the entire annular capacity so the well would be blowing wildly.
8.11.2 Gas Migration

If the well is closed in, the gas bubble will migrate up the annulus and hence cause the Shut In
Casing Pressure (SICP) to increase. Unless there is a float sub in the bottom hole assembly, the
pressure increase will also be reflected on the Shut In Drillpipe Pressure (SIDPP).
If the bubble is allowed to rise but is NOT allowed to expand, then the rising bubble will bring the
bottom hole pressure (BHP) up the well and cause the pressure to increase both ahead of and
behind the bubble.
However, as soon as the rising pressure becomes equal to the fracture pressure at the last casing
shoe (or other weak formation) that formation will break down and fluid from the wellbore will enter
the formation.
At this point, the SIDPP will no longer rise, but the SICP will continue to rise as the bubble continues
to migrate to the surface. The rising gas can now expand, as it will force the mud below it back into
the weak zone.
Note: Gas can be allowed to migrate up the wellbore safely by allowing the SIDPP to rise by 100
psi, 7 bar, and 700 kPa then by keeping the SIDPP at that value by carefully bleeding mud from the
annulus until the gas is at the surface. The gas can then be lubricated out. In effect, this is the
equivalent of the first circulation of the Driller’s Method, but without circulation.
During a kill operation, the gas bubble is allowed to expand in a controlled fashion while keeping the
BHP equal to the original shut in formation pore pressure (plus a small safety factor) and does not
bring the formation pressure to surface.
There are a many factors that can affect the gas migration. These are:
a. Hole size (annular diameter).
b. Difference in density of gas and mud/fluid.
c. The depth of the gas influx.
d. Wellbore temperature.
e. Viscosity of the well fluid.
f. If the gas influx is fragmented.
g. Type of the drilling fluid (Oil base or Water base).
h. Inclination of the well.
However, a rule of thumb when calculating gas migration can be expressed thus:

Migration rate ft/min =

(New SICP - Original SICP)  (Mud Grad. x Difference in time of SICP's)
Note: In horizontal wells and while the gas is in the horizontal section there will be no noticeable
migration of gas. In highly deviated wells the migration can be very slowly or even zero. Even in
vertical wells it can be that no migration takes place.
8.12 Hydrates
The formation of hydrates is dependent upon a combination of the following conditions:
a. Presence of free water
b. Gas at or below it's dew point
c. Low temperature
d. High pressure
The hydrate problem is aggravated by pressure drop / gas expansion (through the choke) and
pressure pulsing.
As the gas passes through these restrictions the resulting pressure drop plus the sudden increase in
velocity cause “expansion cooling” of the gas immediately downstream of the choke.
Hydrates can cause severe problems by plugging valves or chokes and completely blocking flow.
Upstream pressure increases and this compounds the problem.
Prevention of hydrates will always be easier and better than the cure. It may be necessary to inject
methanol or glycol to suppress hydrate formation. Ports can be modified into the choke manifold for
this purpose.
The hydrate problem is virtually non-existent in Oil base muds. With Water base muds, maintaining a
high chloride concentration in the mud will lower the freezing point.
If hydrates do form and plug off the choke or kill line they can be very difficult to remove.
Considerable heat is required for decomposition, for example, circulating hot brine solution.

8.13 Worked Examples
8.13.1 Example Calculations – Kick Tolerance
8.13.1.1 Example using API Field Units:

We are drilling at 8000' with 12 ppg mud. The casing shoe is at 3500' and the current MAASP is
810 psi.
A 40 bbl gas influx (gradient 0,100 psi/ft) enters the well and the surface pressures after close in
are
SIDPP = 520 psi, SICP = 692 psi.
Max. tolerable pressure at shoe = MAASP + Hydrostatic pressure at shoe:
= 810 + (3500 x 12 x 0.052) = 2994 psi.
Formation pressure = SIDPP + Hydrostatic at TVD:

= 520 + (8000 x 12 x 0.052) = 5512 psi
Kick tolerance max. height of influx:

= (MAASP - SIDPP) ÷(Grad. of mud - Grad. of influx)
= (810 - 520) ÷0.624-0,100) = 553 feet,
and if annular capacity is 8.23 ft/bbl then 553 ft becomes 67 bbls. This is the maximum volume of
influx that we could have at the shoe and if we calculate back using Boyles Law to find a tolerable
volume of original influx, the equation reads thus:
P1 x V1 = P2 x V2 or (2994 x 67) ÷5512 = V2 = 36 bbls.
Calculating our 40 bbl influx, then the volume at the shoe would be:
V2 = (5512 x 40) ÷2994 = 73 bbls.
This is clearly not viable to circulate out using the Driller’s Method. However, if the annulus volume
below the shoe is greater than the string volume then there will be kill mud in the annulus prior to
the bubble getting to the shoe and hence lowering the pressure at the shoe.
8.13.1.2 Example using Bar / Litre Units:

We are drilling at 2440 m with 1,44 kg/l mud. The casing shoe is at 1090 m and the current MAASP
is 57 bar.
A 6360 litre gas influx (gradient 0.0271 bar/m) enters the well and the surface pressures after close
in are SIDPP = 36 bar, SICP = 49 bar.
Max. tolerable pressure at shoe = MAASP + Hydrostatic pressure at shoe:

= 57 + (1090 x 1.44 x 0.0981) = 211 bar.
Formation pressure = SIDPP + Hydrostatic at TVD:

= 36 + (2440 x 1.44 x 0.0981) = 380 bar.
Kick tolerance max. height of influx:

= (MAASP - SIDPP) ÷(Grad. of mud - Grad. of influx)

= (57 - 36) ÷(0.141 - 0.0271) = 184 m,
3 3
and if annular capacity is 19 m/m then 184 m becomes (184 x 19) = 9.68 m . This is the
maximum volume of influx that we could have at the shoe and if we calculate back using Boyles
Law to find a tolerable volume of original influx, the equation reads thus:
3
P1 x V1 = P2 x V2 or (211 x 9.68) ÷380 = V2 = 5.37 m
3
Calculating our 6.360 m influx, then the volume at the shoe would be:
3
V2 = (380 x 6.36) ÷211 = 11.45 m .
This is clearly not viable to circulate out using the Driller’s Method. However, if the annulus volume
below the shoe is greater than the string volume then there will be kill mud in the annulus prior to
the bubble getting to the shoe and hence lowering the pressure at the shoe.

8.13.2 Example Calculations: Barite Addition
8.13.2.1 Weight of Barite required for mud density increase.

For mud density in ppg:
1490 x(new mud density  old mud density )
Lbs. Of Barite required/bbl mud =
( 3,55  new mud density )
For mud density in kg/l :

(new mud density  old mud density )
Kg. of Barite required/m3 mud = x 4200
8.13.2.2 Volume increase due to Barite addition

For mud density in ppg:
(new mud density  old mud density )
Volume increase (bbls) =
3 (new mud density  old mud density )

Volume increase (L/m ) = x 1000
8.13.2.3 Example calculations

Old mud density = 1,44 kg/l (mud density before kick)
New mud density = 1,59 kg/l (mud density required to kill the well)
Total active fluid system volume = 263 m3
Calculate the bags of Barite required. ( 1 bag = 25 kg)
Solution:
Kg of Barite required per m3 of mud volume =
 ( new mud density  old mud density ) 

=   x 4200
 ( 4,2  new mud density ) 
 (1,59 1,44 ) 
=   x 4200
 ( 4,2 1,59) 
3
= 241, 37 kg/m
= (241, 37 kg/m3 x 263 m3 /25 kg/bag) 2540 bag.

Volume to take out of original mud due to Barite addition without increasing the volume of mud
amount:
Volume increase to original mud volume:

(L/m ) = x 1000
( 4,2  old mud density )
Weight of Barite required for mud density increase after reduced mud amount
Volume to add Barite after reduced mud amount:

(kg/m ) = x 4200
( 4,2  old mud density )
 (1,59 1,44 ) 
  x 1000 = 54.34 L/ m3
 ( 4,2  1, 44) 
That means: 54.34 L/m³ x 263m³ : 1000 = 14.29m³ have to reduced of the old mud amount
 (1,59 1,44 ) 
  x 4200 = 228.26kg/ m3
 ( 4,2 1,44) 
That means: 228.26kg/m³ x (263m³ - 14.29m³) / 25 = 2271bag need to weight up the

original mud amount.

8.14 Field Worked Example – Drillers method

Scenario
In a straight hole with the last casing at 1066 m a drilling break is experienced at a depth of 2438
m. The pump is stopped and the string is picked up. It is observed that the well is flowing and
therefore it is closed in immediately. The shut-in drillpipe pressure, SIDPP, stabilises at 36 bar, and
the shut-in casing pressure, SICP, at 49 bar. A check of the pit level recorder indicates a volume
gain of approximately 2.4 m³.
This information is added to the pre-recorded data on the IWCF Surface BOP Kill Sheet. We
assume the decision is made to circulate the influx out first. Then with another full circulation the
well will be killed.
Record the remaining data on the Kill Sheet
 Hole Data: Measured depth and TVD
 Volume Data: Length of DP
Calculate remaining Volume
Calculate displacement in pump strokes and time (min)
Circulating out the influx
Calculate
 Initial Circulating Pressure ICP (w/ kill fluid density)
Complete the graph with DP pressure versus strokes
 Draw a horizontal line for the amount of strokes with the ICP from surface to bit.
 Continue the line for the amount of strokes from “the bit to the shoe”
 Continue the line for the amount of strokes from “the shoe to surface”
If the the graph on the kill sheet cannot accommodate all this information, make a separate
graph.
When circulating out commences record the strokes and corresponding pressure on the kill
sheet.
The following Kill Sheet is an example with above information.
In this example the pump volumetric efficiency is assumed to be 100%, no margin is included for
the kill fluid density and the pump strokes and corresponding time is calculated at 50 SPM.
In the meantime we can calculate the:
 Kill Fluid Density
 Kill Fluid Gradient
 Final Circulating Pressure FCP (w/ kill fluid gradient)
 Difference between the ICP and the FCP (K)
 Pressure drop per 100 strokes
Killing the Well
On a new “Kill Sheet page 2” the remaining information can be noted and the graph for killing can
be made.
(a) Draw a line for the amount of strokes from the ICP to the FCP (surface to Bit) (Optional)
(b) Draw a horizontal line for the amount of strokes from “the bit to the shoe”
(c) Draw a horizontal line for the amount of strokes from “the shoe to surface”
Note: If the graph on the kill sheet not accommodate all this information, make a
separate graph.

Kill Sheet Page 1 Driller`s Method.

PAGE 1 OF 2
DATE :

FORMATION STRENGTH TEST (A) 65 bar
DRILLING FLUID DENSITY AT TEST (B) 1,30 kg/l

(A) x 10.2
(B) + = (C) 1,92 kg/l DENSITY 1,44 kg/l
SHOE T.V. DEPTH
INITIAL MAASP =
((C)
- Current Density) x Shoe TVD = 50
SIZE 13 3/8” in
M. DEPTH 1066 m
PUMP NO. 1 DISPL. PUMP NO. 2 DISPL. T.V. DEPTH 1066 m
13,89 l / stroke 13,89 l / stroke
HOLE DATA:
(PL) DYNAMIC P
RESSURE OSS
L [bar]
SIZE 12 1/4” in
SLOW PUMP
RATE DATA: M. DEPTH 2438 m
T.V. DEPTH 2438 m

50 SPM 36 36
60 SPM 52 52

DRILL PIPE 2182 x 9,27 = 20224 VOLUME PUMP STROKES

HEAVY WALL DRILL PIPE 112 x 6,21 = 698 +
DRILL COLLARS 144 x 4,19 = 603 +
DRILL STRING VOLUME (D) 21525 l (E) 1550 stks 31 min
DC x OPEN HOLE 144 x 43,6 = 6278

DP / HWDP x OPEN HOLE 1228 x 62,7 = 76996 +
OPEN HOLE VOLUME (F) 83274 l 5995 stks 120 min
DP x CASING 1066 x 66,1 = (G) 70463 + 5073 stks 101 min
TOTAL ANNULUS VOLUME (F+G)(H)

= 153737 l 11068 stks 221 min
TOTAL WELL SYSTEM VOLUME (D+H) = (I) 175262 l 12618 stks 252 min
ACTIVE SURFACE VOLUME (J) 87450 l 6296 stks
TOTAL ACTIVE FLUID SYSTEM (I +J) 262712 l 18914 stks

Kill Sheet Page 2a Driller`s Method. Step 1: Circulating out all the Kick.
PAGE 2 OF 2
DATE :
KICK DATA :
SIDPP 36 bar SICP 49 bar PIT GAIN 2400 litres

TVD
..................... + =
KMD ............... kg / l

PRESSURE
...36...... + ....36......... = 72 bar
ICP ...............
KILL FLUID DENSITY

PRESSURE
FCP x ................. =
............... bar
(J) x 100
(J) = ICP - FCP Bar --.--------- = Bar/100 strokes
(E)
Keep ICP Constant

72
60
50
40
30
20
10
0 5 10 X1000
ICP constant still all the Influx is out. STROKES

Kill Sheet Page 2b Driller`s Method. Step 2: Circulating in the Kill Mud.
PAGE 2 OF 2
DATE :
KICK DATA :

TVD
......1,44........... +
36 x 10,2
KMD 2438
= ....1,59.... kg / l

PRESSURE
...36...... + ....36......... = 72 bar
ICP ...............
KILL FLUID DENSITY

PRESSURE
FCP 1,59 36
x ................. =
1,44 40 bar
...............
(J) x 100
(J) = ICP - FCP 32 Bar --.--------- = 2 Bar/100 strokes
(E)
72
60
50
FCP now Constant
40
36
30
Keep Casing
Pressure Constant
20
10
0 New Mud 1550 Bit to Surface

Surface to Bit STROKES

8.15 Field Worked Example – Wait & Weight method

Scenario
In a straight hole with the last casing at 1066 m a drilling break is experienced at a depth of 2438
m. The pump is stopped and the string is picked up. It is observed that the well is flowing and
therefore it is closed in immediately. The shut-in drillpipe pressure, SIDPP, stabilises at 36 bar, and
the shut-in casing pressure, SICP, at 49 bar. A check of the pit level recorder indicates a volume
gain of approximately 2.4 m³. This information is added to the pre-recorded data on the IWCF
Surface BOP Kill Sheet.
Record the remaining data on the Kill Sheet

 h of DP
Calculate remaining Volume
Calculate displacement in pump strokes and time (min)
Calculate the following:
 Kill Fluid Density


 uid gradient)


Complete the graph with DP pressure versus strokes
(a) Draw a line for the amount of strokes from the ICP to the FCP (surface to Bit)
(b) Draw a horizontal line for the amount of strokes from “the bit to the shoe”
(c) Draw a horizontal line for the amount of strokes from “the shoe to surface”
Should the graph on the kill sheet not accommodate all this information, make a separate
graph.
Circulating the well to Kill Mud
When circulating out and killing commences record the strokes and corresponding pressure on the
kill sheet.
The following Kill Sheet is an example with the above information. In this example the pump
volumetric efficiency is 100%, no margin is included for the kill fluid density and the pump strokes
and corresponding time is calculated at 50 SPM.

Kill Sheet Wait and Weight Method Page 1.

PAGE 1 OF 2
DATE :

FORMATION STRENGTH TEST (A) 65 bar
DRILLING FLUID DENSITY AT TEST (B) 1,30 kg/l

(A) x 10.2
(B) + = (C) 1,92 kg/l DENSITY 1,44 kg/l
SHOE T.V. DEPTH
INITIAL MAASP =
((C)
- Current Density) x Shoe TVD = 50
SIZE 13 3/8” in
M. DEPTH 1066 m
PUMP NO. 1 DISPL. PUMP NO. 2 DISPL. T.V. DEPTH 1066 m
13,89 l / stroke 13,89 l / stroke
HOLE DATA:
(PL) DYNAMIC P
RESSURE OSS
L [bar]
SIZE 12 1/4” in
SLOW PUMP
RATE DATA: M. DEPTH 2438 m
T.V. DEPTH 2438 m

50 SPM 36 36
60 SPM 52 52

DRILL PIPE 2182 x 9,27 = 20224 VOLUME PUMP STROKES

HEAVY WALL DRILL PIPE 112 x 6,21 = 698 +
DRILL COLLARS 144 x 4,19 = 603 +
DRILL STRING VOLUME (D) 21525 l (E) 1550 stks 31 min
DC x OPEN HOLE 144 x 43,6 = 6278

DP / HWDP x OPEN HOLE 1228 x 62,7 = 76996 +
OPEN HOLE VOLUME (F) 83274 l 5995 stks 120 min
DP x CASING 1066 x 66,1 = (G) 70463 + 5073 stks 101 min
TOTAL ANNULUS VOLUME (F+G)(H)

= 153737 l 11068 stks 221 min
TOTAL WELL SYSTEM VOLUME (D+H) = (I) 175262 l 12618 stks 252 min
ACTIVE SURFACE VOLUME (J) 87450 l 6296 stks
TOTAL ACTIVE FLUID SYSTEM (I +J) 262712 l 18914 stks

Kill Sheet Wait and Weight Method Page 2.

PAGE 2 OF 2
DATE :
KICK DATA :

TVD
......1,44........... +
36 x 10,2
KMD 2438
= ....1,59.... kg / l

PRESSURE
...36...... + ....36......... = 72 bar
ICP ...............
KILL FLUID DENSITY

PRESSURE
FCP 1,59 36
x ................. =
1,44 40 bar
...............
(J) x 100
(J) = ICP - FCP 32 Bar --.--------- = 2 Bar/100 strokes
(E)
72
60
50
FCP
40
Surface
to
30
Bit Bit to Surface
20
10
0 1000 2000 3000 4000

1550 STROKES

9 Appendix 2: Shallow Gas Requirements

9.1 Introduction
Shallow gas is considered to be gas that is encountered in a well, normally near the surface, which
cannot be closed in as the casing scheme has not yet reached a stage where normal BOP
protection can be installed.
Shallow gas can be a hazard in the following operations:
 rig installation
 conductor driving
 top hole drilling.
An understanding of all applicable procedures relating to the avoidance of a shallow gas influx and
the application of sound drilling practices are the most important factors preventing shallow gas
incidents.
Whilst the avoidance of drilling in known shallow gas areas is the primary mitigation of risk and the
Operator’s responsibility; the presence of shallow gas cannot be ruled out in many cases and
certain operational precautions are required. This appendix is designed to serve as a guide for all
parties concerned with equipment, well planning and operations.
This section gives guidance regarding various operational aspects of top hole drilling and
precautions that should be taken at the rigsite. Guidance on the selection of diverter equipment is
included in section 3.2 of this manual.
Drilling small pilot holes for shallow gas investigation is considered an acceptable and reliable
method of shallow gas detection and problem mitigation and should be discussed at the pre-ops
stage with the Operator.
Dynamic kill attempts with existing rig equipment may only be successful if a small pilot hole (9 7/8"
or smaller) is drilled and immediate pumping at maximum rate is applied in the early stage or a
kick.
Whilst a small pilot hole restricts the absolute open hole flow potential considerably, when gas
sands are exposed in the open hole and the well unloads, the original hole can enlarge rapidly as a
result of erosion. Also any influx will result in a higher annular column, thus resulting in a more
rapid reduction in the hydrostatic head.
Surface diverter equipment is not yet designed to withstand an erosive shallow gas kick for a
prolonged period of time and should be regarded as a means of 'buying time' to evacuate the
drilling site.
It should be noted that a shallow gas situation may lead to an underground blowout in addition to
the more common flow to surface.
9.2 Risk and implications of encountering shallow gas.
Wells with an increased risk of encountering shallow gas are summarised as follows:
(a) exploration wells in general
(b) wells drilled in shallow gas prone areas
(c) wells with probable/possible shallow gas identified by a preliminary shallow gas
investigation
(d) wells diverter drilled through hydrocarbons (depending on inflow performance)
(e) wells drilled through possible charged shallow sands (due to leaking or poorly
cemented casing strings
Appendix 2 Shallow Gas Page 124 of 142

9.2.1 Well Planning Considerations

During pre-spud meetings for exploration, appraisal or other wells falling into the categories
described above, KCA DEUTAG personnel should always enquire about the risks of shallow gas
and proposed mitigation procedures.
If there is a possibility of shallow gas and a pilot hole is proposed this should be planned to be
evaluated by:
 monitoring gas readings at flowline
 evaluating cuttings (mud logging)
 logging the open hole for hydrocarbons (wireline logging or LWD )
9.3 Shallow Gas Kick Prevention

A shallow gas kick may be encountered as a result of the following:
 drilling into overpressured shallow gas
 loss of primary well control
 drilling into a producing well
Overpressured shallow gas kicks are difficult to avoid once overpressured gas zones have been
penetrated. The well cannot be closed in and the only alternative is to divert the flow until it
subsides or until attempts to kill the well dynamically are successful. Meanwhile steps should be
taken to prepare for evacuation of the rig
To minimise the loss of primary well control, each rig must prepare shallow gas procedures specific
to each rig.
During top hole drilling all wellsite personnel must be prepared to cope with a shallow gas kick.
Immediate reaction by all personnel and the implementation of the correct actions are essential
and all personnel involved in the drilling operation are to be trained on the subject of shallow gas
and its associated hazards.
Penetrating an adjacent well may be a possible source of a shallow blowout. Producing wells with
a collision risk should be closed in and plugged at a depth below the possible collision point.
Annular and tubing pressures of these wells should be monitored, especially during drilling the
critical section where collision risk exists. A diverter system should always be employed if a
collision risk exists, or if there is a chance of penetrating formations which are charged up by
leaking or poorly cemented casing strings from nearby wells.
9.3.1 Primary well control

As the recommended overbalances for primary well control cannot normally be used in top hole
drilling it is important to ensure that strict procedures and practices are followed at all times in order
to maintain primary well control.
The principle causes of loss of Primary Well Control have been described previously in section 4 of
this Manual. However the four principal causes most relevant to top hole drilling and which may
contribute to the loss of primary well control are as follows:
(a) Failure to fill the hole properly
(b) Swabbing
(c) Insufficient mud weight
(d) Losses
The above causes of loss of primary control clearly indicate the need for stringent top hole drilling
practices and procedures and should be re-iterated to all crews during pre-tour meetings and
shallow gas drills..

9.4 Equipment Selection

The equipment selection and specification criteria for Diverter systems is included in section 3.2 of
this manual.
9.5 Shallow Gas Drilling Practices
9.5.1 Operational Planning

Prior to commencing operations the plans are to be developed and drills conducted that consider
the following.
 Ensuring the personnel on the rig floor and in the immediate vicinity are minimised.
 Putting in place detailed plans for monitoring during drilling, i.e. a bubble watchers.
 Putting in place detailed plans for actions in the event of shallow gas, there are clear actions to
take and who takes these decisions.
 Carrying out drills to test response times and ensure individual responsibilities are clear such
as winching off location.
 Ensuring standby vessels are briefed, aware and stand off up wind.
9.5.2 Shallow Gas Drills

Shallow Gas drills must be performed at the start of each shift when the possibility of shallow gas
has been identified in the Drilling Programme.
9.5.3 Pilot Hole Drilling Practices

The pilot hole drilling method provides limited additional blowout protection due to increased
annular friction (ECD) generated by using the smallest practicable hole size in combination with
maximum annular velocity. The small hole volume also allows for a quick change to a heavier mud.
Pilot hole drilling should be a conducted with the same precautions as for tophole drilling in section
9.5.4 below. However the following precautions are highlighted:
(a) Drilling should be stopped and bottoms up circulated immediately after any of the following
indications:
 LWD equipment detects gas.
 Gas cut mud returns/reduction in mud weight. (Under no circumstances must
drilling ahead proceed when a reduction in mud weight is measured.)
 Possible increase in mud returns, indications of rise in pit level.
Drilling must not be continued until a successful (negative) flow check has been made.
(b) The pilot hole should be kept as close as practical to vertical, while observing any collision
risk with other wells.
(c) The penetration rate should not exceed 20 meters/hour, or at the rate at which mud-
loggers can handle the cuttings samples.
(d) The viscosity and gels must be kept low enough to allow efficient functioning of the solids
removal equipment, while sufficient to clean the drilled cuttings from the well.
(e) At pilot hole total depth, bottoms up should be circulated and a flow check performed prior
to pulling out.
(f) If losses occur during drilling, attempts must be made to keep the hole full with mud to
prevent the loss of hydrostatic head with persistent losses cured with lost circulation
material.
(g) If plugging back, the loss in hydrostatic head by the spacers and the setting of cement
must be compensated for with "heavy" mud.

9.5.4 Top Hole Drilling Practices

The more common drilling practices which are applicable for top hole drilling in general, and
diverter drilling, in particular are summarised below.
(a) Penetration rate should be restricted and particular care should be taken to avoid an
excessive build-up of solids in the hole which could cause formation breakdown and
losses.
Drilling with heavier mud returns could also obscure indications of drilling through
higher pressured formations. The well may kick during circulating the hole clean.
Restricted drilling rates also minimise the penetration into the gas bearing formation
which in turn minimises the influx rate.
An excessive drilling rate through a formation containing gas reduces the hydrostatic
head of the drilling fluid, which may eventually result in a flowing well.
(b) Every effort must be made to minimise the possibility of swabbing.
Pumping out of hole at optimum circulating rates is recommended for all upward pipe
movements (e.g. making connections and tripping). Especially in larger hole sizes (i.e.
larger than 12-1/4 inch) it is important to check that the circulation rate is sufficiently
high and the pulling speed sufficiently low to ensure that no swabbing will take place.
A Top Drive System or Circulating Drillpipe Elevator (Regan Fast Shut-Off Coupling)
will facilitate efficient pumping out of hole operations.
(c) The drilling assembly must be as short as possible and the use of stabilisers should be
minimised as they will increase the risk of swabbing.
(d) All gas detection equipment must be properly calibrated and functioning and a
differential flowmeter used. Accurate measurement and control of drilling fluid is most
critical in order to detect gas as early as possible.
(e) Flow checks must be made at each connection, before tripping, at any time a sharp
penetration rate increase, when tank level anomaly is observed, when any anomaly
appears on any LWD log and at any specific depths referred to in the drilling
programme.
(f) A float valve (NRV) must be installed in all bottom hole assemblies which are used in
top hole drilling in order to prevent uncontrollable flow up the drillstring. The use of two
float valves in the BHA may be considered in potential shallow gas areas.
(g) Large bit nozzles or no nozzles should be used to allow lost circulation material to be
pumped through the bit in case of losses. Large nozzles are also advantageous during
dynamic killing operations, since a higher pump rate can be achieved. The use of
centre nozzle bits will increase the maximum circulation rate even further and also
reduces the chance of bit balling.
(h) Top hole drilling operations in these areas should be simple and quick to minimise
possible hole problems.
(i) BHAs used for kick-off operations also have flow restrictions which will reduce the
maximum possible flow through the drillstring considerably. A successful dynamic well
killing operation will then become very unlikely.
Note: The above drilling practices may be modified for development wells where it is confirmed
that no shallow gas is to be expected.
9.5.5 Gas shows while drilling top hole

In the event that significant gas readings are obtained from the mud returns, the gas must be
circulated out.
If the background gas level cannot be reduced by circulation, the mud weight should be increased
and the hole circulated until the background gas subsides.

If tripping out with an exposed shallow gas zone the following precautions must be followed after
performing a flow check and lining up the trip tank:
 The Drilling Supervisor must be on the drillfloor for the whole trip
 Pump out of the hole, circulating out singles for a Kelly rig, as per appropriate drilling
practices, until at least three joints above the gas zone.
 Whilst handling the bha the hole must continue to be kept full and the fill-up volume
monitored closely
9.5.6 Follow-Up from pilot hole Logging

MWD logging is the preferred method of evaluation vs. wireline logs since early detection obviously
enhances the safety of the operation.
If, from the logging results of a pilot hole, hydrocarbons are indicated it may be possible to
establish the the saturation, porosity and permeability of the hydrocarbon-bearing zone(s), and its
estimated flow capacity.
Depending on these results, one of the following options may be carried out:
(a) open up the hole and set casing at the initially programmed depth;
(b) plug back to above hydrocarbons, open up the hole and set casing (if the resulting
changes in casing design are acceptable, otherwise the well should be abandoned);
(c) abandon the well and shift to a location which is expected to by-pass the shallow
hydrocarbon accumulation.
If it is not certain whether hydrocarbons have been penetrated at the bottom of the hole, the
unlogged section of a logged pilot hole may have to be plugged back.
If it is necessary to trip once hydrocarbons have been confirmed the precautions as outlined in
section 9.5.5 must be followed.
In development drilling where there is sufficient geological information available from surrounding
wells to determine that there is no shallow gas, logging may not be required which avoids pilot hole
drilling and hole opening operations.
9.5.7 Losses
If losses are encountered, they are to be cured using Lost Circulation Material or cement.
Full returns must be regained before proceeding to drill ahead.
If the losses cannot be cured, possible courses of action include
(a) plugging back with cement,
(b) setting casing high, or
(c) abandoning the hole.
Drilling ahead with total losses and using a floating mudcap may be considered in areas where the
geophysical structure is very well known and appropriate dispensation obtained.
9.5.8 Cementing implications in top hole

If hydrocarbons have to be plugged off with cement, it is recommended to have the top of cement
(TOC) not too high above top hydrocarbons in order to avoid excessive loss of hydrostatic head
when the cement sets.

9.6 Actions to be taken in the event of a Shallow Gas Kick
9.6.1 Shallow Gas Kick Whilst Tripping

If a kick is experienced whilst tripping, the first option is to pump all available kill mud as soon as
possible in an attempt to dynamically kill the well as per section 9.6.2 below.
If successful and flow has stopped, the string should be run back to bottom immediately and the
well circulated.
If the dynamic kill attempt with kill mud is unsuccessful, an attempt may be made to strip the string
back to bottom, depending on the severity and type of flow.
9.6.2 Shallow Gas Kick Whilst Drilling

Procedures for diverter operation vary depending on the type of rig and the area in which the well
is being drilled. Following are general guidelines for use of the diverter system in controlling a kick:
1. At first sign of flow or improper hole fill up, pick up the drill string to clear the kelly sub (or
the tool joint if equipped with a top drive). Do not turn off the mud pump.
2. Advise drill floor and service personnel of potential for drilling fluid discharge from diverter
vent line(s) and annular sealing device leakage.
3. Open the diverter vent line(s) considering wind direction.
4. Close the diverter packer and the shale shaker / mud return line valve.
5. Line up both pumps into the tank containing weighted mud and attempt a dynamic kill as
per the following steps and section 9.6.3 below.
6. Increase the pump strokes to maximum speed and circulate the well at the highest rate
possible.
7. Keep eye on the standpipe pressure gauge. Ensure that surface casing pressure limits or
fracture gradient at the shoe are not exceeded.
8. Circulate the well until the well is killed or all the mud has been pumped.
9. Continue pumping water while building mud volume if drilling mud from the active and
reserve systems is exhausted before the well is killed.
10. Diverting the well for several hours may be necessary even if only water can be circulated.
This will reduce the fire hazard and slow the influx of well fluids. During this time, the well
may deplete or bridge naturally and shut off the flow of fluid into the wellbore.
9.6.3 Dynamic Well Killing

Dynamic well killing is the most appropriate technique for terminating a shallow gas blowout,
utilising flowing frictional pressure to supplement the hydrostatic pressure of the kill fluid being
injected up the blowing well.
Flow rates must be maintained such that the sum of frictional and hydrostatic pressure exceeds the
static formation pressure and the well ceases to produce.
The dynamic well killing technique is limited in its application when standard drilling equipment is
used, because of the usually low pump capacity available at the drilling location. The success
depends on how quickly the pumping operation is started. It is imperative to start pumping at
maximum pump rate immediately if flow is observed, because the unloading process of the well
develops exponentially due to the shallow depth of the expanding gas.
Obviously, pumping heavier or more viscous mud immediately once flow is observed would be the
ideal dynamic kill attempt. However, delays in changing over to the heavier mud cannot be
allowed. The practice of pumping heavier mud immediately once flow is observed should only be
used in rig operations which are geared to do this without delays. However it is recommended to

have kill mud of at least the pilot hole content premixed (at recommended 0.12 sg heavier than
original mud) and stored in such a way that it can be pumped immediately at maximum rate
The dynamic kill attempt is described below. At first sign of flow, the following action is required:
(a) pump mud immediately at maximum pump rate
(b) open diverter valve(s) and close diverter element (accomplished on a single actuator)
(c) if the well continues to flow, pump heavier mud at maximum pump rate.
(d) if the well still continues to flow after the heavier mud has been pumped, carry on
pumping mud at maximum rate. When running out of mud, change over to water. Do
not reduce the pump speed.
At this stage, the drilling location may need to be abandoned, depending on the severity and type
of flow and the condition of the diverter equipment. However should a risk assessment deem it
practicable and safe, further dynamic kill attempts may be made as follows:
(a) prepare another batch of heavier mud whilst pumping mud or water at maximum rate
(use mud which is 0,25 sg heavier than the original mud weight).
(b) pump heavy mud at maximum rate.
(c) repeat sequence if dynamic killing is still unsuccessful, but do not use excessive mud
weight which could result in formation breakdown.
Note: The procedure for handling a shallow gas kick with a diverter system is also given in the
form of decision trees in Figure 9-1 below.
If a dynamic kill is unsuccessful (or not attempted) the well must continue to be diverted until it
bridges or depletes. However, most diverter systems are not capable of coping with prolonged
shallow gas flows and will eventually fail as a result of erosion thus an evacuation plan should be
ready to be implemented as soon as conditions dictate.

Note Text refers to : Life First, Blow -Out Second .

When running out of Mud , change over to
Water . Do not change Pump Speed
At first sign of flow , pump mud

immediately at maximum pump rate.
Preferably the proposed kill rate
Open diverter valve (s) and

close diverter elements
NO
Well continues to flow
excessively ?
Activate Blow -out Emergency Procedure
Evacuate non -essential personnel
Abandon location as soon as diverter
system fails
Pump (0.12 SG ) heavier mud

at maximum rate
Circulate bottoms up and

check mud returns
NO
Well continues to flow
excessively ? Increase
mud weight
YES
YES
Pump (0.25 SG ) heavier mud Gas cut mud
at maximum rate
NO
Flow Check
Well continues to flow NO

excessively ?
YES Short Wiper Trip
Continue pumping Water or

Mud while diverting until flow
POOH for
ceases Logging
Figure 9-1 Shallow Gas Well Kill Flowchart
Appendix
Well Control Manual2 Shallow Gas Page 131 of 142
10 Appendix 3: Conversions Factors and Formulae

10.1 Conversion Factors
DEPTH Feet x 0.3048 to give Metres (m)

Metres x 3.2808 to give Feet (ft)
VOLUME (U.S.) Gallon x 0.003785 to give Cubic Metres (m3)

(U.S.) Barrel x 0. 1590 to give Cubic Metres (m3)
Cubic Metre x 6.2905 to give Barrel (U.S.)
PRESSURE PSI x 6.895 to give Kilo Pascals (kPa)

kPA x 0.14503 to give Pounds per Square Inch (psi)
Kg/cm x 98.1 to give Kilo Pascals (kPa)
Bar x 100 to give Kilo Pascals (kPa)
MUD WEIGHT PPG x 119.8 to give Kilogram per Cubic Metre(Kg/rn3)

Kg/m3 x 0.00835 to give (Pounds per Gallon)
ANNULAR Feet/Minute x 0.3048 to give Metres per Minute (m/min)

VELOCITY Metres/Minute x 3.2808 to give Feel per Minute (ft/min)
FLOW RATE Gallons/Minute x 0.003785 to give Cubic Metres per Minute (rn3/min)
Barrels/Minute x 0.159 to give Cubic Metres per Minute (m3/min)
Cubic Metres/minute x 6.2905 to give Barrels per Minute (bbl/min)
Cubic Metres/minute x 264.2 to give Gallons per Minute (gals/min)
FORCE Pound Force x 0.445 to give Decanewtons

Decanewtons x 2.2472 to give Pound Force
MASS Pounds x 0.454 to give kilograms (Kg)

Tons (Long 2240 lbs) x 1017 to give Kilograms (Kg)
Tons (Metre 2205 lbs) x 1001 to give Kilograms (Kg)
Kilograms x 2.2026 to give Pounds (lbs)
PRESSURE PSI/Foot x 22.62 to give kilo Pascals per Metre (k/Pa/m)

GRADIENT kPa/Metre x 0.04421 to give Pounds per Square Inch per Foot (psi/ft)
MUD WEIGHT PPG x 0.052 to give Pounds per Square Inch per Foot (psi/ft)
TO PRESSURE [Pressure Gradient]
GRADIENT SG x 433 to give Pounds per Square Inch per Foot (psi/ft)
lb/ft3 ÷ 144 to give Pounds per Square Inch per Foot (psi/ft)
Kg/m3 x 0.000434 to give Pounds per Square Inch
Or ÷ 2303 per Foot (psi/ft)
Kg/m3 x 0.00982 to give kilo Pascals per Metre (kPa/m)
Appendix 3 Conversion Factors and Formulae Page 132 of 142

10.2 Formulae - SI
Drilling Fluid Density [kg/m 3 ]
1. PRESSURE GRADIENT [kPa/m] =
102
2. DRILLING FLUID DENSITY [kg/m³] = Pressure Gradient [kPa/m] x 102
3
Drilling Fluid Density [kg / m ]
3. HYDROSTATIC PRESSURE [kPa] = x True Vertical Depth [m]
102
4. FORMATION PRESSURE [kPa] = Hydrostatic Pressure In Drill String [kPa] + SIDPP [kPa]
Pressure [kPa] x 102

5. EQUIVALENT DRILLING FLUID DENSITY [kg/m³] =
True Vertical Depth [m]
6. PUMP OUTPUT [m³/min] = Pump Output [m³/stk] x Pump Speed [spm]
3
Pump Output [m / min]
7. ANNULAR VELOCITY [m/min] = 3
Annular Volume [m / m]
8. INITIAL CIRCULATING PRESSURE [kPa] = SCR or PL [kPa] + SIDPP [kPa]
3
SCR or PL [kPa] x Kill Fluid Density [kg / m ]
9. FINAL CIRCULATING PRESSURE [kPa] = 3
Original Drilling Fluid Density [kg / m ]
SIDPP [kPa] x 102

10. KILL FLUID DENSITY [kg/m³] = + Original Drilling Fluid Density [kg/m³]
TVD [m]
11. SHUT IN CASING PRESSURE [kPa] = {(Drilling Fluid Grad [kPa/m] - Influx Grad [kPa/m]) x Influx TVD Height [m]} + SIDPP [kPa]

Annular Pressure Loss [kPa] x 102

12. EQUIVALENT CIRCULATION DENSITY [kg/m³] = + Original Drilling Fluid Density [kg/m³]
TVD [m]
3
Kick Size [m ]
13. HEIGHT OF INFLUX ALONG HOLE [m] = 3
Annular Volume [m / m]
3
Drilling Fluid Density [kg / m ] SICP [kPa] - SIDPP [kPa]
14. GRADIENT OF INFLUX [kPa/m] = -
102 Influx TVD Height [m]
Safety Margin [kPa] x 102

15. TRIP MARGIN/SAFETY FACTOR [kg/m³] = + Drilling Fluid Density [kg/m³]
TVD [m]
2
 New SPM 
16. NEW PUMP PRESSURE WITH NEW PUMP STROKES [kPa] = Current Pressure [kPa] x   (only approximate !)
 Old SPM 
Surface leak - off [kPa] x 102
17. MAX. ALLOWABLE DRILLING FLUID DENSITY [kg/m³] = + Test Drilling Fluid Density [kg/m³]
Casing Shoe TVD [m]
3 3
Max. Allow. Drill Fluid Density [kg / m ] - Kill Fluid Density [kg / m ]
18. NEW MAASP AFTER KILL [kPa] = ) x Shoe TVD [m]
102
3 3
(Kill Fluid Density [kg / m ] - Original Drill Fluid Density [kg / m ]) x 4200
19. BARYTE TO RAISE DRILLING FLUID DENSITY [kg/m³] = 3
4200 - Kill Fluid Density [kg / m ]
Increase in Drill Pipe Pressure [kPa / hr] x 102

20. PERCOLATION RATE [m/hr] = 3
Drilling Fluid Density [kg / m ]

P1 x V1 P1 x V1
21. BOYLE-GAY LUSAC LAW: = P1 V1 = P2 V2 P2 = V2 =
V2 P2
3 3
Drilling Fluid Density [kg / m ] x Metal Displ [m / m]
22. PRESSURE DROP PER MT. TRIPPING DRY PIPE [kPa/m] = 3 3
Casing Capacity [m / m] - Metal Displ [m / m] x 102
3 3 3
Drilling Fluid Density [kg / m ] x (Metal Displ [m / m] + Pipe Capacity [m / m])
23. PRESSURE DROP PER MT. TRIPPING WET PIPE [kPa/m] = 3
Annular Capacity [m / m] x 102
3
Length of Drill Collars [m] x Metal Displ [m / m]
24. LEVEL DROP FOR POOH DRILL COLLARS [m] = 3
Casing Capacity [m / m]
3 3
Overbalance [kPa] x (Casing Capacity [m / m] - Metal Displ [m / m]) x 102
25. PIPE TO PULL BEFORE WELL STARTS TO FLOW [m] = 3 3
Drilling Fluid Density [kg / m ] x Pipe Displ [m / m]
Increase in Pressure [kPa] x OriginalKick Volume[m3 ]

26. VOLUME TO BLEED TO MAINTAIN BHP [m³] =
Formationincrease [kPa] - Increase in Pressure [kPa]

10.3 Formulae - Field Units
1. PRESSURE GRADIENT [psi/ft] = Drilling Fluid Density [ppg] x 0.052
Pressure Gradient [psi / ft]

2. DRILLING FLUID DENSITY [ppg] =
0.052
3. HYDROSTATIC PRESSURE [psi] = Drilling Fluid Density [ppg] x 0.052 x True Vertical Depth [ft]
4. FORMATION PRESSURE [psi] = Hydrostatic Pressure In Drill String [psi] + SIDPP [psi]
Pressure [psi]
5. EQUIVALENT DRILLING FLUID DENSITY [ppg] =
True Vertical Depth [ft] x 0.052
6. PUMP OUTPUT [bbl/min] = Pump Output [bbls/stk] x Pump Speed [spm]
Pump Output [bbls / min]

7. ANNULAR VELOCITY [ft/min] =
Annular Volume [bbls / ft]
8. INITIAL CIRCULATING PRESSURE [psi] = SCR or PL [psi] + SIDPP [psi]
SCR or PL [psi] x Kill Fluid Density [ppg]

9. FINAL CIRCULATING PRESSURE [psi] =
Original Drilling Fluid Density [ppg]
SIDPP [psi]
10. KILL FLUID DENSITY [ppg] = + Original Drilling Fluid Density [ppg]
TVD [ft] x 0.052
11. SHUT IN CASING PRESSURE [psi] = {(Drilling Fluid Grad [psi/ft] - Influx Grad [psi/ft]) x Influx TVD Height [ft]} + SIDPP [psi]
Annular Pressure Loss [psi]

12. EQUIVALENT CIRCULATION DENSITY [ppg] = + Original Drilling Fluid Density [ppg]
TVD [ft] x 0.052

Kick Size [bbls]

13. HEIGHT OF INFLUX ALONG HOLE [ft] =
Annular Volume [bbls / ft]
SICP [psi] - SIDPP [psi]

14. GRADIENT OF INFLUX [psi/ft] = (Drilling Fluid Density [ppg] x 0.052) -
Influx TVD Height [ft]
Safety Margin [psi]

15. TRIP MARGIN/SAFETY FACTOR [ppg] = + Drilling Fluid Density [ppg]
TVD [ft] x 0.052
2
 New SPM
16. NEW PUMP PRESSURE WITH NEW PUMP STROKES [psi] = Current Pressure [psi] x   (only approximate!)
 Old SPM 
Surface Leak - off [psi]

17. MAX. ALLOWABLE DRILLING FLUID DENSITY [ppg] = + Test Drilling Fluid Density [ppg]
Shoe TVD [ft] x 0.052
18. NEW MAASP AFTER KILL [psi] = (Max. Allow. Drill. Fluid Density [ppg] - Kill Fluid Density [ppg]) x 0.052 x Shoe TVD
[ft]
(Kill Fluid Density [ppg] - Original Drill Fluid Density [ppg]) x 1500
19. BARYTE TO RAISE DRILLING FLUID DENSITY [lbs/bbl] =
35.8 - Kill Fluid Density [ppg]
Increase in Drill Pipe Pressure [psi / hr]

20. PERCOLATION RATE [ft/hr] =
Drilling Fluid Density [ppg] x 0.052
P1 x V1 P1 x V1
V2 P2
Drilling Fluid Density [ppg] x 0.052 x Metal Displ [bbls / ft]

22. PRESSURE DROP PER FT. TRIPPING DRY PIPE [psi/ft] =
Casing Capacity [bbls / ft] - Metal Displ [bbls / ft]

Drilling Fluid Density [ppg] x 0.052 x (Metal Displ [bbls / ft] + Pipe Capacity [bbls / ft])
23. PRESSURE DROP PER FT. TRIPPING WET PIPE [psi/ft] =
Annular Capacity [bbls / ft]
Length of Drill Collars [ft] x Metal Displ [bbls / ft]

24. LEVEL DROP FOR POOH DRILL COLLARS (DRY) [ft] =
Casing Capacity [bbls / ft]
Overbalance [psi] x (Casing Capacity [bbls / ft] - Metal Displ [bbls / ft])
25. PIPE TO PULL BEFORE WELL STARTS TO FLOW [ft] =
Drilling Fluid Density [ppg] x 0.052 x Metal Displ [bbls / ft]
Increase in Pressure [psi] x OriginalKick Volume[bbls]

26. VOLUME TO BLEED TO MAINTAIN BHP [bbls] =
FormationPressure [psi] - Increase in Pressure [psi]

10.4 Formulae - Bar Litre
1. PRESSURE GRADIENT [bar/m] = Drilling Fluid Density [kg/l] x 0.0981

Or PRESSURE GRADIENT [bar/10m] = Drilling Fluid Density [kg/l] x 0.981
Pressure Gradient [bar / 10m]
2. DRILLING FLUID DENSITY [kg/l] =
0.981
Pressure Gradient [bar / m]
Or DRILLING FLUID DENSITY [kg/l] =
0.0981
3. HYDROSTATIC PRESSURE [bar] = Drilling Fluid Density [kg/l] x 0.0981 x True Vertical Depth [m]
4. FORMATION PRESSURE [bar] = Hydrostatic Pressure In Drill String [bar] + SIDPP [bar]
Pressure [bar]
5. EQUIVALENT DRILLING FLUID DENSITY [kg/l] =
True Vertical Depth [m] x 0.0981
6. PUMP OUTPUT [liter/min] = Pump Output [litter/stk] x Pump Speed [spm]
Pump Output [litre / min]

7. ANNULAR VELOCITY [m/min] =
Annular Volume [litre / m]
Pump Output [litre / min]

or ANNULAR VELOCITY [m/sec] =
Annular Volume [litre / m] x 60
8. INITIAL CIRCULATING PRESSURE [bar] = SCR or PL [bar] + SIDPP [bar]
SCR or PL [bar] x Kill Fluid Density [kg / l]

9. FINAL CIRCULATING PRESSURE [bar] =
Original Drilling Fluid Density [kg / l]

SIDPP [bar]
10. KILL FLUID DENSITY [kg/l] = + Original Drilling Fluid Density [kg/l]
TVD [m] x 0.0981
Drill Fluid Grad [bar / 10m] - Influx Grad [bar / 10m]

11. SHUT IN CASING PRESSURE [bar] = x Influx TVD Height [m] + SIDPP [bar]
10
or SHUT IN CASING PRESSURE [bar] = Drill Fluid Grad [bar/m] - Influx Grad [bar/m] x Influx TVD Height [m] + SIDPP [bar]
Annular Pressure Loss [bar]

12. EQUIVALENT CIRCULATION DENSITY [kg/l] = + Original Drilling Fluid Density [kg/l]
TVD [m] x 0.0981
Kick Size [litre]

13. HEIGHT OF INFLUX ALONG HOLE [m] =
Annular Volume [litre / m]
SICP [bar] - SIDPP [bar]

14. GRADIENT OF INFLUX [bar/m] = Drilling Fluid Density [kg/l] x 0.0981 - { }
Influx TVD Height [m]
SICP [bar] - SIDPP [bar]

or GRADIENT OF INFLUX [bar/10m] = Drilling Fluid Density [kg/l] x 0.981 - { x 10 }
Influx TVD Height [m]
Safety Margin [bar]

15. TRIP MARGIN/SAFETY FACTOR [kg/l] = + Drilling Fluid Density [kg/l]
TVD [m] x 0.0981
2
 New SPM
16. NEW PUMP PRESSURE WITH NEW PUMP STROKES [bar] = Current Pressure [bar] x   (only approximate !)
 Old SPM 
Surface leak - off [bar]
17. MAX. ALLOWABLE DRILLING FLUID DENSITY [kg/l] = + Test Drilling Fluid Density [kg/l]
Casing Shoe TVD [m] x 0.0981
18. NEW MAASP AFTER KILL [bar] = {Max. Allow. Drill Fluid Density [kg/l] - Kill Fluid Density [kg/l]} x 0.0981 x Shoe TVD [m]

(KillFluidDensity [kg/l] - OriginalDrillFluidDensity [kg/l] ) x 4.2

19. BARYTE TO RAISE DRILLING FLUID DENSITY [kg/l] =
4.2 - KillFluidDensity [kg/l]
3 (KillFluidDensity [kg/l] - OriginalDrillFluidDensity [kg/l] ) x 4200

Or BARYTE TO RAISE DRILLING FLUID DENSITY [kg/m ] =
4.2 - KillFluidDensity [kg/l]
Increase in Drill Pipe Pressure [bar / hr]

20. PERCOLATION RATE [m/hr] =
Drilling Fluid Density [kg / l] x 0.0981
P1 x V1 P1 x V1
V2 P2
Drilling Fluid Density [kg / l] x Metal Displ [l / m]

22. PRESSURE DROP PER M. TRIPPING DRY PIPE [bar/m] = x 0.0981
Casing Capacity [l / m] - Metal Displ [l / m]
Drilling Fluid Gradient [bar / m] x Metal Displ [l / m]

or PRESSURE DROP PER M. TRIPPING DRY PIPE [bar/m] =
Casing Capacity [l / m] - Metal Displ [l / m]
Drilling Fluid Density [kg / l] x (Metal Displ [l / m] + Pipe Capacity [l / m])

23. PRESSURE DROP PER M. TRIPPING WET PIPE [bar/m] = x 0.0981
Annular Capacity [l / m]
Drilling Fluid Gradient [bar / m] x (Metal Displ [l / m] + Pipe Capacity [l / m])

or PRESSURE DROP PER M. TRIPPING WET PIPE [bar/m] =
Annular Capacity [l / m]
Length of Drill Collars [m] x Metal Displ [l / m]

24. LEVEL DROP FOR POOH DRILL COLLARS [m] =
Casing Capacity [l / m]

Overbalance [bar] x (Casing Capacity [l / m] - Metal Displ [l / m])

25. PIPE TO PULL BEFORE WELL STARTS TO FLOW [m] =
Drilling Fluid Density [kg / l] x Pipe Displ [l / m] x 0.0981
Overbalance [bar] x (Casing Capacity [l / m] - Metal Displ [l / m])

Or PIPE TO PULL BEFORE WELL STARTS TO FLOW [m] =
Drilling Fluid Gradient [bar / m] x Pipe Displ [l / m]
Increase in Pressure [bar] x OriginalKick Volume[litre]

26. VOLUME TO BLEED TO MAINTAIN BHP [liter] =
FormationPressure [bar] - Increase in Pressure [bar]

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Well Control Manual

Document No. K-CW-OP-MA-0001 / Version 1.01

Foreword and Contents Page 2 of 142

Foreword and Contents Page 3 of 142

4.5 Causes of kicks ....................................................................................................... 32

Foreword and Contents Page 4 of 142

7.5 Stripping Operations ............................................................................................... 76

Foreword and Contents Page 5 of 142

1 Responsibilities & Summary of Well Control Requirements

Responsibilities during a well control event

Responsibilities & Summary Page 6 of 142

Responsibilities & Summary Page 7 of 142

1.4 Summary of Well Control Requirements

Well Control Standard Section

Management & Client Interfacing

Responsibilities & Summary Page 8 of 142

Competency & Supervision

Kick Detection Hardware

Diverter, BOP Equipment and Control System Specifications

Responsibilities & Summary Page 9 of 142

Superintendent or Asst Rig Superintendent (Toolpusher or Night Toolpusher)

BOP Testing Frequency

Responsibilities & Summary Page 10 of 142

and suitable crossovers must be available on the drillfloor

Well Control Operations

Shallow Gas Requirements Appendix 2

Responsibilities & Summary Page 11 of 142

2 Well and Operational Planning

2.1.1 General Considerations

2.1.2 Bridging Documents

2.1.3 H2S Contingency Planning

2.1.4 Minimum Stock Levels

Responsibilities & Summary Page 12 of 142

2.1.5 Formation Considerations

2.1.5.1 Normally Pressured Formations

2.1.5.2 Abnormally Pressured (or surcharged) Formations

2.1.5.3 Formation Strength

2.1.5.4 Leak-off Tests & Procedures

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2.1.5.5 Maximum Allowable Annular Surface Pressure (MAASP)

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2.1.5.6 Kick Tolerance

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 the reaction time of the crew to a well control situation

2.1.6 Shallow Gas

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3.1.1 Flowline Recorder

3.1.2 Pit Volume Totaliser

3.1.3 Gas Detector

3.1.4 Mud Density Recorder

3.1.5 Mud Density or SD Recorder/Multi Function Recorder

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(b) Mud volume in pits

3.2 Diverter Equipment Requirements

3.2.1 Diverter Selection Criteria

3.2.2 Diverter Line Requirements

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3.2.3 Diverter Equipment Specifications

3.3 Diverter Arrangements

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29 -1/2 “ Bag type

26“ or 30“ Stove pipe/

P Valve (pressure operated, remote

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