Standard Drilling Procedures for Efficient Operations

STANDARD OPERATING PROCEDURES
FOR
DRILLING OPERATIONS
Oil and Natural Gas Corporation Limited

Institute of Drilling Technology
Kaulagarh Road, Dehradun-248195
Uttarakhand, India
2014
For Internal Circulation Only
First edition
June 2014
Published by
K Krishna Pratap
ED-HOI-IDT
Institute of Drilling Technology
Oil and Natural Gas Corporation Ltd
Kaulagarh Road, Dehradun-248195
Uttarakhand, India
Prepared by
Dr. A.K. Pandey Ahmed Javed V.K. Gupta
Rajeev Dhupar Sanjay Dobhal Chandan Paul
A.K. Goyal V.N. Rai Sanjeev Singhal
Designed & Printed by

Saraswati Press, Dehradun
Mob. : 9359211333
Message
from
Director (T&FS)
Drilling is the most cost intensive operation of any E&P company. In the
present competitive environment, high level of efficiency in drilling
services is of paramount importance to achieve ONGC's business
objectives for cost effectiveness. Quality in drilling operations relates to
the way the drilling professionals do their job and the work processes they
follow - to drill a well 'efficiently'.
I am of the firm opinion, that a handbook of 'Standard Operating
Procedures' which can define each technical activity covering the whole
gamut of drilling operations through Drilling Fluid Management,
Cementing Operations as well as Safety in a systematic manner can play a
very important role in bringing about quality and efficiency. These
operating procedures reflect the work culture of a company resulting in
fewer errors, healthy and safe environment besides helping in proper
decision making. Standard Operating Procedures enable you to work
smarter - not just Harder.
I am happy to note that earnest efforts have been made by the Institute of
Drilling Technology in consolidating all the drilling experience as
handbook of “Standard Operating Procedures” of ONGC. I am sure that,
this will help the entire drilling fraternity and in turn the organisation to
carry out operations in safe and uniform manner.
I want every field person should go through the handbook thoroughly to
implement the guidelines and procedures contained therein for
performing drilling operations in most efficient and consistent manner. I
congratulate the entire IDT team which has been associated with this
endeavour.
With best wishes
(Shashi Shanker)
Preface
In the fast changing scenario in the field of oil and gas well drilling,
publication of a Standard Operation Procedure Manual for Drilling
Operations was felt necessary to empower our executives on the rig to
improve efficiency and reduce non-productive time. Director (T&FS), Shri
Shashi Shanker, has been the driving force and a constant source of
inspiration in preparation of this manual.
This manual has been prepared with multitude of inputs: In-house
publications, useful materials from the publications of various
companies/authors/publishers and valuable inputs provided by
engineers and scientists of ONGC working all over India. The manual
provides adequate theoretical and practical knowledge and guidelines in
order to enable the users to understand the operational procedures easily
with a special focus on Graduate Trainees as well as all field professionals.
The standard operating procedures mentioned in the manual will help our
field executives in following uniform Practices & Procedures and taking
quick and well-thought decisions that will help in increasing the efficiency,
safety & productivity of drilling operations.
The manual has been specially designed with the objective of providing
an insight to various operations and procedures carried out right from the
release of a drilling location to completion of drilling of a well. Therefore,
it will be an extremely useful reference handbook to the experienced
drilling engineers, drilling fluid engineers and cementing engineers as well
as to the new entrants in this field for performing their assignment to the
best of their capabilities.
The topics are designed in such a way that manual should give a good
basic understanding of the subject. The topics covered in the manual will
give authentic guidance in proper planning, execution, monitoring of
Drilling, Drilling Fluid & Oil well cementing operations and also towards
solving down hole complications. Proper and effective use of this manual
is bound to develop good understanding and better co-ordination among
the inter-disciplinary groups thereby creating an environment of synergy.
A team of highly qualified and experienced executives have prepared this
manual and it has been reviewed by Senior Executives of IDT. Suggestions
and inputs received from HDS/LMDS/LMMS/LMCS and other specialists
from Assets/ Basins of ONGC at different stages of finalization of this
manual for further value addition have been examined and incorporated
in the manual appropriately.
I am confident that our sincere efforts to bring out this manual will benefit
all the personnel in drilling, cementing and drilling fluid engineering
towards greater efficiency.
(K Krishna Pratap)
ED-HOI-IDT
Acknowledgement
Team-IDT expresses their sincere thanks to ShriShashi Shankar, Director
(T&FS) for giving IDT the opportunity to prepare Standard Operating
Procedures Manual for drilling operations. Standard operating Manual for
Drilling has become a reality only due to his constant guidance, support
and encouragement.
Special thanks are reserved for Sh. V.I. Mathew, ED-CDS for his constant
association and valuable suggestions in giving shape to this manual.
Team IDT would like to thank all Heads of Drilling Services for giving valuable
inputs in spite of their very busy schedule and by inspiring their team to
review the manual. This has helped to improve the quality of the manual.
Team IDT would also like to thank all Location Managers of Drilling, Mud
and Cementing Services and other senior officers who provided valuable
inputs on operational procedures from their vast field experience in
preparation of this manual.
The technical authenticity of this manual has come from deep insights
and experience of Team-IDT consisting of Shri K. Krishna Pratap-ED-HOI-
IDT, Dr A.K. Pandey-GM(Chem), S/Shri A. Javed-GM(D), V.K. Gupta-GM(D),
R. Dhupar-GM(D), S.K. Dobhal-GM(D), Chandan Paul-DGM(D), A.K. Goyal-
DGM(D), S. Saksena-DGM(D) and SajidHussain-DGM(D) who were
actively involved in planning and review of the manual.
The final stage of this document has been achieved through the tireless
efforts of Chapter leaders starting from S/Sh G.P.S. Saggu-DGM(D),
Shashi Kant Singh-DGM(D), S.K. Shrivastava-DGM(D), A.K. Singh-DGM(D),
A.A. Khan-DGM(D), A. Bhattacharjee-DGM(D), Dr K.M. Suyan-
DGM(Chem), V.N. Rai-DGM (Chem), Ajay Kumar-DGM(Chem), Dr A.K.
Mishra-DGM(Chem), Sanjay Singh-DGM(D), S. Singhal-DGM(D), S.K.
Mandal-DGM(D), Vinod Kumar-DGM(D), S.K. Gauba-CE(D), U.K.
Bhagwati-CE(D), S.K. Sinha-CE(D), R.K. Meher-CE(D), C.S. Joshi-CE(D), R.P.
Semwal-CE(D) and Ratan Singh-CC who spared their time in writing and
re-writing the subject procedures.
Special thanks are due to officers from other Assets/ Basins for their
valuable inputs: S/Shri M.M. Khanzode-GM(D), A.X. Parapullil-DGM(D),
V.V. Prasad-DGM(D), A.Veermani-DGM(D), K D N Ramakumar, DGM(D),
D.K. Sonowal-CE(D), I.R. Burman-CE(D), GirindraDeka, CE(D), DS, Jorhat.
Thank are also due to Mr Ravi Arora and all other officers and staff of IDT
who extended their whole-hearted co-operation in preparation of this
manual.
Team -IDT
Contents
S.No. Chapter Page
1. Drilling Operations 1-28
2. Bottom Hole Assemblies 29-38
3. Drilling Bits 39-48
4. Drilling Hydraulics 49-61
5. Drilling Fluid Management 63-117
6. Casing Operations 119-132
7. Cementing Operations 133-172
8. Installation of Well Head 173-181
9. Directional Drilling 183-194
10. Fishing 195-208
11. Well Control 209-246
12. Wire Rope 247-260
13. Safety in Drilling Operations 261-270

Drilling Operations
1 Drilling
Operations
Drilling operations need to be carried out in a safe, efficient, and

environmental friendly manner for successfully completing the well to
meet the desired objectives. By following recommended practices, a well
can be drilled in shortest possible time and with minimum of
complications.
This chapter includes the following topics on drilling operations:
a) Preparation for spudding the well
b) Common drilling practices for all phases
c) Drilling 26" hole section
d) Drilling 17-1/2" hole section
e) Drilling 12-1/4" hole section
f) Drilling 8-1/2" hole section
g) Drilling 6" hole section
h) Casing test
i) Leak off test
j) Recommended practices for tripping out
k) Recommended practices for tripping in
l) Recommended practices for reaming
m) Recommended practices for back-reaming
n) Recommended practices for pack-off
o) Recommended practices for wiper trip in deviated hole
p) Recommended practices for surface seepages
q) Coring
r) Casing Rat hole clearing/ reaming
a) Preparation for spudding the well

1. Ensure mast centering is carried out before spudding.
2. Ensure that the celler pit depth is according to well casing plan & BOP
stack to facilitate proper space for the welding of the well head bowl.
3. Check and test all surface equipment viz engines, mud pumps, draw
works, compressors, mud handling equipment, mud tanks etc prior
to spudding the well.
4. Pressure test high pressure mud lines, mud pump safety valve, rotary
hose and standpipe to 3,000 psi.
5. In normal area, false conductor may be grouted 3 m below cellar pit
bottom.
1
Standard Operating Procedures for Drilling Operations
6. False conductor may be pre-installed to a depth of approximately 20-

25 m below bottom of cellar pit along with concrete grouting with
minimum 1 meter concrete layer at surface to avoid surface
seepages.
7. Ensure surface casing and casing handling equipment are on location.
8. Ensure availability of GTO at appropriate places on the rig.
9. Ensure that minimum 7% pre hydrated bentonite suspension is
available for spudding. LCM material must be available at site for
contingency of seepage loss.
Checklist prior to spudding

1. Check all safety lines are of proper size and are fitted with U-clamps
properly and in recommended numbers and size.
2. Check the condition of air winch line and functioning of brakes.
3. Check the condition of power tongs: Dies, pins, jaws, hanger,
counterweight, and tong hang off line etc.
4. Check the condition of Kelly bushing rollers and bearings.
5. Check the health and condition of Topman Escape Device.
6. Check the health and condition of Fall Prevention Device.
7. Check the proper functioning of Twin Stop Device.
8. Check whether rat hole casing is anchored properly.
9. Dope for drill pipe and drill collar connections are available on site.
b) Common drilling practices for all phases

1. Hold Pre-Job safety meeting /tool box meeting.
2. Record bit make, type, serial number and height.
3. Check and record bit nozzle size before lowering the bit.
4. Check the availability of proper size of slips and condition of the
inserts with one complete set of spare dies.
5. Drill-off tests should always be carried out after lowering a new bit
and on encountering a new formation with significant reduction in
ROP and should be recorded in IADC Report. (Refer to Chapter on
Drilling Bits).
6. Record BHA weight in mud from weight indicator.
7. Ensure required bits along with bit breakers are available on location.
8. Ensure pump output and nozzle sizes are specified in program.
2
Drilling Operations
9. Gauge all stabilizers and check connections of all BHA components

10. Ensure make-up torque for all size of drill pipe, drill collars, casing and
tubing is displayed in dog-house.
11. Flow check all drilling breaks.
12. Slip and cut drill/casing line as recommended.
13. Record slow circulating pump pressure at every bit change/ mud
weight change/ every shift change/200 m of drilling.
14. Carry out safety drills.
15. Use drill pipe wiper during POOH
16. POOH wet in case of pressure loss and expected mud cut in string.
17. Trip tank must be properly connected with suitable volume
measurement system. The shift in charge is the FPR (First Person
Responsible) to ensure that trip sheet is filled for all trips as per
drilling practices.
18. Always keep hole full and monitor pipe displacement during POOH
with trip tank and trip sheets.
19. Keep a Full Open Safety Valve (FOSV) always on the rig floor in open
position with required x-overs during all drilling operations.
20. Record up-weight, down-weight, rotating weight of drill string and
off- bottom torque.
21. Record tight spots/intervals encountered during pipe connections
and trips.
22. Monitor shakers for signs in change of cavings
23. Monitor pit levels for mud loss/gain
24. A schematic of BOP stack indicating distance from rotary should be
displayed in dog house to ensure distance of all rams and annular
BOP from rig floor is known.
25. Ensure Mud Logging Unit is installed and calibrated.
26. Ensure SCADA system is connected and enabled.
27. Ensure that required number of drill collars and HWDP are available
for the next phase in advance.
28. P/o & check string if there is any unexplained pump pressure
reduction of more than 100 psi at constant SPM after due checking of
the surface equipment
29. Observe for minimum 10 minutes to check the static condition of the
well prior to pull out and keep close monitoring of trip tank.
30. Cement should always be drilled with mud not with water and ensure
that the stabilizers should not rotate inside the shoe.
3
31. Equivalent thread connections:

4-1/2 IF=NC 50; 4 IF=NC 46; 3-1/2 IF=NC 38;
2-7/8 IF=NC31; 2-3/8 IF=NC 26.
c) Drilling 26" hole section

Preparation
1. Measure distance from Rotary Table to top of Cellar Pit.
2. Confirm arrangement for cellar pit cleaning is installed and tested.
3. Confirm 20" Casing and casing handling equipment are on location.
4. Ensure that return flow line from conductor to shale shaker is
installed.
List of Handling Tools
S.N. Items Qty required

1 26’’ Bit 02
2 26” Bit Breaker 01
3 Float valve for bit sub 01
4 Totco ring 01
5 Circlip nose plier 01
6 Nozzle gauge 01
7 5" Drill Pipe Elevator (250/350 t) 02
8 6-1/2" Drill Collar Elevator (150 t) 02
9 8" Drill Collar Elevator(150 t) 02
10 9-1/2" Drill Collar Elevator(150 t) 02
11 5" Drill Pipe Slip 02
12 6-1/2" Drill Collar Slip 02
13 8" Drill Collar Slip 02
15 Bit sub (7-5/8 R Box * 7-5/8 R Box ) 02
16 Bit sub (6-5/8 R Box * 7-5/8 R Box ) 02
17 X-over (6-5/8 R Box * 7-5/8 R Pin ) 02
18 X-over (4-1/2 IF Box * 7-5/8 R Pin ) 02
19 X-over (4-1/2 IF Box * 6-5/8 R Pin ) 02
20 X-over (4 IF Box * 6-5/8 R Pin 02
21 X-over (4-1/2 IF Box * 4 IF Pin ) 02
22 Kelly saver sub (4 -1/2 IF Box * IF Pin ) 02
4
Drilling Operations

23 Drill pipe/ Drill collar dope 02 Buckets
24 26” Stabilizer 03
25 Drill pipe wiper 02
26 Steel Measuring tape 2
Sequence of Operations
1. Make up 26” bit and BHA.
2. Install float valve with Totco ring.
3. RIH with the 26” BHA inside the 30” Conductor.
4. Use a lower flow rate when drilling around 30” shoe to avoid washing
out the shoe. Flow rate should be limited to 2,200 LPM until the bit is
5 m below the shoe.
5. While drilling first 50 m below false conductor, conduct controlled
drilling with only one pump or at 60-75% of recommended flow rate.
6. The flow rate then should be increased to 2,400 LPM to drill the first
30m and maintained as per chart given in Chapter on Drilling
Hydraulics for the rest of the section.
7. Drill ahead to 20” casing point as control drilling to avoid annulus
loading.
8. Viscous sweeps of sufficient volume should be frequently used for
drilling this section and monitor the volume of cuttings coming out to
confirm proper hole cleaning.
9. At TD, sweep hole with 10 m3 Hi-Vis pill of 150 sec viscosity and
circulate to clean the hole.
10. Perform wiper trip to conductor casing/false conductor shoe.
11. Ream if necessary. Check for fill and circulate hole clean.
12. Wash down last single @ 20 SPM to avoid plugging of nozzle.
13. Sweep hole with 10m3 Hi-Vis pill of 150 sec and circulate clean with
recommended flow rate.
14. Circulate and condition mud. As a general practice place fresh mud of
0.05 SG higher density in well before pulling out for casing.
15. POOH to run 20” casing.
Note: In case 17-1/2” pilot hole is drilled first, the hole should be enlarged
with 26” Hole Opener in second run.
5
d) Drilling 17-1/2” hole section

Preparation
1. Ensure all required tools and material are available on the rig.
2. Ensure Mud Logging Unit is installed and calibrated for all exploratory
wells.

1 17-1/2" Bit 02
2 17-1/2" Bit Breaker 01
3 Float valve for bit sub 01
4 Totco ring 01
5 Circlip nose plier for nozzles 01
6 Nozzle gauge 01
8 6-1/2” Drill Collar Elevator (150 t) 02
9 8" Drill Collar Elevator(150 t) 02
12 8" Drill Collar Slip 02
13 Cross-over (4-1/2 IF Box * 6-5/8 R Pin ) 02
14 Cross-over (4 IF Box * 6-5/8 Reg Pin 02
15 Cross-over (4-1/2 IFBox* 4 IFPin ) 02
16 Kelly saver sub (4-1/2 IF Box * IFPin ) 02
18 17-1/2" String Stabilizer 03
Sequence of Drilling Operations

1. Install well head & BOP as per guidelines in Chapter on Wellhead
Installation and Well Control.
2. Test BOP and choke & kill manifold.
3. Make up 17-1/2” BHA as per well program (keep Totco ring in place).
4. RIH with 17-1/2” bit and tag cement top.
6
Drilling Operations
5. Test casing to 500 psi or as per specific requirement of well maximum

of 80% of burst rating of casing / well head rating whichever is lowest.
6. Drill through cement and shoe with 2-3 T WOB and 50 to 60 RPM
7. Perform Shoe Integrity Test (SIT) at 1 ppg above the expected LOT.
8. Stabilizer should not be used inside casing and while drilling shoe.
9. Wash down to bottom of 26” hole and drill ahead 3 m fresh hole.
10. Circulate hole clean till mud is conditioned.
11. Minimum flow rate to keep the hole clean is 2,650 LPM.
12. Pull string inside 20” casing shoe.
13. Carry out LOT/ PIT and calculate max allowable MW
(Note: LOT in exploratory well and PIT in development well)
14. Add stabilizer after drilling 20-30 m below shoe.
15. Resume drilling.
16. Perform drill off tests to optimize RPM/WOB combination.
17. Increase flow rate to 3,000–3,400 LPM once BHA is 15m below 20”
casing shoe provided losses are not observed.
18. Drill ahead to 13-3/8” casing point taking directional surveys as
planned.
19. Optimize flow rate (Refer to Chapter on Drilling Hydraulics) and
drilling parameters to maximize ROP
20. Monitor shakers for signs in change and volume of cuttings.
21. Monitor pit levels for mud loss/gain.
22. Make wiper trips preferably after 24 hours/ 300 m of drilling or as the
well demands for control of fluid loss & gel.
23. Drill to TD and drop Totco to take survey at every trip.
24. On reaching TD, circulate bottoms up with full discharge (4,000 LPM)
until the shakers are clean.
25. Make wiper trip to the 20" shoe.
26. Run back to bottom and ream if necessary. Check for fill
27. Circulate until hole is clean and mud is conditioned
28. POOH for logging/ casing as planned.
29. During logging, line up the well on trip tank for monitoring.
30. When logging is complete, run in bit to bottom
31. Ream if necessary. Check for fill and clear the same.
32. Circulate bottoms up with full discharge.
33. Make wiper trip to 20" casing shoe.
7
34. Circulate and condition mud for control of fluid loss and gel.
35. POOH 17-1/2” bit
36. On the trip out once bit is inside 20” casing, mud pumps should be
checked to ensure their reliability during the cement displacement.
37. Rig up for lowering 13-3/8" casing
e) Drilling 12-1/4” holesection

Preparation
1. Keep BOP test plug ready.
2. Keep drilling jar ready if planned.
3. Ensure coring equipment is available at the drill site.
4. Change liners to 6-1/2” size on mud pump if required.
5. Keep FOSV ready in open position on rig floor with required X-overs.
6. Ensure information about PIT, LOT, MAASP, casing burst pressures etc
are available in doghouse and offices.
7. Ensure distance of all rams and annular BOP from rotary is displayed
in doghouse.
8. On exploratory location, ensure Mud Logging Unit is installed and
calibrated.
9. Ensure SCADA system is fully functional and online. Their sensors
meant for transmitting various data are serviced.
10. Ensure well shut-in procedures are displayed in the dog house (refer
Chapter on Well Control).

1 12-1/4’’ Bit (Roller & PDC) As planned
2 12-1/4’’ Bit Breaker (Roller & PDC) 01 each
3 Circlip nose pliers for nozzles 01
4 Nozzle gauge 01
5 5” Drill Pipe Elevator (250/350 t) 02
6 6-1/2” Drill Collar Elevator (150 t) 02
7 8” Drill Collar Elevator(150 t) 02
8 5” Drill Pipe Slip 02
9 6-1/2” Drill Collar Slip 02
10 8” Drill Collar Slip 02
8
Drilling Operations

11 Bit sub (6-5/8 R Box * 6-5/8 R Box ) 02
12 X-over (4-1/2 IFBox * 6-5/8 R Pin ) 02
13 X-over (4 IF Box * 6-5/8 R Pin ) 02
14 X-over (4-1/2 IF Box * 4 IFPin ) 02
15 Kelly saver sub (4 -1/2 IF Box *IFPin ) 02
17 12-1/4" String Stabilizer 03
18 12-1/4" Near Bit Stabilizer 01
20 Core bit 01
21 Core barrel with handling tools 02
22 Safety clamp 01

2. RIH with 12-1/4” bit with Totco ring and BHA as per program.
3. Tag float collar and test 13-3/8” casing to 80% of burst rating.
4. Drill Float Collar and Shoe.
5. Avoid use of stabilizer while drilling shoe.
6. Drill through cement and shoe with 2-3 T WOB and 50-60 RPM.
7. Wash down to bottom of 17-1/2” hole and drill 3 m fresh hole.
8. Circulate and condition mud.
9. Pull out string inside shoe and conduct LOT.
(Note : LOT in exploratory well and PIT in development well)
10. Drill further down 20-30 m.
11. POOH, add stabilizer and drill ahead.
12. Perform drill off tests to optimize RPM and WOB.
13. Maintain flow rate as per chart given in Ch-4 on Hydraulics.
14. Drill ahead to TD (9-5/8” casing shoe) taking directional surveys as
planned.
a. Check drag with pump off on every connection to analyze any
down hole problem.
b. Record all drilling parameters every 30 minutes
9
c. Monitor shakers for change in shape and volume of cuttings and

pit levels for mud loss/gain.
d. If losses occur, refer to Chapter on Drilling Fluid Management
for LCM pill formulations.
15. Make wiper trip after every 48-72 hrs or every 250 m whichever is
earlier in vertical wells. In high angle wells after every 24 hrs or 250 m
whichever is early to ensure there should not be any cutting bed.
Record tight spots. Do not pull into the tight spot.
16. Circulate and condition mud once on bottom.
17. While drilling, lift Kelly after every ½ hr. to observe well behavior.
18. Watch drag during pipe connection. If it is more than normal, perform
wiper trip.
19. Before pulling out for MDT/logging, ensure mud is properly
conditioned.
20. POOH for logging.
21. During logging, monitor well on trip tank.
22. Once logging is over, run bit to bottom.
23. Ream down and clear the fill if any.
25. Make wiper trip. Wash down last single.
26. Circulate and condition mud for casing lowering
27. POOH to run casing.
28. While POOH and once inside 13-3/8” casing, mud pumps should be
checked to ensure reliability during cement displacement
29. Change pipe ram to casing ram.
30. Rig up to lower 9-5/8" casing.
31. Ensure that shift in charges should follow the drilling practices as per
GTO for drilling of different formations.
f) Drilling 8-1/2” hole section

Preparation
1. Change liners to 6-1/2” size on mud pump if required.
3. Keep jar ready if planned.
4. Keep FOSV ready in open position on rig floor with required x-overs.
10
Drilling Operations
5. Ensure information about SIT, LOT, MAASP, casing burst pressures etc
in doghouse.
7. Ensure well shut-in procedures are displayed in the dog house.
10. Ensure activation balls/darts (e.g. for PBL circulating subs, core barrel
etc.) are of correct size and will pass through BHA components and
kept in locker in the dog house.
11. Ensure coring equipment is available on site.

1 8-1/2" Bit (Roller & PDC) As planned
2 8-1/2" Bit Breaker (Roller & PDC) 01 each
3 Circlip nose plier for nozzles 01
4 Nozzle gauge 01
6 6-1/2" Drill Collar Elevator (150 t) 02
9 Bit sub (4-1/2 IFBox * 4-1/2 R Box ) 02
10 Bit sub (4 IF Box * 4-1/2 R Box ) 02
11 Cross-over (4-1/2 IF Box *4-1/2 IFPin ) 02
12 Cross-over (4-1/2 IF Box *4 IF Pin ) 02
13 Kelly saver sub (4-1/2 IFBox * IF Pin ) 02
14 Drill pipe/ Drill collar dope 02
15 8-1/2” String Stabilizer 03
16 8-1/2” Near Bit Stabilizer 01
18 Core bit 01
19 Core barrel with handling tools 02
20 Dog clamp 01
11

1. Lay down 8” drill collars.
3. RIH bit and BHA as per Plan.
4. Tag float collar and test 9-5/8” casing to 80% of burst rating.
5. Before drilling the shoe, BOP drill must be performed.
6. Drill Float Collar and Float Shoe.
7. Drill through cement and shoe with 2-3 T WOB and 50-60 RPM
8. Wash down to bottom of 12-1/4” hole and drill 3 m fresh hole.
10. Pull out string inside 9-5/8 casing shoe.
11. Conduct LOT (Note: LOT in exploratory well and PIT in development
well.)
12. Drill further down 20-30 m.
13. POOH, add stabilizer and drill ahead.
15. Ensure that flow rate is maintained as per chart given in Chapter on
Drilling Hydraulics.
16. Drill ahead to TD (5-1/2” casing/7”liner or casing) taking directional
surveys as planned
a. Record all drilling parameters every 30 minutes
b. Monitor shakers for change in shape and volume of cuttings and
c. Flow check all drilling breaks and report same in DPR.
d. Monitor connection gas and trip gas and report in DPR.
e. Prior to a connection, circulate and rotate to ensure that cuttings
are lifted clear of BHA.
f. The driller should record up, down and rotating string weights in
order to monitor well behaviour.
g. If losses occur, refer to Chapter on Drilling FluidManagement
for LCM pill formulations.
17. Make wiper trip. Report tight spots. Do not pull into tight spot.
18. Circulate and condition mud on bottom. Place 2% EP lube lubricating
mud in open hole to avoid sticking of MDT tool.
19. POOH for logging and rack pipe stands keeping in view of logging
requirement.
12
Drilling Operations

21. After logging, run bit to bottom
22. Check for fill and ream if necessary.
23. Circulate and condition mud. Ensure conditioning of mud prior to
pulling out, minimum one and half cycle at 70-80 SPM in vertical
wells and two cycle at 100-120 SPM for directional wells. Always keep
the string in rotation to avoid cutting beds & accumulation of cutting
in annulus.
24. Make wiper trip.
25. Circulate and condition mud, keeping optimum discharge.
26. Pulling out and running in should not be less than 1 to 1.5 minutes per
stand in open hole depending on well condition to avoid swabbing
and surging.
27. During running in last 3 single should always be washed down.
28. POOH to run casing/ liner
29. Lay down stabilizers.
30. While pulling out and once inside casing, mud pumps should be
checked to ensure reliability during the cement displacement.
31. Change pipe ram to casing ram.
32. Rig up to run 7” liner/ 5-1/2" casing.
g) Drilling 6” Hole Section

Preparation
1. Change mud pump liners as required.
3. Keep FOSV ready in open position on rig floor with required x-overs.
4. Ensure information about PIT, LOT, MAASP, casing burst pressures etc
in doghouse.
6. Ensure well shut-in procedures are displayed in the dog house.
13
9. Ensure activation balls/darts (e.g. for PBL circulating subs) are of

correct size and will pass through BHA components and kept in locker
in the dog house.
1 6’’ Bit (Roller & PDC) As planned
2 6’’ Bit Breaker(Roller & PDC) 01 each
3 Circlip nose pliers for nozzles 01
4 Nozzle gauge 01
5 2-7/8” or 3-1/2” Drill Pipe Elevator 02
6 3-1/2” or 4-3/4” Drill Collar Elevator 02
7 5” Drill Pipe Elevator 02
8 3-1/2” Drill Pipe Slip 02
9 5” Drill Pipe Slip 02
10 4-3/4” Drill Collar Elevator 02
11 Bit sub (3-1/2 IF Box * 3-1/2 R Box) 02
12 Bit sub (2-3/8 IF Box * 3-1/2 R Box)
15 Cross-over (2-7/8 IF Box *2-3/8 IFPin )
16 Kelly saver sub (4 -1/2 IF Box* 4-1/2 IFPin )
17 Drill pipe/ Drill collar dope 02
19 2-7/8” or 3-1/2” Drill pipe wiper 02
20 5” Drill pipe wiper 02
21 Dog clamp 01

1. Lay down 6-1/2” drill collars
3. RIH with 6” bit and BHA as per plan.
4. Tag float collar and test casing/ liner to 80% of burst rating
(Whichever is minimum).
5. Before drilling shoe, BOP drill must be performed.
6. Drill float collar and float shoe.
7. Drill through cement and shoe with 2-3 T WOB and 50-60 RPM.
14
Drilling Operations
8. Wash down to bottom and drill 3 m fresh hole.

10. Pull out string inside 7” liner shoe.
11. Conduct LOT.
(Note : LOT in exploratory well and PIT in development well)
12. Resume drilling ahead 6” hole with flow rate as per chart given in
Chapter on Drilling Hydraulics.
14. Drill ahead to TD point taking directional surveys as planned
a. Record all drilling parameters every 30 minutes
b. Monitor shakers for change in shape and volume of cuttings and
c. Flow check all drilling breaks and report same in DPR.
d. Monitor connection gas and trip gas and report in DPR.
e. The driller should record up, down and rotating string weights in
order to monitor well behaviour.
f. If losses occur, refer to Chapter on Drilling FluidManagement for
LCM pill formulations.
15. Make a wiper trip. Report tight spots. Do not pull through tight spot.
16. Circulate and condition mud
17. POOH for logging.
19. After logging, run bit to bottom.
20. Check for fill and clear the same if any.
22. Make wiper trip.
23. Circulate and condition mud
24. POOH to run 5” liner.
h) Casing Test
After casing cementation, casing is pressure tested prior to further drilling
with due consideration to pressure rating of well head and BOP.
Casing test before drilling float collar:
The sequence of operations to test casing are as follows:
- RIH and tag cement top.
- Break circulation.
- Clear cement to float collar.
15
- Circulate and condition mud

- Test casing to the pressure to be limited to a maximum pressure
equivalent to whichever is the least of:
§ 80% of the burst rating of the casing.
§ Wellhead test pressure
§ BOP test pressure
- Test duration is 5 minutes.
- Test is considered OK, if drop in pressure is not more than 5 %.
- As a guideline it may be noted that approximately 4-5 litres of
fluid/cubic metre of casing volume is required to raise the pressure
by 100 kg/cm2.
Drilling of cement, float Collar and shoe
- Drill cement with 2-3T WOB and 50-60 rotary rpm only
- Drill float collar and clear up to shoe.
- Repeat casing test as above.
- If OK, drill shoe and further 0.50m. (Formation should not be
opened).
- Circulate cuttings out of the well.
Note : No stablizer should be used during drilling of cement, float
collar and shoe.
Casing Shoe Test
This test is conducted to determine competence of cement job around the
shoe.
- Pull the drill string in the casing.
- Close pipe ram BOP and kelly cock.
- Connect cementing unit with kill line.
- Flush BOP stack and kill &choke lines.
- Close HCR valve on choke line
- Conduct shoe integrity test to anticipated LOT value.
§ Shoe test pressure is sum of surface pressure and hydrostatic
pressure of drilling fluid.
- Pump steadily at the rate of 50-100 liter per minute till test pressure is
reached.
- Plot the increase in surface pressure against volume pumped.
- If the shoe is holding, the plot will be linear.
- Hold the required test pressure for 15 min. The shoe is considered OK
if the pressure does not fall more than 10% of the test pressure
during this time.
16
Drilling Operations
- Release the pressure and measure the volume of fluid recovered in

trip tank. Compare pumped volume with return volume which
should be almost equal.
- Open kelly cock.
- In case, shoe does not hold up to the required pressure, squeeze
cement and repeat all the procedures for testing shoe.
i) Leak-off Test (LOT)

LOT is carried out to determine the competency of the formation. The
procedure for LOT is as follows:
- Drill 3 meters of fresh formation.
- Circulate & condition mud.
- Pull out string inside shoe.
- Connect Kelly and close lower Kelly cock.
- Close the pipe ram BOP.
- Open kill line and both the outlet valves of casing head housing,
- Close choke line.
- Connect the cementing unit through kill line.
- Start pumping mud in the well at a controlled rate of ¼ bbl/min
(About 40 litre/min)
- Note down pressure without stopping the pump after pumping each
incremental volume of ¼ bbl (About 40 litre)
- Initially pressure increases proportionally after pumping each
incremental volume of ¼ bbl (About 40 litre).
- Plot pressure rise against volume pumped on a graph immediately
otherwise this may sometime lead to over pumping and formation
breakdown.
- Draw a trend line with a minimum of 2 readings on graph paper to
predict pressure rise vs volume pumped
- As soon as any deviation in pressure rise from trend line is observed,
stop pump. Record volume pumped and leak off test pressure
- Hydrostatic pressure due to mud column is calculated at the depth
where leak-off is being performed as under.
PH=Hydrostatic Pressure with present mud (Kg/cm2)=D*MW/10
Where D = Present depth (metre);
MW= Specific gravity of test drilling fluid
17
Ps=Surface pressure in kg/cm2at the point after which formation

pressure does not increase linearly any more (formation leaks)
- EMW from LOT value (gm/cc) = [10 *(Ps + PH)]/D
- After the test is completed, bleed off the pressure in the line.
- The volume of returned mud should be almost equal to the volume of
pumped mud.
Note :
- In exploratory well, LOT should be conducted. In development well,
Pressure Integrity Test (PIT) to the expected maximum mud weight
value for the phase should be conducted until and unless specified
otherwise
- If a sand zone is just below shoe, drill down 2-3 mbelow sand zone
before conducting LOT.
j) Recommended practices for tripping out

1. Circulate bottoms up till hole is clean.
2. Re-confirm final drilled depth with 2 to 3 T of WOB.
3. Flow check well for 5 minutes or as required. Reciprocate pipe slowly
to prevent string getting stuck.
4. Take deviation surveys if required.
18
Drilling Operations
5. Hole conditions will determine when to pump slug. It is advisable to

pull pipe “wet” where there is the possibility of pump out/back
ream. If conditions are good, pump slug.
6. Line up well on trip tank and start trip tank pump.
7. After pulling out 5 stands, flow check again.
8. Install pipe wiper.
9. Pull out of hole. Pipe speed is dependent on hole conditions and
swabbing effects
10. Trip Sheet should be ready and filled up by Shift-in-charge.
•
Record hole fill volume for every 5 stands of drill pipe
•
Record hole fill volume for every stand of drill collar
• If improper fill is observed, run back to bottom and condition the
well before restarting POOH.
11. It is good practice to break different connections at each trip i.e. pull
out “stand/double/single” on different trips.
12. FOSV and its operating wrench should be ready at all times for fast
make-up to drill string.
13. Regular trip drills to be carried out inside casing to ensure proper and
quick responses by drilling crews.
14. Flow check well at casing shoe and before pulling BHA into BOP, and
any other time there is doubt.
15. Remove pipe wiper before pulling BHA out.
16. While tripping, keep the tool joint above slips as minimum as possible
to avoid bending of tubulars during making up/ breaking out tool
joint.
17. In high angle wells where formation of cutting bed is an issue, pull out
6-7 singles at a time and then circulate with recommended discharge
& rotation. After that again pull out 6-7 singles and repeat the process
of pump out upto shoe.
k) Recommended practices for tripping In

1. Run BHA carefully through BOP
2. Break circulation at shoe.
3. Run into open hole slowly observing held up on weight indicator.
4. In case of held up, do not push through tight spots. Try to clear the
same with reciprocation.
5. If not cleared by reciprocation, wash down with circulation.
19
6. If not then ream down as explained below.

7. Connect Kelly/ top drive one single off bottom.
8. Start circulation slowly and observe returns. Increase SPM gradually
to recommended SPM and lower string only after normal circulation
is established.
9. Wash down last 1-2 stands as a practice wherever top drive is
available and at least last 2-3 singles where Kelly is used to avoid hole
pack-off and resume further operations.
I) Recommended practices for reaming

1. After drilling each single, ream the drilled length quickly at full
circulation rate and with no WOB.
2. During RIH if held up persists even after reciprocation, proceed to
ream as follows:
a. Ream with no or minimum weight and keep an eye on rotary
torque and pump pressure that may be quite abnormal/erratic.
Do not release WOB till rotary torque and pump pressure
becomes smooth and are no more erratic.
b. Higher WOB with erratic torque may lead to severe back-torque
causing bit failure/ string back-off
c. Once rotary torque is normal, lower the string and ream further
d. When circulation is nearing bottoms up, check shale shaker for
type and volume of cuttings/ cavings coming out
Note: Reaming is a very critical and time-consuming operation
and should be carried out patiently with utmost care keeping
close watch over torque & pump pr.
3. Sustained reaming is not recommended with PDC/ diamond bits.
4. If excessive reaming is foreseen, pull out PDC/ diamond bit and run
roller bit
m) Recommended practices for back-reaming

1. Back-reaming should be used as the last resort and with the same
flow rate that was used during drilling.
2. Back-ream for 5 m maximum, circulate cuttings clear of the BHA, then
try to pull through the obstruction without pumps or rotation.
3. During back-reaming, shut down the pumps quickly in the event of a
pack-off.
20
Drilling Operations
4. In the event of a pack-off, which can be identify by pressure shoot up.

stop the pumps - go down with the pipe (maintaining rotation), re-
establish circulation and circulate hole clean.
5. Attempt to pull through troublesome zone again without pumps and
rotation.
6. Repeat the above process - with patience. The objective is to POOH
with the absolute minimum of back-reaming.
7. Back reaming should be done with nearly zero pull and
recommended pump discharge & rotation.
8. Pumping-out with back reaming is an accepted procedure in high
angle wells. The best way to deal with the cutting beds is to first try
normal pull out, if necessary pump-out at moderate GPM and finally
pump-out with back reaming if needed at 500 to 550 GPM. The
important point is that, if back reaming is resorted then the string is to
be pulled all the way by back reaming only to shoe to avoid cutting
bed packing-off.
Note : If required based on well condition back ream upto previous
casing show. Once inside casing shoe, circulate at least one bottoms
up to clear the cuttings out of hole.
n) Recommended practices for wiper trips in deviated hole

1. Carry out wiper trips for effective cutting bed removal at
progressively reducing intervals as the hole length and exposure
increase at 350-300 meters, 250 meters, 200 meters.
2. Circulate at casing shoe for 1 bottoms up or 1 cycle if required in wiper
trips to remove all cuttings from the annulus if pumping out due to
tight pull is a frequent observation.
3. Wash down last 1-2 stands as a practice wherever top drive is
available and at least last 2-3 singles where Kelly is used to avoid hole
pack-off.
o) Recommended practices to clear pack-off

In case of any serious held-up, circulate and clean the hole to avoid
possible pack-off later on.
Procedure to clear pack-off
1. Prevent annulus loading and consequent packing-off by ensuring that
recently drilled cuttings are well above the BHA length by circulation
especially when the ROP is more than 25-30 meters per hour prior to
connection.
21
2. Stop pump as soon as pack-off is suspected. Continuous pumping will

lead to rise in pressure resulting in compacting of cuttings resulting in
permanent pack off and stop all chances of establishing circulation.
3. Try to go down while POOH or come up while RIH and establish
circulation.
4. Try to reciprocate the string with low pump pressure of 500-700 psi
for hydraulic hammering to physically dislodge the packed cuttings.
Intermittently try establishing circulation patiently as it may take
several hours to establish circulation but do not continue pumping
and fracture the formation.
5. If circulation is regained, small pressure drop will be observed, try to
maintained same pressure till free circulation is established followed
by circulation with recommended discharge.
6. Maintain a reserve mud volume of minimum of one tank.
7. In case of persistent difficulty in pulling out of hole in spite of all
practices, circulate hole clean, go back to bottom and recondition the
well with maximum recommended pump discharge and
recommended pill sweeps as explained in DFE chapter. All mud
cleaning equipments should run continuously and in good health.
p) Recommended practices for surface seepages

Seepages during drilling especially in top hole results in serious
consequences such as rig foundation sinking and toppling of rig in
extreme cases.
The surface seepages may be due to unconsolidated formations at
shallow depths that allow seepage of mud under relatively lower
pressures due to negligible bearing strength of the sands at surface.
It may also be due to artesian effect where water from high altitude flows
into and around the well bore from adjoining mountainous area.
It may also happen during drilling deeper horizons, if the annulus barrier/
cementation at surface give up during course of drilling or due to
uncontrolled tripping and drilling operations.
At suspected locations, the false conductor should be driven to a depth of
25 meters or more as per soil/water table data as against normal depth of
3 to 6 meters from GL.This can be accomplished by:
1. Drilling 36”/26” hole to a depth of about 25 m or more and placing
Conductor casing (As per well design) with annulus cementation job
soon after.
22
Drilling Operations
2. Drilling the top hole to a depth of 25 m (or more depending upon past
experience and soil data) through a suitable tube-well drilling / Air-
Hammer drilling contractor and annulus-cement job thereafter.
3. Drilling required size hole (36”/26”) using Dyna-drill / motor and
lowering suitable sized conductor at the rig followed by top up
cement job.
Recommended procedures
Due to possibility of communication from behind conductor casing/false
conductor as the same is not cemented around the annulus, the following
measures are suggested;
a) The well should spudded with the following drilling fluid composition
to effect complete sealing of permeable zone:
i) Spud mud
- 10% Bentonite suspension with no flocculation
- Add Sulphonated Asphalt – 2-3%
- System LCM as LSP (lime stone powder) -3%
- Dilute mud to pumpable viscosity.
ii) After drilling to 100 m, the remaining section of the hole – Dilute
the above mud and reduce bentonite content by 5%, Treat with
PGS 3-4%, XCP-0.4%, Glycol-1%, DD-1%, Limestone powder 3-
5%. Change into foam mud by entrapping air through hopper.
iii) In order to stabilize a large hole in both 26” & 17-1/2” sections,
sweeps of 100 bbls/50 m may be given as a slug of following
composition which will coat the bore hole & get mixed in mud
system :
- PAC-R:0.5%.
- CMC: 2%
- Sulphonated Asphalt : 2%
- Resinex: 1% (if required)
b) Spud and drill initial 100 m of 26” hole by controlled drilling with low
discharge.
c) Use 26” stabilizer at 60'during drilling the complete phase.
d) After completing drilling, make a round trip with 2 stabilizers at 30'
and 60' for proving the hole prior to lowering casing.
e) Intermittent high viscous sweeps of 100 bbls are recommended after
every 50 m.
f) Wiper trips to be made after 200 m.
23
In case mud loss is not controllable by system drilling fluid,

1) Option for light weight cement slurry / micro-bubble cement slurry
will be more suitable to contain seepage loss while drilling at shallow
depth / sand formation.
2) 20” surface casing setting depth may be planned to cover the
anticipated loss zone.
3) Prolonged mud circulation should be avoided at any point.
4) Excessive mud circulation during idle period/ before pipe connection
should be avoided.
q) Coring
In general, geological data are gathered from direct observation and
analysis of rock cuttings collected at surface during drilling. However for
better and detailed understanding of rock properties, a solid core is cut
from rock from the zone of interest.
Procedure for making up Core Barrel
1. Junk sub should be used on the trip prior to core bit run to ensure hole
is junk free
2. Check gauge of pulled out bit prior to running core bit. If under gauge,
it is advised to run a new roller bit again to prove the hole
3. The most commonly used coring equipment in ONGC is :
a. Core bit size: 8-15/32” or 8-7/16”
b. Core barrel: 6-3/4”OD: Core size:4”; Core barrel length:30'/60'
4. If 9 m core is required, run only one core barrel.
5. For 18 m core, run core barrel with extension.
6. Ensure recommended make-up torque values of core barrel
connections are displayed on the rig as these are less as compared to
drill string.
7. Safety joint 'O' ring should be checked before each run and replaced if
required. Oil should be applied on safety joint thread. Only
manufacturer's recommended make-up torque should be applied on
safety joint.
8. Tighten all joints of inner barrel using chain tong only
9. Check inner barrel shoe threads.
10. Check vertical play in bearing by resting inner barrel on outer barrel
with the help of a solid rod. It should be less than ¼”. Change bearing if
required.
24
Drilling Operations
11. Do not change the bearing on rotary as the steel balls of thrust
bearing may fall into the hole
12. Check swivel joints for free rotation.
13. Place core marker inside inner barrel
14. Install core catcher on inner barrel. Check length of inner barrel shoe
lip from bottom of outer barrel sub with the help of the manufacturer
supplied gauge before the bit is made up(it is 3-23/32” in case of 6-
3/4” x 4” Christensen core barrel).
15. If the length of the inner barrel shoe lip below outer barrel is not as
per gauge, adjust the same by changing shims which otherwise may
affect the core recovery.
16. Ensure the steel ball is not inside the core barrel while laying down
core barrel after coring and should be kept in locker.
17. Check core bit is free of ring out groove in the bottom face of bit.
18. Ensure bit breaker is in proper condition
19. Core bit should be made up with outer barrel initially by hand rotation
only and power tong should be used only for final tightening upto
recommended torque.
Procedure for coring
1. Drift drill string and drill collars during RIH.
2. Use pipe wiper during RIH to ensure junks do not fall into well.
Remove wiper before making Kelly.
3. Run core barrel carefully in open hole and do not push the core bit
through tight spots.
4. If excessive reaming is required, POOH core barrel and run roller bit to
clear the hole.
5. Wash down last 10-15 m with max circulation and without rotation
6. Circulate one foot off bottom for half an hour for clearing bottom
before starting coring operation.
7. Tag bottom.
8. Check the space out of the string is such that when on bottom the
maximum kelly length is above the rotary to ensure maximum
continuous coring prior to making a connection. Add 5'/10'/15' drill
pipe pup joint for space out if available. Ensure that pup joints will not
be across the BOP stack during coring operations.
9. Make sure steel ball is of proper make and size. Break Kelly and drop
the steel ball
25
Core bit
Core catcher
Swivel
Assembly
26
Drilling Operations
10. Confirm seating of ball in core barrel with rise in pressure.

11. Record off bottom and on bottom pressure for a particular discharge.
The difference is the pressure drop across the bit face.
12. Record SCR.
13. Keep circulation rate around (255-380 gpm) for coring which is
optimum for 6-3/4” Core Barrel.
14. Start coring with 1-2 T WOB and 30/40 RPM.
15. Increase WOB (to 3-4 T or as required) and RPM (to 50-60) after 1 foot
core is cut
16. Cut 9 m core. Do not ream after coring.
17. Stop rotation and circulation. Give over pull of 5 Ton to break core. If
core does not break, hold pull and start circulation.
18. After core breaks, pick up 3 m and then lower within 0.50 m off
bottom to confirm the core is broken
19. In case more than 9 m core is required, make up new pipe connection
without using rotary. Start pump and run back to bottom without
rotation. Apply 3-4 T WOB to release core from core catcher to
engage with the remaining piece of core at bottom before starting
rotary for further coring.
20. Cut core to required core point. Break core as in Point No-18.
21. Abandon coring and pull out core barrel;
a. If abnormal rise in stand pipe pressure is observed. If it is more
than the pressure drop across the bit face and cannot be
accounted for, barrel may be pulled out for inspection.
b. If appreciable decrease in penetration rate is observed.
c. If coring is not progressing at desired rate and erratic torque is
observed, pull out and check core bit.
22. Pump slug and POOH without rotation
23. Rest core barrel on slips. Make up the lifting sub on core barrel Install
safety clamp around core barrel.
24. Break out safety joint and pick up inner barrel.
25. Fit core tong just above core catcher and remove core catcher while
inner barrel is just nearly touching the floor to avoid falling of core.
26. Raise inner barrel and tap it so that core comes out of inner barrel.
27. Use core tong to remove core safely and without breaking till core
marker comes out of inner barrel
27
28. Place core in boxes as per proper sequence

29. After core recovery, place the core marker inside the inner barrel
30. Break all core barrel joints, clean and apply grease/oil before laying
down.
31. Inner barrel should be coated with lubricating oil to avoid corrosion
before laying down.
32. After breaking Core bit, install end protecting sub.
r) Casing Rat Hole Clearing/Reaming

If a casing is short landed due to well condition, the following guidelines
may be followed :
1. Clear cement inside casing float collar, float show with a sleek
assembly.
2. There is always a chance of formation of block of cement in the rat
hole.
3. Clearing of rat hole below casing show should be done with sleek
assembly.
4. Block of cement while drilling with smaller size bit might get broken,
causing stuck pipes.
5. Avoid rotating BHA with stablizers in the rat hole.
6. While drilling fresh hole, use moderate drilling parameters with
recommended pump discharge, avoid any vibration/wobbling of drill
string.
7. Incorporate stablizers in the BHA, only after enough fresh hole has
been drilled to accomodate stablizer part of the BHA. This is to ensure
that while drilling fresh hole, stablizers should not rotate in the casing
rat hole.
8. Rat hole with freshly drilled smaller size hole creates a telescopic hole
where accumulation of cutting due to annular velocity reduction will
be an issue. It will be a good idea to circulate when the BHA is just
below the telescopic part.
28
Bottom Hole Assemblies (BHA)
2 Bottom Hole
Assemblies (BHA)
BHA is the lowest part of the drill string and is required to impart
necessary weight on bit (WOB), hole stability, stiffness to drill string,
maintenance of desired well profile to achieve target depth in most
effective manner. BHA consists of bit, bit sub, stabilizers, drill collars,
heavy weight drill pipe (HWDP), drilling jars along with cross over subs and
required directional drilling tools.
This chapter deals with
a) BHA design
b) Operational guidelines
c) Guidelines on WOB
d) Use of stabilizers
e) Critical points while making BHA for various hole sizes
f) BHA for various hole sizes
g) Drilling Jar
a) BHA Design
The bottom hole assembly specified in the drilling program is to be used in
each hole section.
The following points should be considered while selecting BHA
components:
•HWDP stands are run between the drill collars and drill pipe to
provide a transition zone.
•In deep and difficult hole condition, use of drill collar should be
minimum and HWDP should be maximum.
•Ensure that crossovers from large diameter drill collars to smaller drill
collars or drill pipe do not exceed a 2" reduction in size, or that the
stiffness ratio does not exceed 5.5 for a non-critical well or 3.5 for a
critical well.
•Stiffness Ratio is ratio of section modulus of various sections of the
drill collars and drill pipe.
29
•Bending Strength Ratio(BSR) is ratio of section modulus of box and

pin. Maintenance of BSR within recommended limits is very
important to prevent failure of string at the joints where size
changeover is beyond limits
•Formula for calculating BSR
4 4
p
---- (D -b ) (D4-b 4)
ZB 32 D D
BSR= ---- = ------------------- = -------------------
ZP p (R4 -d4 ) (R4 -d4 )
----
32 R R
Where,
ZB-Box Section Modulus,
ZP-Pin Section Modulus,
D-OD of Pin & Box,
d-ID of Bore,
b-Thread root dia. of Box threads at the end of Pin,
R-Thread root dia. of Pin threads ¾” from shoulder of pin.
•BSR between 2.50 and 2.75 are preferablefor all BHA connections in
hard formations.
Long stabilizer Welded Blade Machined

Short
Stabilizer
30
•BSR between 2.25 and 2.75 are preferable for softer formations.
•When lost circulation is expected, select components of BHA
considering lost circulation material requirements (nozzles, motors,
MWD, PBL)to avoid plugging when pumping LCM.
•Ensure that all BHA connections have bore back box and relief
grooves on pins for stress relief.
•Spiral drill collars are preferred to minimize differential sticking.
•Straight welded blade stabilizers minimize swabbing in gumbo
sections. Stabilizers with a longer contact area increase wall support
area in soft formations. Stabilizers with a shorter contact area are
preferable in hard formations.
b) BHA Operational Guidelines

•Making up new drill collar
§Clean box and pin thread and apply dope on thread and shoulder.
§Make up new drill collar using chain tong with drill collar in
floating condition (i.e. Do not release DC weight as it may
damage threads)
§Make up to recommended torque using both power tongs.
§Break drill collar and unscrew
§Clean thread and apply dope again.
§Repeat this step one more time
•The following points are very important for satisfactory drill collar
performance:
§
Proper cleaning of thread and shoulder
§
Proper lubrication of shoulders and threads
§
Proper make up torque
§
Repairing minor damage on shoulder and thread
§
Use thread protector while laying down, lifting and transportation.
•Never make up drill collars or BHA using rotary.
•After crack opening DC during POOH, open drill collars with chain
tongs and with a slight upward pull on the blocks to avoid galling. Do
not allow threads to jump after the collar is backed out.
•Keep changing working joints of drill string on every trip.
•Ensure there are sufficient HWDP above drilling jars.
31
•Keep drawings of all BHA components with dimensions like OD, ID,
fish neck lengths for selecting proper fishing tool.
•Gauge the bit after makeup to ensure, it is not pinched by the bit
breaker.
•According to the BHA program, stabilizer should be lowered with
required gauge. Gauge the stabilizer every trip out and replace
sleeve/ stabilizer as required.
•Lift sub pins should be cleaned, inspected and lubricated on each trip.
If these pins have been damaged and go unnoticed, they will
eventually damage all of the drill collar boxes.
c) Guidelines on WOB
•WOB is decided as per the hole size and lithology to be drilled
•The maximum WOB that can be given for a particular BHA is limited to
80% of the buoyant weight of BHA to keep neutral point within BHA.
•Neutral point is the point of changeover where the string changes
from compression to tension. Above neutral point Drill string is
always under tension and below Neutral point it is under
compression
d) Use of stabilizers
•Single Stabilizer at 60 feet is called a pendulum assembly which will
help to maintain the hole vertical.
•A stiff assembly consists of minimum 3 stabilizers at 0 feet, 30 feet
and 60 feet above bit which is useful to straight hole.
•A slick assembly (without any stabilizer) is to be used only in specific
conditions like cement / shoe track drilling, lost circulation etc.
•Normal drilling without stabilizer may lead to walking tendency of bit
and will increase tortuosity in the well.
•Under gauged stabilizers are used only as specific directional drilling
requirement.
e) Critical points while making BHA for various hole sizes

Making-up tubular joint to recommended torque is of utmost
importance. Under-torquing and over-torquing are not recommended.
Recommended torque of drill pipe, drill collar and HWDP is given below in
tables:
32
Drill Pipe Make up Torque

Drill NomWeight
Pipe Grade Conn- Class Tool Joint OD Torque
Size ppf Kg/m ection in mm Ft-lb Kg-m
I 3⅜ 85.7 3500 485
2⅜” 6.65 9.89 E S 81.0 2500 346
3-3/16
NC26
II 3⅛ 79.4 2000 277
(EU)
III 3⅛ 79.4 2000 277
I 4¾ 120.6 9100 1261
3½” 13.3 19.8 E 3½”IF S 114.3 7300 1011
4½
NC38
II 4-13/32 111.9 5800 804
(EU)
III 4- 110.3 4800 665
11/32
I 6⅜ 161.9 18900 2618
E 4½”IF S 149.2 15800 2189
5⅞”
NC50
II 5-25/32 146.8 13300 1843
(EU)
5” 19.5 29.02 III 5-11/16 144.5 10800 1496
I 6½ 165.1 25800 3570
G 4½”IF S 154.8 21900 3030
6-3/32
NC50
II 5-31/32 150.6 18400 2071
(EU)
III 5-25/32 146.8 15000 1953
I 6⅝ 168.3 31800 4406
S 4½”IF S 160.3 28400 3934
6-5/16
NC50
II 6⅛ 155.6 22900 3173
(EU)
III 6 152.4 19300 2674
3½” 26 38.69 3½”IF 4¾ 120.6 9900 1372
HWDP
5” 50 71.41 4½”IF 6½ 165.1 29400 4073
HWDP
Drill Collar Make up Torque

DC OD & ID 9½”* 3” 8”*2-13/16” 6½”*2-13/16” 4-3/4”*2-1/4”
Connections Unit 7-5/8 Reg 6-5/8 Reg 4 IF 3-1/2 IF
Min make-up Kg-m 12,166 7,327 3,069 1,380
torque Ft-lbs 88,000 53,000 22,200 9,986
33
f) BHA for various hole sizes
12 X HWDP
12 X HWDP
9 X 6-1/2” DC
9 X 6-1/2” DC
X-Over 6-5/8 RP X 4-1/2 IF X-Over 6-5/8 RP X

4-1/2 IF
10 X 8” DC
10 X 8” DC
12-1/4”Stabilizer
17-1/2”Stabilizer
2 X 8” DC 2 X 8” DC
Bit sub 7-5/8 RB X 6-5/8 RB Bit sub 6-5/8 RB X 6-5/8 RB

17-1/2” Bit
12-1/4” Bit
Tentative BHA for Drilling 17 ½” Hole Tentative BHA for Drilling 12¼” Hole
34
15 X 5” HWDP
15 X 3-1/2”
HWDP
10 X 6-1/2” DC 4 3/4” DC
6”Stabilizer
8-1/2”Stabilizer
2 X 6-1/2” DC 2 X 4-3/4” DC
Bit sub 4-1/2 RB X 4-1/2 IFB Bit sub 3-1/2 RB X 3-1/2IFB
8-1/2” Bit 6” Bit
Tentative BHA for Drilling 8 -1/2” Hole Tentative BHA for Drilling 6” Hole
35
Rotary BHA used in directional drilling
Holding Assemblies Dropping Assemblies Building Assemblies
g) Drilling Jar
The construction of drilling jar is sturdy and can be run for long rotating hrs
without damage to its seals.
Jarring is the process of transferring stored energy (drill pipe stretch) in
the drill string to kinetic energy. When the jar trips the energy is released
providing sudden impact.
The two basic types of jars are mechanical and hydraulic
Mechanical jars
- Both up & down jarring system is mechanical
- Have preset trip load and detent is released at trip load.
- Is sensitive to load and not time
Hydro-mechanical
- Up jarring is hydraulic and down jarring system is mechanical
36
Hydraulic jars
- Uses oil to delay jar firing till desired stretch is achieved.
- Time delay is by forcing oil through small ports or a series of jets & a
detent mechanism.
- Delay in firing is dependent on load & time
- Both up & down jarring is hydraulically
Pump open force Pump open force chart
with higher pump pressure

up jarring force will be
increased
With high pump pressure

down jarring force will be
reduced
Pump Open Force

This is the force which acts on drill string from the bottom of hole when
pump is running. This force reduces the impact of downward jar and
increases the impact of upward jar.
Pump open force= Pressure drop across bit * Piston area of jar.
The area is listed in the specification sheet of the different jar.
37
Upward Jarring
Weight indicator set at =Normal Hook load when lifting the string – BHA
weight below jar – pump open force + Desired upward blow
Cock the jar from full open position
Weight indicator set at = Hook load while lowering the string– BHA
weight below jar - jar friction - pump open force
Downward Jarring
Weight indicator set at = Normal hook load when lowering the string –
BHA weight below jar – pump open force – desired downward blow
Recock the jar from closed position
Weight indicator set at = Hook load while lifting the string– BHA weight
below jar + jar friction - pump open force
Reason for Jar failure
Ø
Jar not firing up
§
String is stuck above jar.
§
Insufficient time for firing.
§
Jar not cocked.
§
Jar Needs Repair
Ø
Jar not firing down
§
String is stuck above the jar.
§
Effect of drag not taken into account.
§
Sufficient time is not given for firing.
§
A lot of pump pressure is applied while jarring.
§
Jar needs Repair
General guidelines for jar operation
§Avoid placing the jar below stabilizers, reamers, key seat wiper or
other tools with a larger O.D. Jar should be placed at least 2 joints
above.
§Leave 3-5 feet of Kelly above bushing to provide slack off length to
cock the jar.
§Avoid using jars at cross over point i.e. DC to jar to HWDP
§R/I slowly through tight spot to avoid down jar firing.
§In zones where differential sticking is anticipated, locate jar relatively
high in the BHA
§Where mechanical sticking is anticipated , locate jar lower in the BHA
38
Drilling Bits
3 Drilling Bits
Achieving the highest ROP with the least possible bit wear and minimal
hole problems is the goal of every drilling engineer. The factors affecting
the drilling performance have complex relationships with Formation
Properties, Drilling Bit Design and Operational Parameters. Formation
drillability plays an important role in selection of suitable bit. In view of
high operating cost of drilling rigs, improvement in ROP will reduce open-
hole formation exposure time & any complications associated with it and
eventually result in significant savings in Drilling Time &Well Cost.
The Chapter covers the following topics:
a) Basics
b) Bit Operating Guidelines
c) Bit Breaking (Commence Drilling with a New Bit)
d) Optimizing Drilling Parameters&Drill-off test procedure
e) Do’s & Don’ts for Roller &PDC Bit
f) Bit Selection
g) IADC Roller & Fixed Cutter Drill Bit Classification
h) IADC Dull Bit Grading methodology
a) Basics
•Roller bits with long, sharp and widely spaced teeth are the first
choice for soft and sticky formations that are prone to Bit Balling. In
this case, ROP is high and drilling action is by gouging & scraping the
rock.
•Roller bits with short and closely spaced teeth/inserts drill by
crushing & chipping action at deeper depths.
•Bits with Roller Bearings are run at lower WOB and higher RPM as
compared to Journal Bearings.
•Bits with Journal Bearings are run at higher WOB and lower RPM as
compared to Roller Bearings.
•Bits with Sealed Bearings have a longer life than bits with non-sealed
Bearings.
39
•Hard-facing and gauge protection are used for hard and abrasive
formations with alternating layers of shales and sandstone.
•PDC Bits have longer life as they have no bearings.
•PDC Bits drill the rock by shearing action and generally ROP is much
higher as compared to a roller bit.
•PDC Bits are run at higher RPM as compared to Roller bits.
•Shale has a better drilling response to RPM whereas Limestone has a
better drilling response to WOB.
b) Bit Operating Guidelines

•Install/change nozzles as mentioned in hydraulic program
(Use tools supplied by manufacturer).
•Measure nozzle size with gauge before lowering the bit and ensure
nozzles are properly installed and clear of debris.
•Use proper size bit breaker plate.
•Do not use damaged/worn out bit breaker to avoid bit jamming.
•Make up the bit to recommended torque only as bit torque is
considerably less as compared to drill collar for the same type of
thread.
•Hoist & lower bit slowly through BOP stack,liner hanger topand in
open hole especially in dog legs and tight spots.
c) Bit Breaking (Commence Drilling with a New Bit)

1. Wash down last single to bottom
2. Approach bottom with full circulation and low RPM to prevent
Plugging of nozzles
3. Tag bottom with low WOB and low RPM.
4. If torque is normal, gradually increase RPM first and then WOB in
steps to recommended parameters.
5. If abnormal torque is observed while breaking in bit, stop drilling. Pick
up string and go down with rotation and circulation repeatedly till
drilling torque becomes normal. Thereafter start drilling with low
WOB and RPM.
6. If torque remains abnormal even after repeated attempts, pull out
the bit as there may be junk at bottom.
40
Drilling Bits
d) Optimizing Drilling Parameters & Drill-off test procedure

Drill-off Test optimizes WOB & RPM and maximizes ROP based on
manufacturer’s recommended range of RPM & WOB for the particular
formation to be drilled.
Drill-off tests should be carried out:
•At the start of the new bit runs.
•On encountering a new formation with significant reduction in ROP.
Drill-off test procedure
1. Start test with minimum WOB and RPM as recommended by
manufacturer.
2. Drill ahead and record the time till WOB drops by 2 T
3. Record length of kelly drilled in step-2 and calculate ROP in m/hr.
4. Now increase WOB in increments of 2 T and record drilling time till
WOB drops by 2 T
5. Step-4 may be repeated 2 or 3 more incremental values.
6. The last test should be at the same value as the first test. This will
determine if any formation change has taken place.
7. Select the WOB with best ROP. Calculate ROP as mentioned in Step-3
above.
8. Now maintain this WOB constant and repeat the above procedure by
changing RPM used in above steps in increments of 10 in soft
formations and 5 in hard formations.
9. Select the RPM with best ROP.
10. Select the optimum WOB and RPM
e) Do’s & Don’ts for Roller & PDC Bits

Ø
Do’s& Don’ts for Roller Bits
Do’s
•Use lifting plug for handling the bit with crane to avoid pin thread
damage.
•Make up small size bit initially by hand to avoid cross threading.
•Make up bit to recommended torque.
•Use proper size bit breaker.
41
•Rollers of non-sealed bearing bit should be made free before

lowering it into the well.
•Gauge the bit before lowering with ring gauge and record it.
•Clean and wash pulled out bit thoroughly before dull bit grading.
•Grading of pulled out bit should be done precisely and ring gauge
should be used to measure gauge wear of pulled out bit.
•A wooden plank or rubber sheet should be placed below insert and
PDC bit while making up.
•Always run Junk Sub on the last bit run prior to lowering insert/PDC
bit to collect broken/lost teeth/inserts and other junk material from
hole.
•Remove rotary bowls before pulling out bit through rotary table.
•If allowed preferably photograph the pulled out damaged/ worn out
Bit. Take shots of damaged/worn area from different angles and store
on rig computer.
Don’ts
•Do not make up bit in reverse rotation and with jerk.
•Do not try to free the roller of the sealed bearing bit before lowering.
•Do not try to push the bit through tight spots.
•Do not touch the bottom with a jerk.
•Do not give WOB while reaming.
•Do not load new bit immediately with normal WOB while resuming
drilling.
Ø
Do’s and Don’ts for PDC Bit:
Do’s
•Junk sub should be run on the last roller bit to collect broken/ lost
inserts if the next run is PDC or Core bit.
•Handle PDC bit very carefully on rig.
•Ensure all nozzles are properly tight.
•A wooden plank or rubber sheet should be placed below the PDC bit
while making up.
42
Drilling Bits
•Initially rotate the PDC bit at 50-60 RPM, with full discharge for 5-10
minutes. This will pump up junk or loose formation off bottom
through the junk slots on bit.
•Always use PDC bit with maximum pump discharge.
Don’ts
•Do not run PDC bit if the previous pulled out bit is found under gauge
and with broken teeth/ inserts.
•Do not ream long sections of the hole because the bit is not stable off
bottom. PDC breakage may occur near the gauge point.
•Do not try to push PDC bit through tight spots.
•Do not allow PDC bit to vibrate or bounce on formation being drilled.
Optimize WOB and RPM to reduce vibration or bit bouncing.
f) Bit Selection
Guidelines for bit selection are as follows:
•Bit selection generally calls for optimum ROP and best suited for
anticipated lithology.
•Generally soft formation milled teeth bit is suitable for surface hole
drilling.
•Sealed journal bearing bit is recommended for drilling at deeper
depths with high WOB and less RPM.
•In deeper hole sections requiring multiple bit runs, new bit should be
selected based on Dull Bit Grading of last pulled out bit.
6. Offset well bit records to be used to know the performance of bits
used previously in the corresponding formations.
7. Worldwide ‘Rock Compressive Strength based Bit Selection’ is being
used nowadays by leading Bit Manufacturers with the help of
Proprietary Software.
8. IDT has also developed in-house computer spread sheet programme
for computing ‘Rock Compressive Strength’ with the help of digital
Sonic, Gamma & Density Logs inputs. Depth wise Lithology, Casing
policy, Well configuration & Bits Performance data of offset wells can
be forwarded to IDT for the respective development field(s) for
methodical Drill Bits Selection based on Rock Compressive Strength.
43
Pin threads for Drilling Bits

Bit size (in) Bit thread type
3 ½ to 4 ½ 2-3/8 Reg
4-5/8 to 5 2-7/8 Reg
5-1/8 to 7-3/8 3-1/2Reg
7 ½ to 9-3/8 4-1/2Reg
9 ½ to14-3/8 6-5/8 Reg
14 ½ to18 ½ 6-5/8 or 7-5/8 Reg
18-5/8 to 26 7-5/8 or 8-5/8 Reg
Make-Up Torques for Drilling Bits

Bit Make-up torque
thread (daN.m) (ft.lb)
2-3/8 Reg 400–480 3,000–3,500
2-7/8 Reg 600–750 4,500–5,500
3-1/2Reg 950–1,200 7,000–9,000
4-1/2Reg 1,600–2,200 12,000–16,000
6-5/8 Reg 3,800–4,300 28,000–32,000
7-5/8 Reg 4,600–5,400 34,000–40,000
8-5/8 Reg 5,400–8,100 40,000–60,000
g) IADC Roller Bit Classification System

§ First Digit: Cutting Structure Series
Eight categories or “Series” numbers 1 to 8 describe general
formation characteristics.
a. Series 1, 2 and 3 refer to steel tooth (milled tooth) bits.
b. Series 4, 5, 6, 7 and 8 refer to insert (tungsten carbide) bits.
Within the steel tooth and insert group, series numbers
increases as the formation becomes harder and more abrasive.
§ Second Digit: Cutting Structure Types
Each Series is divided into 4 “Types” or degrees of hardness from 1 to 4:
•Type 1 refers to bits designed for the softest formation in a
particular Series.
• Type 4 refers to the hardest formation within the Series.
§Third Digit: Bearing/Gauge
Seven categories of bearing design and gauge protection are defined
as “Bearing/Gauge”.
44
Drilling Bits
•1= standard roller bearing

•2= roller bearing, air-cooled
•3= roller bearing, gauge-protected
•4= sealed roller bearing
•5= sealed roller bearing, gauge-protected
•6= sealed friction bearing
•7= sealed friction bearing, gauge-protected.
•8 & 9= Categories reserved for future use.
§ Fourth Digit: Additional Features

A= air application
B= special bearing seal
C= center jet
D= deviation control
E= extended jets
G= gauge/body protection
H= horizontal/steering
J= jet deflection application
L= lug pads
M = motor application
S= standard steel tooth model
T= two cone bits
W= enhanced cutting structure
X = predominantly chisel insert
Y = conical tooth insert
IADC Fixed Cutter Drill Bit Classification System
§ First Character
The first character specifies body construction:
• M = matrix body construction
• S = steel body construction
§ Second Character
The second character tells density of cutters on bit and ranges from
• PDC bits: 1 to 4 for in increasing order of no of cutters
- 1 = 30 or fewer ½” cutters
- 2 = 30 to 40 ½ in cutters
- 3 = 40 to 50 ½ in cutters
- 4 = 50 or more ½ in cutters
Note: Cutters larger than ½” and smaller than ½” are converted
to ½” equivalent size.
45
§Third Character
The third character represents digits 1 to 4 about the size of PDC
cutter on this type of bit, or
•1: Cutter size larger than 24 mm dia
•2 : Cutter size 14 to 24 mm dia
•3: Cutter size 9 to 14 mm dia
• 4: Cutter dia 8 mm or less
Note:One bit may have different size of compacts
§Fourth Character:
The fourth character (digits 1 to 4) gives an idea of profileof the bit
based on overall length of the cutting face of the bit.
•1 = Fishtail PDC bit or flat TSP and natural diamond bit
•2 = Short bit profile
•3 = Medium bit profile
• 4 = Long bit profile
For example, a long flanked “turbine style” bit would be categorized
as 4.
Examples:
•Code S323:This is a (S) Steel body PDC bit with a cutters density (3) of
40 to 50 cutters and a size (2) (14 to 24mm) for the cutters. The profile
(3) is a medium profile.
h) IADC Dull Bit Grading

All pulled out bit should be graded for wear and damage according to the
IADC Dull Bit Grading System.
The dull grading system applies both to roller bits and fixed cutter bits.
Cutting structure Bearing Gauge Other Reason
Inner Outer Dull Loca- seals Dull pulled
charact - tion charact - out
eristic eristics
Col-1 Col-2 Col-3 Col-4 Col-5 Col-6 Col-7 Col-8
Column-1 and 2
Inner cutting structure (inner is 2/3rdof the bit body from centre point)
Outer cutting structure (outer remaining 1/3rdof bit body beyond inner
body)
46
Drilling Bits
In the columns 1 and 2 a linear scale from 0 to 8 is used to describe the

wear condition of the cutting structure according to the following:
Steel tooth bits
• 0 = No loss of tooth height
• 8 = total loss of tooth height
Insert bits
• 0 = No lost, worn and/or broken inserts
• 8 = All inserts lost, worn and/or broken
Fixed cutter bits
• 0 = no lost, worn and/or broken cutting structure
• 8 = All of cutting structure lost, worn and/or broken.
Column-3 and 7
•Write only cutting structure (Cone and cutters) related codes in
Column -3. All other problems may be indicated in Column-7.
Code Problem Code Problem
BC* Broken Cone LN Lost Nozzle
BF Bond Failure LT Lost Teeth/Cutter
BT Broken Teeth/Cutters OC Off Center Wear
BU Balled Up Bit PB Pinched Bit
CC* Cracked Cone PN Plugged Nozzle
CD* Cone Damage RG Rounded Gauge
CI Cone Interference RO Ring Out
CR Cored SD Shirttail Damage
CT Chipped Teeth/Cutters SS Self-Sharpening Wear
ER Erosion TR Tracking
FC Flat Crested Wear WO Washed Out Bit
HC Heat Checking WT Worn Teeth/Cutters
JD Junk Damage NO No Dull Characteristics
LC* Lost Cone
Show cone # or #’s under Column -3
Column-4: Location
Roller cone Bit Fixed cutter Bit
Code Location Code Location Code Location Code Location
N Nose row #1 Cone#1 C Cone S Shoulder
M Middle row #2 Cone#2 N Nose G Gauge

G Gage row #3 Cone#3 T Taper A All rows
A All rows All Cones
47
Column-5: Bearings/Seals
Non-sealed bearings: Sealed bearings
Linear scale estimating bearing life on 0 -8 scale
is used
0=No life used E=Effective seals
8=All life used N=Not able to grade
F=Failed seals
X= Fixed cutter bit
Loose cones, stuck cones and bearing exposure caused by shirttail wear
are all indicators of bearing wear.
Column-6– Gauge Condition

Code Remarks
I Pulled out bit is in Gauge
1/16 Under gauge up to 1/16”
2/16 Under gauge 1/16” to 1/8”
3/16 Under gauge 1/8” to 3/16”
Degree of under gauge can be measured using a standard gauge ring of

steel with a known ID with ring touching two cones. Measurement of
under gauge is calculated from the gap between the third cone and inside
of the ring.
•Under gauge for roller bit(In 1/16th of an inch)=
Gap measured (Inch) x 2/3
•Under gauge for PDC bit(In 1/16th of an inch)
= Gap measured (Inch)
Coumn-8– Reason for Pulling out bit or Terminating Bit Run

Code Reason to pull out Code Reason to pull out
BHA Change BHA HR Hours On Bit
CM Condition Mud LIH Left In Hole
CP Core Point LOG Run Logs
DMF Down hole Motor Failure PP Pump Pressure
DP Drill Plug PR Penetration Rate
DSF Drill String Failure RIG Rig Repair
DST Drill Stem Test TD Total /Casing Depth
DTF Down hole Tool Failure TQ Torque
FM Formation Change TR Weather Conditions
HP Hole Problems TW Twist Off
48
Drilling Hydraulics
4 Drilling
Hydraulics
Hydraulics means flow of drilling fluid in drill string and annular space
between drill string and hole/casing. Hydraulics deals with Annular
velocity, Critical velocity, ECD, Pressure Losses, Hydraulic Horse Power/Sq.
inch (HSI) and impact force which affect hole cleaning and ROP. Drilling
fluid hydraulics is of vital importance and serves many purposes in the
well. Proper hydraulics and hole cleaning are important for improving ROP
and minimizing well complications.
The hydraulics has following effects on the well:
1. Remove cuttings from the well
2. Cool & clean the bit
3. Increase penetration rate
4. Influences sizing of surface equipment such as mud pumps
5. Minimize hole erosion due to the mud’s washing action during Pipe
movement
This chapter deals with
a) General Guidelines
b) Hydraulics in vertical hole
c) Hydraulics and Hole Cleaning in Intermediate & High Angle Sections
d) Hole Cleaning and Monitoring
e) Remedial Hole Cleaning Practices
f) Cleanup Cycle
a) General Guidelines
•In soft and unconsolidated formations especially at shallow depth,
limit jet velocity to minimize hole erosion and wash-out.
•In high angle holes, maximize flow rate for better cutting lifting and
hole cleaning.
•Run bit without nozzles in expected loss circulation zones.
•The large pressure losses in the BHA in high angle wells necessitate
use of larger bit nozzles.
49
•Use 6 5/8" and 5 ½” Drill pipes to maximum extent to reduce pressure

losses in high angle wells.
b) Hydraulics in vertical hole

Proper hydraulics program gives correct nozzle combination and
circulation rate for a particular condition that improves bottom hole
cleaning and ROP. It is also important to expend maximum available pump
hydraulic horse power at the bit.
Annular Velocity
Upward velocity of mud in the annulus against drill pipe is called annular
velocity. Drilled cuttings are heavy and travel upward initially but tend to
fall thereafter. This downward velocity of cuttings is called slip velocity.
The role of annular velocity is to transport these cuttings out of the hole.
Generally, annular velocity is kept about or more than twice the slip
velocity.
Va, Annular velocity of mud
Vs, Slip velocity of particle
Table-1 gives the range of annular velocities for different sizes of

holes. Normally selection of annular velocity will be the first step in
hydraulic program.
50
Drilling Hydraulics
Table-1: Annular Velocities for different hole sizes
Hole Size Annular Velocity

(Inch) Feet per minute Meters per min.
4-3/4 140-220 42-66
6 140-200 42-60
8-1/2 120-180 36-54
12-1/4 70-110 21-33
17-1/2 60-100 18-30
26 30-50 9-15
Annular velocity should be maintained in the recommended range for

effective removal of cuttings. If annular velocity falls below the minimum
value, then cuttings fall back to the bottom of the hole and the bit keeps
on regrinding these cuttings. This results in poor ROP.
There is maximum annular velocity limit to avoid hole erosion problem as
enlarged hole may lead to many other problems later on.
Since in caved portion of hole section excessive enlargement takes place,
annular velocity suddenly drops causing accumulation of cuttings. To
maintain the recommended annular velocity in caved zone it is
recommended to increase pump discharge accordingly.
Circulation Rate
The circulation rate depends upon:
1. Hole size
More annular clearance in larger hole requires higher circulation rate
which also takes care of large volume of cuttings generated. Smaller size
hole needs less circulation rates as annular clearance is less and lesser
amounts of cuttings are generated.
2. Annular velocity requirement
Higher annular velocity needs higher circulation rate and vice versa.
While drilling with both pumps, if one pump fails and discharge of other
pump is insufficient to develop minimum annular velocity, then it is
advisable to stop drilling and repair pump first.
Normally tables give annular velocity against drill pipe annulus as in most
cases drill pipe body OD is same for all the pipes in hole where as there
may be different sizes of drill collars in the hole at the same time.
Nozzles
Nozzle size is normally given in whole numbers like 6, 7, 8, 9, 10, 11, 12, 13,
51
14, 15, 16, 18, 20, 22, 24 etc. Size ‘20’ means nozzle diameter of 20/32".
Sometimes nozzle size is also given in mm.
Normally wide variation in nozzle sizes in a bit is not preferred. For
example, 13-13-14 nozzles will be preferable to 12-12-16 nozzles in
conventional TCR bits.
Where loss zones are expected, smaller size nozzles (less than 16) are not
used as these can get choked during pumping of LCM materials
Pump Output
In ONGC, mostly 7" liner is used in the first phase of drilling with Oilwell A-
1700-PT/National 12-P-160 pumps and replaced with 6-1/2" liners in the
later phase.
Triplex pump output( liter/ stroke) = 0.0386 * D2 * H
where D = Liner bore or internal diameter, inch
H = Stroke length of piston, inch
Pump Efficiency
Pumps are mechanical equipment and do not work at 100 % efficiency.
But use of super charger pumps has increased pump discharge efficiency
to a very high level and efficiency as high as 97 % can be realized. Actual
pump discharge is less than calculated discharge.
Actual pump output = Calculated pump output * Efficiency
Pump Operating Pressure
Normally pumps are rated at 3000 psi or 5000 psi. Oilwell A-1700-PT
pump is rated at 5,000 psi (350 kg/scm2). But 6-1/2" and 7" liners have
pressure ratings of 3,370 psi (237 kg/cm2) and 2,915 psi (205 kg/cm2)
respectively. Further, a margin of about 250 psi (~18 kg/cm2) is allowed to
avoid any accident. So normally maximum pump operating pressure will
be liner rating minus 250 psi (~18 kg/cm2).
However if rotary hose condition or any other equipment dictates lower
pressure rating, then that will be maximum operating pressure limit.
Mud pump safety valve should be set according to liner rating and should
be tested for proper functioning.
Pump pressure losses
Standpipe pressure gauge gives total pressure losses in the system.

Standpipe gauge pressure or total pressure loss is sum of pressure
losses in surface equipment, drill pipe bore, drill collar bore, bit
nozzles, drill collar and drill pipe annulus.
52
Drilling Hydraulics
Remarks
1. In shallow depths, circulating pressure loss is less as compared to bit
pressure loss.
2. In deeper depths, circulating pressure loss increases significantly.
3. Pressure loss is directly proportional to depth as string pressure loss
increases with depth.
4. So in deeper intervals, a compromise between discharge and
pressure loss has to be made.
5. Pressure losses are directly proportional to mud weight.Thus in high-
pressure wells, pressure losses increase.
Pressure losses in surface equipment
This includes pressure losses in standpipe lines, rotary hoses, swivel and
Kelly. This is a small fraction of total pressure losses. Sharp and abrupt
bends leads to higher pressure losses and erosion. Bends should be 45 or
90 degree and smooth. Surface equipment is divided into four categories
as follows:
53
Table-2: Friction factor for Pressure loss in surface equipment

Type of Friction Standpipe Rotary hose Swivel Kelly
equipment factor
Length, ft
Length, ft
Length, ft
Length, ft
ID, inch
ID, inch
ID, inch
ID, inch
1 1.00 40 3 45 2 4 2 40 2-1/4
2 0.36 40 3-1/2 55 2-1/2 5 2-1/4 40 3-1/4
3 0.22 45 4 55 3 5 2-1/4 40 3-1/4
4 0.19 45 4 55 3 5 3 40 4
Pressure losses in drill pipe bore

In drill string, only drill pipe length changes as drilling progresses. So
pressure losses in drill pipe increase with depth.
Pressure losses in drill collar bore
Pressure losses inside drill collar bore are quite high as compared to drill
pipe as drill collar ID is much less as compared to drill pipe. 5"-19.5 ppf drill
pipe ID is 4.27" whereas 8" drill collar ID is 2-13/16". Number of drill collar
should be used as minimum as possible to avoid unwanted pressure
losses. Drill collar bore pressure loss for the complete bit run will remain
the same if discharge is not changed.
Pressure losses in drill pipe annulus
Pressure loss in drill pipe annulus is quite small and can be neglected in
large size holes of 17-1/2" and 12-1/4". But this should be considered in
smaller hole sizes like 8-1/2" and 6" hole sizes.
Pressure losses in drill collar annulus
Pressure losses in drill collar annulus is quite small and can be neglected in
large size holes of 17-1/2" and 12-1/4". But this can be considered in
smaller hole sizes of 8-1/2" and 6" hole sizes.
Note:Tables in Data Books give pressure losses in drill pipe bore and
annulus per 1,000 m length whereas pressure losses in drill collar bore
and annulus are per 100 m length for 10 ppg mud.
Pressure losses in bit nozzles
Pressure losses in bit nozzles form the major part of total pressure losses.
Nozzle size is selected to optimize hydraulics. Hydraulics optimization
leads to improvement in ROP.
Hydraulics Optimization
Hydraulics optimization takes place when pressure loss in bit is between
50 to 65 % of total system pressure loss. For optimizing hydraulics, pump
54
Drilling Hydraulics
pressure should be as high as possible but subject to the maximum

operating pressure.
There are two theories of optimization:
1. Maximum BHHP Theory
Maximum Bit Hydraulic Horse Power theory gives about 65 % of total
pressure loss in the bit. Nozzle size is smaller and pump pressure is high.
Higher jet velocity gives better ROP in top-hole soft formation.
2. Maximum Impact Theory
At deeper depth, higher jet velocity does not help in improving ROP.
Moreover, it may not be possible to have 65 % pressure loss in bit as loss in
drill string also increases significantly. While drilling, excessive hydrostatic
pressure of mud column does not allow dislodging cuttings. Pressure loss
in bit is around 50 % in this theory to optimize impact force which
dislodges these cuttings. There is less wear and tear of mud pumps.
Maximum Impact Force optimization is more important than maximum
BHHP at deeper depth. This theory implies that higher discharge can be
given by bigger nozzle size and less pump pressure in deeper depth.
Effect of mud weight on pump pressure
Increase in mud weight will increase the pump pr proportionally.
New pump pressure
=Old pump pressure * (New mud weight / Old mud weight)
Effect of pump discharge on pump pressure
Increase in discharge will increase the pump pr proportionally.
New pump pressure
=Old pump pressure*(New discharge/Old discharge)2
Effect of drill string bore on pump pressure
Increase in bore size will decrease the pump pr proportionally.
New pump pressure
=Old pump pressure*(Old bore, inch/ New bore, inch)5
Hydraulics Optimization Criteria
The three criteria for hydraulics optimization are as follows:
1. Pressure loss in bit nozzles is 50-65 % of total pressure loss
2. Jet velocity is in the range of 100-168 m/sec
3. Bit Hydraulic Horse Power per square inch of hole size (HSI ) is in the
range of 2.0-5.0
55
Note : Ideally, minimum 2.0 and maximum 3.5 HSI should be maintained
for different types of bits. HSI of 2.0 for TCR (Steel bodied bit) & 2.5 to 3.5
HSI is preferred for PDC bits considering discharge requirements.
Reynold Number and Flow Profiles
Reynold number is a dimensionless number that relates the velocity to
the ratio of inertia force and viscous force (viscosity).
Reynold number, Rn= 928 ρ Van /60 µ
Where D= Hydraulic diameter (inch)=Dh-Dp
Dh=Hole diameter (inch)
Dp=Pipe OD (inch)
µ=Viscosity (cps)
ρ=Mud weight (ppg)
Van=Annular velocity (ft/min)= 24.5 Q/(Dh2-Dp2)
Q=Circulation rate (gpm)
•Flow is laminar if Reynold number <2000
•Flow is in transition for Reynold number 2000-4000
•Flow is turbulent for Reynold number>4000
The lower transition range of Reynold number is called the Critical
Reynold Number, i.e. 2000. If the actual Reynold Number is less than
Critical Reynold Number i.e.2000, the flow is laminar, otherwise, it is
turbulent.
Pressure losses are more in case of turbulent flow. Normally flow inside
drill string and against drill collar annulus is turbulent and laminar against
drill pipe annulus.
Hydraulics calculations
The following equations can be used for pressure loss calculations and
hydraulics optimization on the rig. However, for more accurate
calculations, hydraulics software can be used that provides option for
selecting different mathematical models like Bingham Plastic, Power Law
and Modified Power Law. These models give different pressure loss
values.
56
Drilling Hydraulics
Table-3: Hydraulics Formulae

Parameter FPS System MKS System
2 2 2 2
Annular 24.5 Q/(D h -D p ) 1.973 Q/ (D h -D p )
velocity, Van
1.86 -6 1.86
Surface C?(Q/100) 9.40 x 10 C ? Q
-4 1.86
equipment = 1.90 x 10 C ? Q
pressure
losses, D P Surface
1.86 4.86 -6 1.86 4.86
Drill stem bore 0.000061 ?LQ /d 9.87x 10 ?LQ /d
pressure
losses, D P Bore
2 2 -6 2 2
Jet nozzle ?Q / 10858 An 3.77x10 x ?Q /A n
pressure
losses, D P Bit
-7 2 -6 2
Annular [(1.4327x10 )?LVan ] [(2.97x10 ) ?LVan ]
pressure [D h -D p ] [D h -D p ]
losses, D P Ann
Jet velocity, Vn 0.320086 Q/A n 0.0258 Q/A n
Jet impact 0.000516?QVn 0.001695?QVn

force, I f
Hydraulic PQ/1714 PQ/456.22

Horsepower,
HHP
Bit HHP D
P Bit Q/1714 D
P Bit Q/456.22
HSI Bit HHP/Area of hole Bit HHP/Area of hole

(square inch) (square inch)
57
Table-4: Nomenclature
Nomen- FPS System MKS System
clature
C Coefficient of Friction whose Same as in FPS
value can be found
in Table-2: Friction factor for
Pressure loss in surface
equipment given above
Q Circulation rate (gpm) Circulation rate (lpm)
Dh Diameter of hole (inch) Diameter of hole (inch)
Dp Pipe OD (inch) Pipe OD (inch)
d Pipe bore or ID (inch) Pipe base of ID (inch)
V an Annular velocity (ft/min) Annularvelocity (m/min)
Vn Jet velocity (ft/sec) Jet velocity (m/sec)
? Mud weight (ppg) Mud weight (gm/cc)
L Length of component (ft) Length of component (m)
An Area of nozzle (Square inch) Area of nozzle (Square inch)
D P Surface Surface equipment pressure Surface equipment pressure
2
losses (psi) losses (kg/cm )
D
P Bore Drill stem bore pressure Drill stem bore pressure
2
losses(psi) losses (kg/cm )
D
P Bit Jet nozzle pressure losses Jet nozzle pressure losses
2
(psi) (kg/cm )
D
P Ann Annular pressure losses Annular pressure losses
2
(psi) (kg/cm )
Pf Jet impact force (lb f ) Jet impact force (kg f )
HHP Hydraulic Horsepower (hp) Hydraulic Horsepower (hp)
P Total Pr loss (psi) Total Pr loss (kg/cm2)
c) Hydraulics & Hole Cleaning in Intermediate & High Angle Sections

Following procedures are recommended for the deviated portion of the
wellbore where problems due to formation of cutting beds are
anticipated:
•Circulate at the recommended flow rate for high angle wells with
intermittent rotation and reciprocation prior to starting a trip.
•Maintain maximum pipe rotation, which can directly contribute to
hole-cleaning. While using MWD, maintain 50-55 RPM
•String rotation aids in hole cleaning significantly in high angle
58
Drilling Hydraulics
holes.Use minimum 55 rpm and up to 120 rpm based on directional

assembly in use to stir-up and remove cutting bed
•Rotate string at higher rpm say 120 rpm periodically to clean the hole
if large section of hole was drilled under sliding mode or with mud
motor.
•In the deviated section, POOH at 2 to 3 minutes per stand with close
watch on weight indicator.
•If excess drag is indicated (half of buoyant BHA weight), stop pulling
out and circulate at least one bottoms up at the maximum allowable
flow rate.
•If hole condition is bad and continuous drag is observed during POOH
in high angle hole section, the following action is recommended:
§If top drive is not available
Pump out one single at a time at the maximum allowable flow
rate while pulling at 1-2 minutes per single. Continue till hole
becomes free of cuttings. Pump out of the hole preferably to
casing shoe.
§If a top drive is available
Pump out of the hole preferably to casing shoe at the maximum
allowable flow rate while pulling out at 3-6 minutes per stand.
•Once string is inside casing, circulate at least one bottoms-up at the
maximum allowable flow rate or hole is clean
•POOH without pumping.
•Prevent annulus loading and consequent packing-off while making
connection by ensuring that recently drilled cuttings are well above
the BHA length by circulation especially when the ROP is more than
25-30 meters per hour.
•Pumping-out with back reaming is an accepted procedure in high
angle wells. However, practice in Mumbai offshore showed that the
best way to deal with the cutting beds is to first try normal pull out, if
necessary pump-out at moderate GPM and finally pump-out with
back reaming if needed at 500 to 550 GPM. The important point is
that, if back reaming is resorted then the string is to be pulled all the
way by back reaming only to shoe to avoid cutting bed packing-off.
For effective hole cleaning in directional wells with more than
350angle, the recommended flow rates are as follows:
59
Table-5 : Recommended Discharge for High angle wells

Hole size Min pump discharge Best pump discharge, if
possible
gpm lpm gpm lpm
17-1/2”-16” 1,100 4200 1,200-1,400 4,500-5,300
12-1/4” 800-1,000 3,000-3,800 1,000-1,100 3,800-4,200
8-1/2” 450 1,700 500-550 1,900-2,100
6” 250 950 300 1150
Following table can be used to calculate actual bottoms up strokes in

deviated wells for ensuring effective well cleaning:
Table-6: Minimum no of circulations to clean well in High angle wells
Section Length Factor (= No of circulations)

Hole size 17-1/2” 12-1/4” 8-1/2” 6”
Well
Inclination
(Degrees)
0 - 10 1.5 1.3 1.3 1.3
10 - 30 1.7 1.4 1.4 1.4
30 - 60 2.5 1.8 1.6 1.5
60 - 90 3.0 2.0 1.7 1.6
d) Hole Cleaning and Monitoring

•Flow rate – Maximize flow rate as per well plan
•RPM– Maximize within system limitations like surface
limitations, vibrations, ECD, down hole tools, etc.
•ROP– Maximize based on Torque & Drag monitoring and hole
cleaning.
e) Remedial Hole Cleaning Practices

•Control ROP until hole cleaning improves.
•If the hole still does not clean up, stop drilling and perform a
cleanup cycle.
•If hole cleaning continues to be a problem, other options may
include sweeps, wiper trip, back reaming, change in mud weight
and rheology.
60
Drilling Hydraulics
f) Cleanup Cycle
Following procedure may be used to clean up hole prior to pulling
out or for remedial purpose while drilling:
•Circulate 2.5–3.0 times bottoms up and until shale shakers are
clean.
•Monitor the quantity of cuttings coming over the shakers every
15 minutes.
•Maintain rpm and flow rate at their maximum level.
•Monitor relative changes in Torque & Drag. Improvement is
expected as the hole cleans up.
•Generally 2 distinct waves of cuttings over the shakers will occur
during the cleanup cycle (second peak generally comes at 1.0-
1.5 times bottoms up after the first peak).
•In deeper depth the main concern is pump pr and in upper
section it is discharge for hole cleaning, so accordingly liner size
and nozzle size should be selected.
61
Drilling Fluid Management
5 Drilling Fluid
Management
Drilling fluid is a critical part of the drilling process. Drilling fluid provides
the primary well control through its hydrostatic head and provides the
most important hole cleaning function. It is also needed to realize the
twin objectives of minimizing the drilling cost through control of Non-
Productive Time (NPT) due to down-hole complications and maximizing
the productivity of the well by control of formation damage in drilling.
Functions of Drilling Fluid
1. Hole cleaning:
a) Transport drilled cuttings and caving to the surface.
b) Suspend drilled cuttings and caving in the annulus when
circulation is stopped.
2. Primary Well Control: Control sub surface pressure.
3. Lubricity: Cool and lubricate the bit and drill string.
4. Hole stability:
a) Stabilize the down hole formation through inhibition, cake
formation etc
b) Support the walls of the well bore.
5. Hydraulic Horse Power (HHP): Deliver hydraulic energy upon the
formation beneath the bit.
6. Data transmission: Provide a suitable medium for transmitting data
from down hole tools like MWD, LWD etc.
Types of Drilling Fluid
1. Water Base Drilling Fluid: Clay & Polymer Drilling fluid.
Clay based drilling fluid are dispersed and non-dispersed types
whereas polymer based drilling fluid are inhibitive and non damaging
types.
2. Oil Base Drilling Fluid: All oil base & Invert Emulsions drilling fluid.
The base oil for these fluids may be diesel, low toxicity mineral oil or
synthetic base oil.
63
This chapter covers the following aspects of drilling fluid:

a) Pre-requisite for Drilling Fluid Management
b) Preparation of Mud Tanks/ Circulating System
c) Conversion of Top Hole Drilling Fluid to Treated Mud System.
d） Procedure for Making KCL-PHPA Drilling Fluids.
e) Guidelines for Running PHPA Drilling Fluid.
f) Solids Control in PHPA base Drilling Fluid.
g) Preparation/Maintenance of Non Damaging Drilling Fluid.
h) Preparation/Maintenance of Formate Base Drilling Fluid.
i) Preparation/Maintenance of Micro-bubble Drilling Fluid.
j) Preparation/Maintenance of HTHP Drilling Fluid.
k) Mixing Procedure, Testing & Maintenance for Low Toxic Mineral Oil/
SOBM Drilling Fluids.
l) Drilling Clay Formations.
m) Drilling Shale Formations.
n) Drilling Pay Zone/ Reservoir Section.
o) Drilling Coal Section.
p) Standard Methods of Testing and Control of Water Base Drilling Fluid
Parameters.
q) Hole Cleaning.
r) Recommended Drilling Fluid Practices.
s) Bore Hole Instability.
t) Stuck Pipe.
u) Lost Circulation.
v) Trouble Shooting Oil base Drilling Fluid Issues.
w) Guidelines for Operating Solid Control Equipment like Decanting
Centrifuge, Maintenance & Troubleshooting of Desanders &
Desilters.
x) Gas/ Water Influx Detection and Control.
y) Well Conditioning for Casing Cementation.
z) Well Conditioning for Logging Operation.
aa) Well conditioning for Hermetical Test
bb) Hydrogen Sulphide (H2S) Control
Appendix
1. Recommended drilling fluid properties in different hole sizes
64
2. Stacking & handling of mud chemicals,

3. Key safety precautions
4. Emergency First-Aid procedures.
a) Pre-Requisite for Drilling Fluid Management

For effective drilling fluid management, the followings are essential pre-
requisites:
1. Geo-Technical Order (GTO) with lithological sequences (Sand, Clay,
Shale and Reservoir), temperature & Pressure data, caving, mud loss
and oil/ gas show zones.
2. Availability of all solids control equipment viz. shale shaker,
desander, desilter/mud cleaner, centrifuge (if available) in proper
working condition.
3. Handling equipment such as hoppers, agitators, jet shearing device,
guns and tanks with proper isolation and dump valves.
4. Drilling fluid testing equipment such as mud balance, Marsh funnel,
API fluid loss kit, Retort kit, Rheometer, pH meter, sand content kit,
MBC kit, labs centrifuge etc.
5. Chemical testing kits for salinity, KCl, PHPA, Ca++/Mg++, alkalinity
determination.
6. Additional chemical testing kits for SOBM and emulsion testing kit
7. Ensure that the technical water is tested for chemical composition.
8. Minimum 100 MT Baryte stock may be maintained in exploratory
wells at rig to meet any well control exigencies.
b) Preparation of Mud Tanks/ Circulatory System

It is necessary to check and prepare the tanks and the circulatory system
of the rig before spudding a well. The following may be ensured:
1. Active and all other tanks are placed in order and inter connected.
2. All valves are functioning properly and have no leakage.
3. Agitators in the tanks are functioning properly.
4. Active pit is properly connected to incoming water line and mud
pumps.
5. Flow line is of sufficient diameter to handle maximum discharge of
drilling fluid without overflow and with sufficient margin for gas
influx/ expansion.
65
6. Bell nipple is properly aligned with the return flow line having proper
slope to possum belly at shale shaker and without leakages.
7. Ensure provision of minimum of 2” diesel line to slug pit.
8. Settling pits and other tanks of the circulatory systems are properly
lined up with no leakage.
9. Solid control equipment like shale shaker, desander, desilter, mud
cleaner and centrifugeare properly installed and functional. There
should be no leakages from the gland packings.
10. All motors to be properly protected from drilling fluid & water.
11. Degasser is properly installed and tested.
12. Both hoppers are functional and lined up.
13. Flow between different compartments of settling tank and to
intermediate tank is in over flow mode. Interconnection valves at
bottom to be kept closed to allow solids settle down.
14. Place Baryte platforms close to hopper.
15. Sensors for measurement of pit volume, flow rate, gas show, fluid
density etc. are installed properly.
Preparation of Gel in Mud Tanks
1. Check salinity and calcium content of technical water. Chloride as
NaCl should be less than 1000 mg/l and Calcium less than 50 mg/l.
2. Clean the mud tanks thoroughly by flushing with drill water.
3. Take sufficient quantity of water in the mud tank.
4. Add soda ash to remove Ca++/Mg++ and to maintain pH at 9.5 for
optimum hydration. Recommended soda ash dose: To treat Ca++out
of technical water, multiply the total hardness of water (mg/L) by
0.0009 to find ppb of Soda Ash to add. Generally 0.7-1.4 Kg/M3 Soda
Ash is required in field conditions.
5. Mix bentonite powder through hopper using water of active pit. The
rate of addition of dry bentonite powder is controlled to avoid
choking of hopper nozzle. Normally 7.5% bentonite powder w/v is
sufficient to achieve desired viscosity. However, thick gels of 10% or
more bentonite may also be prepared for keeping as reserve mud in
other tanks.
6. Check pH value of the gel under preparation and maintain in the
range 9.0to 10.0 by adding required quantity of caustic soda.
7. Keep the gel for hydration for 6-8 hours with agitators running during
66
period of hydration.
8. Avoid contamination of drill water with salt, lime and cement etc., to
get proper hydration of bentonite.
c) Conversion of Top Hole Drilling Fluid to Treated Mud System

The bentonite gel is used for spudding the well. Normally, this drilling fluid
is maintained only with pH control and dilution. The well is drilled to a
depth of 200/ 300 m or more. The surface casing is lowered and cemented
to isolate fresh water sands. While drilling cement inside casing, cement
contamination causes viscosity hump in the mud system.The fluid is pre-
treated with soda ash (0.1-0.2 %) and citric acid to control pH and viscosity
hump. Minor treatment with thinner may be required to smoothen the
fluid flow.
After drilling top hole section with highly dispersibleclays,before opening
shale section, the bentonite gel based drilling fluid is converted to Gel
Polymer mud using specialty chemicals to control rheological and
filtration properties as follows:
1. Treat the mud with 0.5 % CMC with continuous dilution to maintain
rheology in order.
2. Add 0.2-0.3 % XC-Polymer along with continuous dilution and 0.5
%PAC-LV to maintain desired fluid loss around 10 cc.
With this continuous treatment during drilling, the gel polymer system is
conditioned to the desired parameters by the end of the section for
logging and casing operations.
Note: Alternately, based on formation suitability/ specific well
requirement KCl-PHPA/ SOBM system may be used for top hole drilling.
d) Procedure for making KCl-PHPA Drilling Fluids

The ingredients of polymer mud are mixed in following order:
Mix required dose of Biocide in technical water.
Add KCl as per design. (Minimum 5%)
Add PHPA for encapsulation. (0.3-0.4%)
Add PAC　
for　
fluid　
loss　
control．
(0.5-1.0%)
Add XC-POLYMER　
for　
viscosity　
and　
Low　
Shear　
Rate　（
Viscosity　LSRV）．
(0.3-0.5%)
Add weighing material for increasing mud weight.
67
If weighing material is not used then mix 6% calcium carbonate for
bridging purpose.
All the polymers should be mixed very slowly to avoid hopper choking
and preferably through jet shearing device for proper shearing.
Particularly PHPA should be added slowly with sufficient shearing to
avoid the formation of fish eyes (lumps).
Mix lubricants and polyol as per requirement and well profile.
Add maintenance dosages of these mud additives at regular intervals
to ensure that properties of drilling fluid remain within the limits set
in GTO/plan.
e) Guidelines for Running PHPA Mud

The following guidelines for running PHPA mud are based on careful
analysis and field experience.
•Ensure that the rig has adequate solids control equipment. If the
solids control equipment is inadequate, then massive dilution will be
required for control of solids. Low gravity solids should be
maintained below 5% by volume.
•Maintain at least 1 lb/ bbl [2.9 Kg / m3] active PHPA in the mud system
as determined by a materials balance calculation. The PHPA depletes
from the system as it coats on the solids and the well bore. PHPA is to
be added slowly in the system for replenishing its concentration as
fresh formation is being drilled. For 12 ¼”hole section 50-75 Kg and 8
½”section 25-50 Kgs of PHPA is to be added for each 100 m drilling
depending on formation reactivity and as experienced in drilling
operation.There are several methods to test for PHPA concentration
in the mud. The best way to ensure sufficient PHPA in the system is
to add additional quantity of PHPA for every unit volume of dilution.
•To maintain the mud system, prepare a premix in separate pit
containing all ingredients and add to active mud system. Product
concentrations in the premix can be adjusted if necessary to increase
product concentration in the active system. The premix should be
sheared at high shear rates prior to adding to the active system. It is
a normal practice to maintain about 2% higher KCl in the premix to
compensate loss of Potassium ion in the drilling fluid system. Usually
about 20-40 m3 of premix addition per day may be required to
maintain fluid loss, inhibition, LSRV of the total mud system in the
desired range. The premix technique will minimize temporary
68
viscosity fluctuationsand will also facilitate material balance

calculation.
•When mixing the mud, use a shearing device to eliminate viscosity
hump problems. Alternatively, if the initial viscosity is too high when
mixing new mud, mix only 50% of the required PHPA. Balance
quantity of polymer can be added to the system as soon as
circulation commences.
•PHPA muds are sensitive to high pH, especially in the presence of high
calcium levels. For this reason, it is not recommended to drill cement
with this, unless the mud system is to be discarded after drilling. If it
is unavoidable to drill cement with a PHPA system, the system should
be pretreated preferably with citric acid or sodium bicarbonate to
knock out calcium ion and to control pH. If cement contamination
occurs, dump excessively contaminated patch of mud and replenish
PHPA concentration.
•The calcium ion concentration in PHPA mud should not be more than
400 mg/L. Higher calcium ion levels will interfere with the PHPA
polymer. Avoid excessive treatment with soda ash to remove calcium
as this could lead to self-induced carbonate contamination in the
mud.
•Maintain pH in the 8.5 to 9.0 range. At higher pH, PHPA degrades to
release Ammonia.
•PHPA muds can be run at any salinity from fresh water to salt
saturation. They are particularly effective in seawater. For greater
inhibition, sodium chloride at a chloride ion concentration of
125,000 mg/L has been quite effective in many areas. PHPA should
be pre-hydrated in fresh water for maximum yield prior to adding to
the active system.
•If insufficient yield value or initial gel strength is obtained from the
initial mud formulation, Xanthan gum can be used at 0.25 lb/bbl [0.7
Kg/m3] for the required low shear rate viscosity.
•When adding Baryte, it is recommended to add about 0.25 to 0.5
lb/bbl [0.7 to 1.4 Kg/m3] of poly-acrylate deflocculant (in the premix)
to minimize viscosity fluctuations in the active system.
•Another effective technique to enhance the inhibitive quality of
PHPA muds is to use Sulphonated asphalt in concentrations of 6 to
8lb/bbl [17 to 23 Kg/m3] to seal shale micro-fractures.
69
•If viscosity increases are noted with increasing drill solids, take steps
to reduce drill solids through increased use of solids control
equipment or dilution and increase the PHPA concentration in the
active system.
•To control the HTHP fluid loss at 2500F [1200C], utilize PAC polymer at
1 to 2 lb/bbl [2.9 to5.7 Kg/m3]. To control HTHP fluid loss at 3000F
[1500C], use high temperature fluid loss control polymers (such as
vinyl sulfonate / vinyl amide copolymer and modified lignin) to
supplement the Bentonite.
•Observe the drill cuttings across the shale shaker. If the cuttings stick
together when squeezed, additional PHPA polymer may be required.
Ideally, the cuttings should have a glossy appearance and have a
slippery feel.
•Observe the cuttings size distribution at the shale shaker/ flow line.
They should be coarse with a minimum amount of fine particles. If
shaker screen blinding occurs with the PHPA mud, use a shearing
device while pre-hydrating the PHPA or switch to the next coarser
screen size.
•When drilling with PHPA mud, tight hole may be encountered as a
result of gauged hole or drill cuttings smeared to the well bore. This
phenomenon often occurs only in the newly drilled section and
clears up after the first trip through the drilled section. If tight hole
across the same section persists on consecutive trips, investigate
other causes.
•Although PHPA mud stabilizes well bores, unconsolidated sands and
mechanically weak shale will still be susceptible to hydraulic and
mechanical erosion. In such areas, maintain proper yield value, use
lowestoptimum bit /annular hydraulics.
f) Solids Control in PHPA based Drilling Fluids

The success of PHPA drilling fluid depends mainly on two key factors.
1. Maintenance of adequate quantity of polymer i.e. PHPA at all times
in the drilling fluid because below a critical polymer concentration
there is an unacceptable rise in viscosity mainly due to high yields
and gels. So, it is advisable to always maintain sufficient
concentration of PHPA in the drilling fluid system.
2. The second key factor is maintenance of good control over the low
gravity solids.This in turn requires the following solid control
70
equipment on the rig in proper working condition to prepare and

maintain high specific gravity KCl-PHPA Polymer drilling fluid:
•Shale Shakers capable of handling 150 X 150 mesh screens or
above.
•Linear Motion Mud Cleaner capable of handling large volumes of
high specific gravity KCl-PHPA Polymer drilling fluid.
•A Centrifuge of adequate capacity to handle high specific gravity
KCl-PHPA Polymer drilling fluid.
Besides, the rig must also be well equipped with jet shearing device in the
mixing tanks and active system. It should also have an additional high
shear rate mixing device downstream to hoppers to ensure thorough
mixing of PHPA in the system without formation of lumps or fish eyes. The
rig should also be provided with sufficient tanks for the storage of polymer
premix and reserve volumes of drilling fluid.
g) Preparation/maintenance of Non-damaging Drilling Fluid

NDDF is the drilling fluid to be used in all drain hole drilling to minimize
formation damage and maximize productivity. NDDF drilling fluid is also
used for drilling pay zone/ reservoir section having hydrostatic as wells as
sub hydrostatic pressures. The components used in its preparation are
eco-friendly and biodegradable. The mud cake formed by NDDF can be
removed by mild acids/ mud cake removing formulations.
Following is the general formulation for its preparation:
•Technical water + 5.0% KCL + 0.45-0.5% XC polymer + 3-4 % PGS+
6.0% Micronized CaCO3 + 0.1% formaldehyde (biocide).
Maintenance of NDDF is similar to KCl-PHPA polymer fluid as
described above. Particle size of the micronized calcium carbonate in
NDDF needs to be designed based on 1/3rd of average pore throat
diameter of the pay zone being drilled.
•When NDDF is used for pay zone drilling in conventional wells other
than drain holes, with cased hole completion, for improved
performance efficiency2-4% Sulphonated Asphalt, 3-4% Polyol (at
high temperature~120°C) and antioxidant (0.1% for thermal
stability) may be added to the NDDF system.
•Even though starch which is easily biodegradable is chosen for NDDF,
alternatively for maintaining optimum filtration loss, 0.3 to 0.5% PAC
(LV) or PAC-R (Regular) may be used.
71
h) Preparation/ maintenance of Formate base drilling fluid:

For drilling above hydrostatic pay zones, the NDDF is prepared with
Sodium Formate brine (1.33SG max) and Potassium Formate brine (1.57
SG max).
The main benefit in formate fluids is the use of solids free drilling fluid at
higher density even up to 2.1 SG in case of cesium formate. Following are
the added advantages of the formate based NDDF:
•Higher temperature stability of viscosifier & fluid loss polymers
•Low crystallization temperatures and low corrosion potential
•Biodegradable
•Excellent acceptable toxicity
•Enhanced shale stabilization
•Compatibility with most organic polymers
•Inhibit bacterial growth
•High tolerance to solids contamination etc.
The composition for formate base drilling fluid :
•Technical water + 0.45% XC polymer + 3.0% PGS + 6.0% MCC + 20-
30% Sodium Formate
i) Preparation/maintenance of Micro bubble Drilling Fluid:

Micro bubble drilling fluids are used for drilling depleted reservoirs, loss
prone section, with alternate sand and shale or fractured lime stone
formations.
To prepare micro bubble base drilling fluid, a blend of two different
surfactants is mixed in technical water/Sea water/Sodium formate/
Potassium Formate along with foam stabilizers for creating stable micro-
bubbles of sufficient low shear rate viscosity (LSRV). A co-surfactant is also
added to form a stabilized foam system. LSRV of the system may be
maintained as per requirement depending on well condition by
increasing or decreasing the dose of Bioviscosifier. When micronized
calcium carbonate (MCC) and KCl are mixed in the system, LSRV is reduced
and also beyond 110°C system looses LSRV. However, it is compatible with
varying concentrations of sodium chloride up to saturation level. HTHP
fluid loss measurements indicate good sealing properties of this system.
Micro-bubble system with 6% KCl, having good LSRV, can be prepared
with proper surfactants for applications up to 92°C.
72
Following general formulation can be used to drill and simultaneously

control mud loss up to 110°C:
Technical/sea water/Sodium formate/Potassium formate + Biocide
(0.1%) + Surfactant-1 (0.4 to 0.5%) + Surfactant-2 (0.3 to 0.4%) + Co-
surfactant (0.3%) + Foam stabilizer-1 (0.2%) + Foam stabilizer-2 (0.1%) +
Foam stabilizer-3 (0.1%) + Bioviscosifier (1.0 to 1.4%) +pH buffer (0.1 to
0.3% or more as per requirement) + Fluid loss reducing polymer (0.3 to
0.4%) + Polyol Grade-II (0.5%).
j) Preparation/maintenance of HTHP drilling fluid

The HTHP drilling fluid is recommended for formations having Bottom
Hole Temperature (BHT) in the range of 150°C to 230°C.
The drilling fluid properties must be maintained as under:
1. Plastic viscosity should be as low as possible to minimize ECD.
2. The yield value should be sufficient to prevent sag but not so high as
to cause gelation resulting in high surge & swab pressures.
3. Fluid loss should be as low as reasonably possible to prevent
formation damage and risk of differential sticking.
4. Rheological properties should not change over time under static or
dynamic conditions. It should be stable and tolerantto
contaminants.
General Formulation for HTHP Drilling Fluid
2% pre-hydrated bentonite suspension (PHBS) + KOH ( to maintain pH 9.0
to 9.5) + 5–7% KCl( or as recommended) + 0.4% XC polymer + 2.0% HT fluid
loss additive + 0.5 % HT deflocculant + 0.6% PAC(LV) + 1.5 to 2.0%
Resinated lignite +2.0% SA +0.1% Sodium Sulphite+ Baryte as per mud
weight required
(0.5-1.0% EP Lube/ graphite flakes may be added for better lubrication).
Guidelines
Before drilling a HTHP phase, convert the drilling fluid of previous phase to
HTHP system or prepare fresh HTHP drilling fluid. Salient points are as
follows:
1. HTHP drilling fluid has high volume fraction of solids (due to high
mud weight) so clay content should be as low as possible.
2. Maintain Methyl Blue Capacity (MBC) value equivalent to 3-5 ppb
bentonite to avoid excessive viscosity and gelation.
73
3. For preparation of fresh drilling fluid, 1.5-2.0% PHB should be used.

4. Sepiolite clay performs better at high temperature and can be used in
place of bentonite if available.
5. Use high quality Baryte (4.2 SG) with particle size in the range 10-75
microns and free from any clay or impurities.
6. Weighing materials of higher specific gravity like Hematite or
manganese tetra oxide may be used to reduce solid content.
7. Additives like PHPA, PAC cannot withstand high temperature (above
150°C) so their use may be avoided.
8. Lignite, Resinated lignite and sulphonated asphalt can be used along
with HTHP chemicals to control fluid loss & rheology.
9. pH should be maintained between 9.0 to 9.5.
10. HTHP fluid loss reducing polymers should be mixed during
circulation to avoid any pumping problem.
11. HTHP deflocculant should be mixed very slowly in small quantity as
per requirement.
12. For preparing HTHP drilling fluid, prepare 4 cp PHB + 0.4% XC
polymer (Sacrificing polymer). Load with Baryte to desired specific
gravity. Raise pH with caustic to 10.5. Mix 1.5% resinated lignite and
2% sulphonated asphalt. Add 1.5% HTHP fluid loss reducing polymer
and 0.5% HT polymeric deflocculant. Mix it thoroughly by circulating
in the well.
13. Where flow line temperature is very high (> 900C), use of mud cooler
is recommended for safety of crew and to maintain proper ambient
temperature around mud tank area. Use of mud coolers can also
reduce consumption of mud pump expendables in HTHP wells.
k) Mixing Procedure, Testing & maintenance for Low Toxic Mineral

Oil/SOBM Drilling Fluid
Take required quantity of Base oil and mix additives in following order
with vigorous agitation:
Add primary and secondary emulsifiers.
Add lime in excess.
Add required amount of brine
Add organophilic clay/ viscosifier.
Add filtration control additives.
74
Mix and agitate for extended period to ensure good emulsion

formulation, especially immediately after adding brine. A well
emulsified SOBM should present a glossy mirroring finish.
Add weighing agents.
The addition of components in their proper sequence is essential
because initial mixing will optimize the performance of each
product.
Mixing time may vary depending on the amount of shear either at
the rig or mud plant.
Organophilic viscosifier require considerable shear to develop full
viscosity.
Table-1: Tentative concentration of additives in LTMO.

Sl.No. Chemical Concentration
1 Primary Emulsifier 2.00-2.25 % w/v
2 Secondary emulsifier 0.60% w/v
3 Organophilic clay 3-4%w/v
4 Fluid loss agent 2-3% w/v
5 Lime 3-4% w/v
Testing & Maintenance of SOBM

Besides general tests carried out for Water base drilling Fluid, some
special tests are carried out for Oil base Drilling Fluid. These are:
Ø
Alkalinity (OBM/Synthetics)
Determine the whole-mud alkalinity and lime content ofan oil-based mud
(OBM) or synthetics.
Equipment
500-ml Erlenmeyer flask with a rubber stopper ora pint jar with a lid.
3-ml disposable syringe
50-ml graduated cylinder
250-ml graduated cylinder
Two 1-ml pipettes
Two 5-ml pipettes
Base fluid
Distilled water
Phenolphthalein indicator solution
75
0.1N (N/10) sulfuric acid solution

0.1N (N/10) sodium hydroxide
Procedure
1. Collect a drilling fluid sample.
2. Measure 100 ml. of base fluid into the Erlenmeyer flask.
3. Add 1.0 ml of the fluid sample to the Erlenmeyer flask using the
syringe.
4. Stopper the flask and shake vigorously.
5. Add 200 ml of distilled water and 10 to 15 drops of phenolphthalein
indicator solution to the flask.
6. Stopper the flask and shake vigorously for aminimum of two minutes.
7. Allow the phases to separate.
•If pink color develops and remains, go to Step 8.
•If pink color does not develop, Alkalinity is zero. Go to Step 16.
8. Add 3 ml of sulfuric acid solution to the flask using the 5-ml pipette.
9. Stopper the flask and shake vigorously.
10. Allow the phases to separate.
•If the solution remains pink, go to Step 11.
•If the solution turns colorless, go to Step 12.
11. Continue to add sulfuric acid solution in 3-ml increments with
shaking until the pink color disappears.
12. Record the volume of sulfuric acid used in ml.
13. Back titrate with sodium hydroxide using the 1-ml pipette until the
pink color first reappears and remains.
14. Record the volume of sodium hydroxide used in ml.
15. Calculate alkalinity.
•Alkalinity = ml N/10 sulfuric acid - ml N/10 sodium hydroxide
16. Calculate excess lime pounds per barrel of mud.
•Excess lime, lb/bbl = 1.3 × alkalinity
Calculation of Lime content
Lime lb/bbl = 0.026 (Pm - Pm x Fw)
Lime Kg/M3 = 0.742 (Pm - Pm x Fw)
Where Fw =Volume fraction of water
76
Ø
Filtrate: HTHP
Equipment
Baroid 500-mL HTHP filter press
Filter paper
30-minute interval timer
Thermometer up to 500°F (260°C)
25- or 50-mL graduated cylinder
High-speed mixer
Gas supply (CO or nitrogen)
Procedure
1. Collect a fluid sample.
2. Preheat the heating jacket to 10°F (6°C) above the desired test
temperature.
3. Close the bottom valve stem on the filter cell and pour a stirred, fluid
sample into the cell.
4. Place the filter paper in the cell.
5. Place the cap on the cell, tighten all set screws, and close the valve
stem on the cap.
6. Place the cell in the heating jacket with the cell capon the bottom.
Rotate the cell until it locks.
7. Put a thermometer in the cell thermometer well.
8. Connect the pressure unit to the top valve stem and lock the unit in
place.
9. Connect the pressure receiver to the bottom valve stem and lock the
receiver in place.
10. Apply 600 psi (4,140 kPa) on the top and 100 psi(690 kPa) on the
bottom.
11. Open the top valve stem and maintain this pressure until the desired
test temperature is reached.
12. Open the bottom valve when the cell reaches the desired test
temperature.
13. Adjust the pressure immediately on the top and bottom regulators.
Use the following specifications as a guide:
77
Table-2: Temperature and Pressure on Top & Bottom Regulator
Temperature Top regulator Bottom regulator

0 0
Up to 300 F (149 C) 600 100
0 0
300-400 F (149-204 C) 700 200
0 0
400-500 F (204-260 C) 800 300
14. Filter for 30 minutes while maintaining the temperature at ± 5°F (±

3°C) of the test temperature and maintaining the pressure. Collect
filtrate by draining in to a graduated cylinder.
15. Close the top and bottom valve stems.
16. Release the pressure off the top regulator and disconnect the
pressure system.
17. Back off the T-screw on the bottom regulator.
18. Drain the filtrate cautiously from the receiver into a graduated
cylinder.
19. Wait a few seconds for the filtrate to drain to the bottom of the
receiver.
20. Tighten the T-screw slowly to flush any filtrate remaining in the
receiver into the graduated cylinder.
21. Release the pressure off the bottom regulator and disconnect the
pressure system.
22. Remove the cell from the heating jacket and allow the cell to cool.
23. Hold the filter cell with the cap down and loosenthe filter cell’s valve
stem to release pressure.
24. Close the valve stem when all the pressure has been released.
25. Hold the filter cell with the cap up and loosen the valve stem.
26. Loosen the set screws and remove the cap.
27. Remove and measure the filter cake to the nearest1/32 inch (1.0
mm).
28. Record the HTHP filtrate as two times the filtrate volume collected.
Ø
Electrical stability
Equipment
Fann model 23D electrical stability tester
12-mesh screen or Marsh funnel
Thermometer: 32 to 220°F (0 to 104°C)
Heating cup
78
Procedure
1. Collect a drilling fluid sample.
2. Pour the sample through the 12-mesh screen or Marsh funnel.
3. Use the heating cup to adjust the temperature of the fluid to 120°F
(49°C).
4. Immerse the probe in the sample with the tester turned off. Ensure
the fluid covers the electrode surfaces.
5. Stir the sample with the probe for 15 to 30 seconds.
6. Turn the electrical stability tester on and press the Test button to start
the test.
7. Record the voltage when the values in the display stabilize.
Ø
Retort Analysis
Equipment
Complete retort kit-50 ml capacity
Volumetric receiver
Fine steel wool
High temperature lubricant
Pipe cleaners
Putty knife or spatula with blade
Procedure
1. Collect a fluid sample and cool it to approximately 80°F (27°C).
2. Pack the upper retort chamber with very fine steel wool.
3. Lubricate the threads on the sample cup and condenser with a light
coating of lubricating/anti-seize compound.
4. Fill the retort sample cup with gas-free mud.
5. Place the lid on the retort cup; rotate the lid slowly.
6. Wipe off any excess mud and screw the retort sample cup into the
upper retort chamber.
7. Place the retort in the insulator block and put the insulator cover in
place.
8. Place the volumetric receiver under the drain of the condenser.
9. Heat the sample until the liquid stops coming out through the
condenser drain tube, or until the pilot light goes out on the
thermostatically controlled units.
79
10. Remove the volumetric receiver and examine the liquid recovered. It
should be free from solids/ emulsion bands.
11. Allow the volumetric receiver to cool to approximately 80°F (27°C).
12. Read and record the volumes of oil, or synthetic and water in the
volumetric receiver.
13. Calculate % by volume of the liquid and solid components of the fluid.
a) % by volume water = ml water × 10
b) % by volume oil/synthetic = ml oil/synthetic ×10
c) % by volume total solids = 100 - % by volume water - % by volume
oil/synthetic
14. Calculate the oil: water (OWR) ratio or synthetic: water (SWR) ratio if
the fluid is oil based or Synthetic mud.
Oil Fraction= 100 X Oil/ synthetic % v/v
Oil/synthetic % v/v + water% v/v
Water fraction = 100 - oil/synthetic fraction
OWR = oil fraction: water fraction
SWR =synthetic fraction: water fraction
l) Drilling of Clay formation

1. Drilling fluid should be pre-treated with soda ash (0.1-0.2%) to
remove calcium ions while drilling float collar/ casing shoe to control
cement contamination in drilling fluid.
2. Gel-Polymer Drilling Fluid : It is the most preferred drilling fluid to
drill clay sections. Although gel/polymer drilling fluid is normally
prepared fresh, but existing bentonite spud mud or native clay mud
can also be converted by diluting the systems and adding the
appropriate fluid loss polymers.
3. Slower drilling rate in clay results in gain in viscosity with shoot up in
YP.
4. Use symptomatic doses of available thinner, dilution and water loss
control agent (CMC) towards relaxed fluid loss control of <16 cc.
5. Use drilling detergent (0.2%) to prevent bit balling.
6. Shale shaker screen capable of handling circulating discharge should
be used (Preferably, 60-100 mesh).
7. Monitor active pit volume.Reserve tank should be kept full of mud for
seepage losses.
80
8. Run solid control equipment continuously.

9. Use maximum recommended discharge for proper hole cleaning &
better ROP.
10. LCM should be kept at drill site to cure loss problems whenever
encountered.
§System LCM: Calcium Carbonate (Fine, Medium, Coarse grade)
§Granular LCM: Saw Dust, Mica flakes, Rice husk, Walnut shell,
Coconut hull etc.
11. Maintain viscosity, pH, W/L, Sand content, Specific gravity as per GTO
m) Drilling of Shale Formation

•Shale is the most frequently encountered Lithological segments in
the drilling of a well.
•To drill shale section, changeover to inhibitive mud system (KCl-PHPA-
Polyamine/ Choline Chloride-XCP-Polyol-Sulphonated Asphalt).
•Inhibition is provided by additives like KCl, Choline Chloride,
Polyamines, PHPA and Polyol.
•Maintain mud weight as per requirement of the well / GTO.
•Never cut down mud weight from the initial mud weight with which
shale interval was opened.
•Incase caving is observed at shale shaker; gradually increase the mud
weight to control caving. Hole should be swept with 5% sulphonated
asphalt pills regularly to effectively seal the shale micro fractures.
•Start shale drilling with low API water loss (4-6 ml).
•Maintain pH for polymer mud system in the range of 8.5-9.0.
•Run mud cleaner (Screen size 150-200 mesh) continuously
throughout drilling.
•Maintain plastic viscosity as low as possible (ALAP).
•Treat the mud with Sodium Sulphite (0.01%) prior to trips for oxygen
scavenging especially in polymer mud.
•Maintain YP/PV ratio>1 for good hole cleaning.
•Add lubricant for providing lubricity.
•Ensure proper hole cleaning without turbulence against unstable
shale sections.
81
n) Drilling of Pay Zone/ Reservoir Section

•Change over to NDDF for drilling pay zone/ reservoir.
•Here the main objective is to avoid formation damage. Baryte and
Bentonite should not be used in NDDF.
•Micronized calcium carbonate is used as bridging agent and also for
providing specific gravity upto1.30.
•For higher specific gravity, formate salts may be used (Sodium
formate ~1.33, Potassiumformate~1.55)
•Use Pre-gelatinized starch (PGS) as water loss control agent, KCl as
clay inhibitor, XCP as viscosifier and Biocide for controlling bacterial
degradation
•Add only bio-degradable lubricants like linseed oil (0.5%).
•Maintain mud parameters with special attention on pH (8.5-9.0) and
water loss as per GTO.
•Run mud cleaner continuously to minimize entry of fine solids into
NDDF.
o) Drilling Coal Section

•Coal is highly brittle and caving prone.
•Polymer mud system (KCl-PHPA-XCP) is useful in drilling coal.
•High mud weights may not be of much use to stabilize coal formations
as they have inherent low fracture gradients.
•The recommended technique to drill coal is to controlled penetration
rate.
•Good hole cleaning is essential - it may be necessary to increase
cleaning capacity of the mud by having YP/PV ratio up to 2 while
drilling coals. The properties can be restored to normal after the coal
section has been drilled.
•Alternatively, viscous asphalt sweeps can be used to enhance hole
cleaning.
•If pipe gets stuck in coal and circulation is possible, spotting caustic
pill around the coal may help to free the pipe.
•While coring with water based mud, low water loss and lower jet
velocity should be used. Avoid turbulence against coal section. To
stabilize fractured coals, sulphonated asphalt (3-4%) and FLC-2000
may be used.
82
p) Standard methods of testing and control of water base drilling fluid

parameters
Ø
Mud Weight:
Mud balance is graduated in different units in the scale of Specific
Gravity (0.72 – 2.88) and pounds/gallon (ppg) (6-24)
Procedure
Fill mud in cup and place the lid. Close the hole on lid with finger & wash
the cup thoroughly. Place the balance on the fulcrum and adjust spirit
bubble on the leveler with sliding weight. Read the value.
Balance can be calibrated by unscrewing the screw at the end of the bar &
adding or removing lead shots.
Mud Weight Control
In case of rise in specific gravity
Every section of the hole is drilled with a certain desirable specific gravity
range based on the pore pressure and fracture pressure values of the
formation exposed in that section of the hole. Besides control of
pressured and highly dipping formations also sometimes require higher
values of specific gravity of drilling fluid. If however the specific gravity of
drilling fluid rises above the desired values, the main cause is
accumulation or build up low gravity solids which must be curtailed and
thrown out to keep the specific gravity of the drilling fluid in check.
Following step wise procedure is recommended for trouble shooting this
event.
•Check the type of formation being drilled, if it is sand, silt, or compact
shales then the specific gravity build up is due to inefficient
application of solids control equipment.
•Check the shale shaker for efficiency and screen size ensure proper
size screens are installed. Preferably 60 or 80 mesh at the bottom if
the prevalent flow rates permit the same.
•Make sure that integrity of screens is intact & they are not torn. If
torn replace them immediately.
•Do not bypass shale shakers to avoid mud wastage in case of high flow
rates; instead enhance their efficiency by their proper servicing and
maintenance.
•Always ensure thorough and regular cleaning of shaker screens for its
optimum efficiency.
83
•Check the desander’s cones for their efficiency. This can be done by
checking the desirable pressure (2.5 kg/cm2~35 psi)developed on the
head of hydro cyclones. If there is leakage get it rectified
immediately.
•Ensure that cones are in good condition and they are not mud cut.
•Ensure that the nozzle size of desander is proper. This can be checked
by inserting finger through the nozzle while desander is running. If a
distinct force is experienced by the finger tending to suck it in, the
nozzle size of the desander is correct. This force is developed due to
central portion created in an efficient vortex of a hydro cyclone.
•Watch the discharge of cones; it must be a spray discharge. If any
time rope discharge is observed get the cone checked and corrected
immediately. Rope discharge means inefficient operation of hydro
cyclone (desander & desilter).
•During round trip, clean and service the cones of desander & desilter
for their efficient operation in next cycle.
•Measure the specific gravity of under flow (i.e. discharge of cones.
This shall give an idea of efficient running of desander.
•Follow all the above guidelines for proper operation, maintenance
and servicing of the desilter also.
•Run both desander and desilter simultaneously to remove the
undesirable low gravity solids up to silt range. This shall certainly
reduce the specific gravity of drilling fluid and it may come within the
desirable range.
•Once the specific gravity has come within desirable range maintain it
at that level by prudent alternate operation of desander and desilter
and efficient use of shale shaker.
•Use Linear Motion shale shaker and Linear Motion Mud cleaner if
available, for most efficient solids control results.
•In case the formation being drilled is soft clay, the rise in specific
gravity is due to particles finer than silt range and a good number of
them may fall in colloidal size range. The only option for their control
and weight reduction is by centrifuge or dilution with base liquid i.e.
water or brine as the case may be hence dilute with water at an
optimal rate commensurate with rate of drilling (ROP) to nullify the
effect of clay solids getting mixed in the system.
•For every cubic meter of water being added. Add desired quantities
84
of caustic soda for maintaining pH, fluid loss control additive, and
other specialty additives composed in the prevalent mud so that
their percentage dosages are maintained.
•Once the specific gravity reaches desirable value minimize water or
base fluid addition along with other chemicals and additives, to a
level to maintain specific gravity at that desired level.
In case of fall in specific gravity
If it occurs, an immediate remedial action must be initiated before the
control on the formation is lost and the well becomes active. The
following steps are recommended to trouble shoot this problem.
•Check if there was an inadvertent mixing of water or low gravity fluid
in the active circulatory system of drilling fluid. It may be due to a
leaking tap or valve failure allowing transfer of water or low gravity
fluid like reserve bentonite gel in the active system. If such is the case
rectify the cause of dilution of drilling fluid immediately.
•Measure the present specific gravity of the drilling fluid and add
calculated amount of weighting material i.e. Baryte over one or two
cycles, homogenously till the fluid specific gravity reaches back again
to the desired value.
•In case the fall in specific gravity is due to undesirably low viscosity of
the drilling fluid (YP<6), which is unable to suspend Baryte in the
system, then build up viscosity immediately by adding highly viscous
bentonite suspension/ viscous gel/ XC polymer till it is able to
suspend Baryte again for desired specific gravity.
•Add more Baryte to compensate for the added low specific gravity,
high viscosity gel.
Ø
Funnel Viscosity
Funnel viscometer is used to measure funnel viscosity. It consists of a
Marsh funnel and a mug. Funnel is conical in shape, 12 inches long,
diameter at top of 6 inches &fitted with 10 mesh screen. Lower end has 2
inches long tube with an orifice of 3/16 inches.
Procedure
Fill mud in the funnel by closing the orifice at bottom. Allow the mud to
Drain from the funnel into the mug up to the marked point (1 quart or 946
cc)& measure the time taken in sec. Report funnel viscosity in sec.
85
Viscosity Control
KCl-PHPA Drilling Fluid
This is one of the most common problems encountered during operations
and needs proper diagnosis after careful analysis of the causes of the
problem.
The rheological behavior of PHPA mud is controlled largely by viscosifying
effect of high molecular weight polyacryl polymers. The key to the
maintenance of PHPA mud is to ensure that the clay solids and barite
minimally add to the mud viscosity. This is achieved by keeping the clay
content within a specified range (by keeping MBC below 5.0 ppb) and an
excess of polymer is available.
At low concentration of polymers, the polymer chains bridge clay particles
resulting in a yield point increase. At high concentrations, however,
enough polymer chains are adsorbed on clay surfaces to leave few free
surface sites for a single polymer chain to bridge two particles. The surface
saturation results in steric stabilization reduced bridging flocculation and
a reduced yield point.
Many failures of the PHPA mud systems have resulted from not keeping
enough PHPA in the mud during incorporation of drilled solids or addition
of barites. Without sufficient polymer, the influx of new free surface area
(drilled solids or barite) into a stable mud of desired viscosity causes
adsorbed polymers to redistribute so that bridging flocculation occurs.
The mud viscosity increases, sometimes drastically. Often, the mud is
then diluted or even dispersed. PHPA muds that become too viscous while
drilling usually have been thinned by the addition of PHPA (preferably in
premix form). Material balance is calculated daily and polymer additions
are adjusted to ensure that 1 ppb active PHPA is maintained preferably
in the mud system at all times to account for PHPA loss and degradation.
Actual PHPA content is to be analyzed regularly to support material
balance %.
Mud viscosity could become excessive after adding PHPA, when:
(1) Adding PHPA to the mud too quickly.
(2) Adding premixed PHPA without shearing the premix first.
(3) Adding PHPA to a system with a high mud weight or a high
concentration of filtration control materials where free water
has been depleted.
86
HTHP Drilling Fluid

In the case, the rise in viscosity is due to partial thermal degradation of
deflocculant in the dispersed system along with reaction of clay with
caustic soda at this temperature (>1500C or more).Replenish deflocculant
after every 2-3 cycles so that it never falls below minimum required levels.
Drilled solids (LGS) should be kept below 5.0% to keep the viscosity in
range.
Ø
Filtration Loss Control
If fluid loss value exceeds the desired limits
In relatively deeper sections of the hole, a prudent fluid loss control
regime is necessary to avoid uncontrolled flow of drilling fluid’s liquid
phase to formation pores and channels. This requirement becomes even
more important when permeable sand stone sections are drilled. If fluid
loss values of the drilling fluid goes above the desired limits and
permeable formations are exposed, the risk of a differential stuck up gets
greatly enhanced due to formation of a thick fluffy filter cake against the
formation face of the well bore. It is therefore, essential to keep the fluid
loss value within desirable limits and for that following steps are
recommended:
- If the fluid loss values exceed desirable limit, check the type of cake
deposited on the filter paper. Also check if there was a spurt loss
when the fluid loss was measured using API filter press. Normally
both spurt loss and a fluffy cake shall be observed.
- Check the mud rheological parameter, if the viscosity, yield point and
gels are within the desired limit, add fluid loss control additive over a
cycle so as to get its homogenized mixing with the drilling fluid.
- Let the mud be conditioned for one more cycle after addition of fluid
loss additive.
- After that measure API fluid loss again and record the drop in fluid
loss value, spurt loss if any and quality of mud cake.
- If the new fluid loss value falls within desirable range and there is no
spurt loss and cake has become thin & tough in appearance, the
desired percentage of Fluid loss additive is achieved in the system.
- Maintain this desired dosage by regular intermittent treatment of the
fluid loss additive depending upon the rate of drilling and rate of
dilution of drilling fluid with water/ pre-mix / bentonitic gel.
- If the new fluid loss value does not fall within desirable range,
87
continue addition of fluid loss additive as per above procedure till the
desired value of API fluid loss is achieved.
- If the rise in fluid loss value of the drilling fluid is associated with
concurrent rise in viscosity, yield point and gels, the drilling fluid is
flocculated. Add sufficient quantity of deflocculant/pre-mix till
viscosity / Rheological parameter fall within desirable limits
Ø Filtrate / Mud analysis
Filtrate Alkalinity (Pf& Mf) & Mud Alkalinity (Pm)
The analysis gives concentrations of hydroxyl/carbonate/ bicarbonate
ions Reagents required
i) N/50 H2SO4
ii) Phenolphthalein indicator
iii) Methyl orange indicator
Ø Procedure
Filtrate Alkalinity (Pf & Mf)
•Take 1 ml of filtrate
•Add 2-3 drops of Phenolphthalein indicator
•Titrate with N/50 H2SO4.
•End point. Colour changes from pink to colorless
•Pf = ml of N/50 H2SO4
•To the above solution, add 2-3 drops of Methyl orange indicator and
titrate with N/50 H2SO4
•End point. Colour changes from yellow to pink.
•Mf = total nos. of cc of N/50 H2SO4
Mud Alkalinity (Pm)
•Take 1 ml of mud with syringe
•Add 25 ml distilled water and 2-3 drops of Phenolphthalein indicator
•Titrate with N/50 H2SO4.
•End point. Colour changes from pink to colourless.
•Pm = ml of N/50 H2SO4
Ø Salinity:
Reagents required
(i) 0.05N AgNO3
(ii) K2CrO4 solution
88
Procedure:
Take 1 ml of filtrate, add 2-3 drops of K2 CrO4 solution and titrate with
0.05N AgNO3
End point. Colour changes from yellow to brick red due to precipitation of
Ag2CrO4
Calculation:
Salinity as NaCl (gm. /lit)
= 0.05 x ml of AgNO3 x 58.5 / ml of filtrate
Ø
KCl Determination (NaClO4 method)
Reagents required
NaClO4 solution (150g/100ml Distilled Water)
Standard solution of NaClO4
Procedure
Take 7 ml of filtrate, add 3 ml of NaClO4 solution and slowly invert the
centrifuge tube to mix the contents very gradually. Centrifuge for 1 min
at1800rpm. Read volume of precipitate. Determine % KCl from standard
graph given below for illustration. (Prepare standard graph with different
concentration of standard solution of KCl for actual measurement).
Ø
PHPA Determination
Reagents required
(i) SnCl4 solution (20 g/100ml Distilled Water (DW))
(ii) Standard PHPA solutions
89
Procedure
Take 7 ml of filtrate, add 3 ml of SnCl4 solution and centrifuge for 1
min at 1800rpm. Read volume of precipitate & determine PHPA
percentage from standard graph given below for illustration.
(Prepare standard graph with different concentration of standard
solution of PHPA for actual measurement).
0.35
0.3
0.25
0.2
0.15
0.1
0.05
0
0 0.05 0.1 0.15 0.2 0.25 0.3 0.35
%PHPA
Ø
Total Hardness, Calcium & Magnesium determination
Reagents required
1. 0.01M EDTA solution
2. Erichrome black-T indicator
3. Solochrome dark blue or Calcon indicator
4. Ammonia buffer pH-10.0
5. 4N KOH buffer pH >12
Procedure
•Take 1 ml of filtrate and add 10 ml of hypochlorite solution.
•Boil for 10 min to oxidize organic matter.
•Cool.
•Add 50 ml DW, 2 ml of buffer pH-10 and Erichrome black-T indicator.
•Titrate with 0.01M EDTA solution.
•End point. Colour change wine red to blue.
•Record ml of 0.01M EDTA solution = V1
•Take 1 ml of filtrate and add 10 ml of hypochlorite solution.
•Boil for 10 min to oxidize organic matter.
90
•Allow to cool.
•Add 50 ml DW, 2 ml of buffer pH > 12 and Calcon indicator.
•Titrate with 0.01M EDTA solution.
•End point. Colour changes from red to sky blue.
•Record ml of 0.01M EDTA solution = V2.
Calculations
Total Hardness (ppm)(As CaCO3) = 0.01 x 100 x V1 x 1000
Ca++ (ppm) = 0.01 x 40 x V2x 1000
Mg++ (ppm) = 0.01 x 24x (V1 -V2)x 1000
Ø
Sand Content
Sand content kit has a glass tube, a funnel &a cylindrical part fitted with 74
micron screen.
Procedure
•Fill the mud in the tube to the mark ‘Mud to here’.
•Add water up to the mark ‘Water to here’.
•Shake & pour the contents of the tube over screen.
•Wash the solids by pouring water over the screen.
•Place the funnel over cylindrical part and invert it into the clean glass
tube.
•Pour water to transfer the contents into the tube.
Read the volume of sand (% V/V).
Ø
Methylene Blue Capacity (MBC)/ Cation Exchange Capacity (CEC)
Reagents Required
1. Methylene blue solution (3.74 g /litre)
2. H2O2 solution (3%)
3. 5N H2SO4
Procedure
•Take 1 ml of mud through syringe and add 10 ml DW, 15 ml of H2O2
solution (3%) and 0.5 ml of 5N H2SO4.
•Boil gently for 10 min.
•Allow to cool.
•Dilute to 50 ml by DW and titrate with Methylene blue solution in 0.5
ml increments & taking a drop of the suspension on filter paper.
91
•At the end point, excess of Methylene blue elutes forming a halo.
Calculation
MBC (cc) =ml of titrant solution / ml of mud
Bentonite / clay (lbs/bbl) = 5 x MBC (cc)
Bentonite / clay (Kg/M3) = 2.853 x 5 x MBC
Bentonite (% w/v) = 1.4265 x MBC
Ø
pH Measurement
pH value is a very important parameter for performance of the drilling
fluid.
pH Strip Method
Take an inch of the strip & place it on the surface of the mud for ~45 sec.
Match the colour& report pH to the nearest 0.5 unit.
pH Meter Method
This is more accurate method. Calibrate pH Meter with standard buffers.
Place the sample under pH Meter & measure stabilized value of pH.
Report the value to the nearest 0.1 unit
Ø
Oil Water Retort Kit Analysis (Solid analysis)
The equipment used is called Oil Water Retort Kit. It has a sample cup of
10 ml capacity, a condenser and a heating system placed in insulator of
steel container. The contents are heated. Liquids evaporate, condense &
are collected in graduated 10 ml cylinder. The solids are left behind in
sample cup.
Procedure
•Take out retort assembly out of the insulator and remove mud
chamber or cup.
•Fill mud chamber with mud.
•Fit the assembly after applying silicone grease over the joint.
•Heat the assembly in the retort.
•Collect volume of liquid in the cylinder.
Calculations
Find out the value of S from the relation:
A x 100 = (B x 1.0) + (C x S) + (D x 0.8)
Where
A = SG of mud
B = % of water by volume
92
C = % of solids by volume
D = % of oil by volume
S = SG of solids
C (4.2 – S)
% by volume of LGS = —————————
(4.2 – 2.6)
% by volume of Baryte = C - % by volume of LGS
q) Hole Cleaning
§ Monitoring of Shale shaker
1. The best way to monitor hole cleaning is by observing the volume and
shape of cuttings coming out at shale shaker.
2. Shale shaker may show excessive cuttings (more than normal) which
may indicate that the well is caving.
3. Reduced volume of cuttings on shale shaker indicates poor hole
cleaning which means cuttings are floating in the annulus and not
getting lifted to the surface. It may lead to hole pack off.
4. If any of the above abnormalities are observed, corrective action
needs to be taken for proper hole cleaning.
5. A thumb rule for effective hole cleaning is to keep PV as low as
possible (ALAP)
6. Maintaining YP/PV ratio > 1 is an effective way for good hole cleaning.
Shear thinning properties must be imparted to the mud system with
addition of Xanthan gum. It increases YP/PV ratio.
7. Use high viscosity sweep for vertical wells. Funnel viscosity of the
viscous sweep should be >150 sec. Observe the surfacing of the pill
for additional cuttings and viscosity.
8. Use combination of low viscosity sweep followed by high viscosity and
high density sweeps for directional wells.
9. Use low Vis (<40 sec) and high density sweep in high angle well (>350).
Minimum volume of the sweep should be calculated for 150 m of
annulus height. Weighted sweep should be 0.20 to 0.25SG higher
than the existing mud weight. When the sweep is coming out of bit,
circulation rate and rotation should be at their maximum. The next
sweep should be pumped only after the first sweep has been
circulated out of the well.
10. Approximately 5% Sulphonated Asphalt is to be used for preparing
Asphalt sweep in case of severe caving in shale/ coal.
93
§Other Factors
•Annular velocity is the other important factor in hole cleaning
efficiency in vertical as well as directional wells. This is to be
maintained according to requirement which varies from 100-200
feet/ minute.
•Pipe rotation (60-120 rpm) improves hole cleaning efficiency.
•Circulate out cuttings prior to tripping and away from the BHA prior to
connection.
r) Recommended Drilling Fluid Practices

•All the solid control equipment should be in good working condition
to maintain sand and solid content of the drilling fluid in desired
range.
•Ensure maximum GPM and RPM possible for high angle wells to
avoid cutting bed formation.
Table-3: Recommended Discharge for High angle wells
Hole size Min pump discharge Best pump discharge, if
possible
gpm lpm gpm lpm
17-1/2”-16” 1,100 4200 1,200-1,400 4,500-5,300
12-1/4” 800-1,000 3,000-3,800 1,000-1,100 3,800-4,200
8-1/2” 450 1,700 500-550 1,900-2,100
6” 250 950 300 1150
•Rule of Thumb
§Up to 300 well inclinations, 20 % more annular velocity is
required as compared to a vertical well.
§When well inclination is 50-600, annular velocity should be twice
as compared to a vertical well.
Table-4: Minimum no of circulations to clean well in High angle wells
Section Length Factor (= No of circulations)
Well Hole size 17-1/2” 12-1/4” 8-1/2” 6”
Inclination
(Degrees)
0 - 10 1.5 1.3 1.3 1.3
10 - 30 1.7 1.4 1.4 1.4
30 - 60 2.5 1.8 1.6 1.5
60 - 90 3.0 2.0 1.7 1.6
94
Requirement of Low Shear Rate Viscosity (LSRV) to Avoid Baryte sag and
Cutting Bed Formation
1. Maintain Fann 3 rpm reading at least 12-15 and 6 rpm reading 1.1
times hole diameter to avoid cutting bed formation, achieve better
hole cleaning and less torque and drag in high angle wells.
2. For more accurate LSRV, the following formula may be used LSRV=2Q3
– Q6whereQ3and Q6are 3 and 6 rpmreadings respectively.
3. LSRV should be maintained

- Equal to 0.4-0.8 times of well diameter in inches in normal
condition
- Equal to well diameter in inches in critical situation.
4. If Brook Field viscometer is available, then measure LSRV at 0.3 rpm
using L-3 spindle and maintain LSRV at 20,000 to 50,000cp(reading on
Brook Field Viscometer) depending on well angle. Higher the
holeangle, more is the required LSRV value.
5. In deviated wells when angle is less than 450:
Sweeps with YP of 1.5-2.0 times that of running mud should be
pumped in laminar flow, preferably mixed with a fibrous
materials/polymers covering 60-90 m of annular height to clear
cutting beds.
6. When well inclination is more than 450:
Then apart from conventional high vis-low vis pills; pumping of high
weight (3-4 ppg higher than mud weight in use), low vis (vis<40 sec)
pill covering at least 150 m annular height is recommended. Fibrous
material is helpful in this pill also.The next sweep should be pumped
only after the first sweep has been circulated out of the well.
7. This high weight- low vis pill must be circulated out before any trip
for P/O with maximum rotation possible (at least 80 + rpm). Once
sweep is pumped; do not stop pumps till sweep is out of the hole.
Because of high density, fracture gradient must be taken into
consideration for volume selection of this pill.
8. In high angle well with a horizontal drift of 1,500 m or more; very high
torque and drag is expected. The above recommended sweeps of
low vis high weight pill should be used regularly.
95
s) Borehole Instability (Caving– detection and control)

The following steps are recommended for proper detection and control of
caving while drilling:
1. Designing of drilling fluid specific gravity is generally done on the
basis of pore pressure data provided and mud system is chosen on
the behavior of shale cuttings (dispersion characteristics of shale
when exposed to drilling fluids).
2. When drilling directional and horizontal wells in tectonic areas,
dipping weak bedded formations and depleted reservoirs; geo-
mechanical studies of the shale/ caving formations is essential for
establishing the minimum mud weight required to control caving as
per collapse pressure data calculated.
3. If geo-mechanical studies are not possible, then decision regarding
increasing mud weight may be taken during actual course of drilling
depending on presence of caving at shale shaker, tight pull and held
up during round trip and increase of torque etc.
4. Monitor cuttings at shaker; both in quantity and size while drilling
through caving prone shale sections especially during bottoms up.
5. Big chunks of formation cutting in large quantities at the shale shaker
are indicative of caving.
6. Stop drilling ahead; circulate with a pill as discussed in hole cleaning
section to clean the annulus.
7. Simultaneously, condition drilling fluid with sufficient quantities of
shale stabilizer, sulphonated asphalt and polyol. Running mud may
be loaded with 3-5% Sulphonated asphalt and intermittently used as
sweep as well as placed at bottom before pull out of hole.
8. Also ensure that sufficient quantities of all other chemicals are
present in the drilling fluid to ensure the best possible values of
rheology and filtration loss.
9. Follow good drilling practices
§Avoid pressure surges/ swabs during tripping
§Do not use rotary for opening joints in open hole.
10. If the caving are due to pressured shale, tectonically stressed and / or
highly dipping formations, raise the specific gravity of the drilling
fluid to counter balance these pressure.
11. 1.5-2.0 % NIF (non- invasive drilling fluid additive) can be mixed in the
drilling fluid during drilling to strengthen the well bore.
96
12. In any case mud weight must not be decreased from running mud
weight in caving prone formations.
t) Stuck-Up
§Non-Weighted Spotting Fluid:
1. Immediate spotting without loss of time can ensure release of stuck
pipe.
2. Placing of spotting pill by observing differential pressure as soon as
pill goes out of bit is the best method to ensure that pill is in place.
3. Before and after the stuck breaker pill (SBP), a balanced high viscous
high weight (1ppg higher than current mud weight) spacer pill should
be pumped to prevent mixing of SBP with mud.
4. 2-4% Spotting fluid is mixed in HSD to prepare non weighted spotting
fluid pill.
5. Size of the pill should be such that it covers the drill string annulus at
least up to the free point or alternately the whole BHA length
including HWDP. Add 25% extra volume for hole washout especially if
hole has been showing caving problems. However it must be made
sure that hydrostatic head under balance due to SBP pill does not
allow formation fluid to enter the well bore.
6. In some cases it has been observed that during soaking period of 6-8
hours, the pill starts to surface at the shale shaker. This makes the pill
ineffective. In such cases, pumping a balanced hi-vis pill before and
after spotting fluid is useful.
7. It is recommended to leave at least 50-100 m more of SBP column
inside the drill string compared to the column height in the annulus
and close Lower Kelly cock. Every half an hour, 5 strokes should be
pumped through drill string into the annulus.
8. String should be kept under compression if bit is off bottom by a few
meters and mud circulation is free or partial and stuck up has taken
place while picking up the string or string was static.
9. In case stuck up took place while running in hole and mud circulation
is free or partial, drill string should be kept under tension during
soaking.
10. In case mud circulation exists, it is recommended to at least try with
three or four stuck breaker pills before going for other fishing
operations.
97
Preparation of Weighted Spotting Pill

•Clean out tank and fill with HSD. The volume shall be equal to 100 %
excess over the annular volume around the drill collars. Mix the pill in
accordance with the following procedure.
Table-5: Formulation for preparing weighted spotting fluid (1M3)
SG required 1.2 1.44 1.68 1.92 2.16

Spotting Fluid
80 80 80 80 80
(Weighted), litres
Water, litres 540 490 450 430 410
HSD, litres 295 270 245 135 110
Baryte, Kg 350 660 960 1280 1600
•Add Baryte until the desired weight is achieved.

•Normally, 8–10 % of weighted spotting fluid has been found
satisfactory.
•Weight of the pill should be the same or preferably 0.06–0.12 SG
above the weight of the mud system to minimize migration of the pill
through the static mud column.
•Care shall be taken to isolate oil-based spotting fluid and any
contaminated mud, when it is returned to the surface.
§Mud Acid Job To Release Stuck Up
1. The mud acid job is suitable up to 1200C circulating temperature.
2. Rig up acid pumper, Water tanker, Acid tanker, Oil tanker and Fire
tender at site.
3. Make necessary connections.
4. Pump 5.0 M3 crude/ HSD + 2% spotting fluid (NW) as spacer.
5. Prepare and pump 3.0M3 (HCl-HF: 9:6) acid solution containing
§15% HCl (by diluting 1,500 liters of 28% HCl)
§60 liters of ACI grade II (2% v/v)
§90 liters Acetic acid (3% v/v)
§30 liters Surfactant (1% v/v)
§250 kg Ammonium Bi-fluoride (9.26% w/v)
6. Pump 5.0M3 crude oil / HSD as spacer.
98
7. Place acid solution at the bottom with mud.

8. Pump acid solution into annulus in 500 liters batch. Wait for 10-15
minutes after pumping each batch.
9. Work on string during acid placement and soaking.
10. Pump out acid solution after soaking it for 90 minutes. Take
necessary safety precautions while handling out coming spent acid
and do not mix spent acid with active mud.
11. This recipe is for 3M3 mud acid pill, for bigger or smaller jobs
quantities of the chemicals are to be adjusted accordingly.
u) Lost Circulation
The best industry accepted solution for loss circulation is prevention of
loss circulation. Hence, each particular case needs to be studied into the
possible reasons and the well design may be optimized and preventive
measures such as planning for suitable system LCM, controlled drilling,
minimizing ECD etc are to be in place during planning stage itself.
1. Monitor mud returns at shale shaker.
2. Monitor active pit volumes closely and record all mud additions and
transfers.
3. Ensure there is no leakage in surface equipment and no surface
losses.
4. In case of mud loss, analyze & identify the probable causes and depth
of loss zone. In competent formations, it is usually just below the
casing seat of the previous casing.
5. Record rate of loss in dynamic as well as static condition.
6. Ensure that hole is always kept full of drilling fluid to avoid well bore
instability and influx of fluids from the pressurized formations.
7. Prepare a pill with a blend of fibrous and granular bridging materials
like Mica flakes, Rice husk, Sawdust, Bagasse (fibrous sugar cane by-
product), granular walnut shell, Calcium Carbonate (Fine, Medium,
Coarse) etc. in a separate tank.
99
Table-6: LCM Pill Composition

Dynamic LCM Pill LCM pill LCM pill composition Remarks
loss rate/ pill volum, compositi for other than pay
3
hr conc. M on in pay zone
zone
50 bbl 30 ppb 50 bbl Ca CO3 Mica/walnut shell/saw
3 3
(8 M ) (8 M ) only dust/ cotton seed/rice
(F, M & husk in 1part coarse
Coarse) (Walnut shell) & 2
parts fine
100 40 ppb 50 bbl Ca CO3 -do- Max conc. to be

3 3
bbl(16 M ) (8 M ) only (F, M pumped through
& Coarse) bit with nozzle
300 bbl 60 ppb 80 bbl Ca CO3 -do- 100-200 ppb

3
(48 M ) (~13 only (F, M LCM pill can be
3
M) & Coarse) used with Ca
CO3alone
Total loss >60 80 bbl Ca CO3 -do- Higher conc. pills
ppb (~13 only (F, M to be pumped
3
M) & Coarse) through PBL tool
or OEDP
Note:
i. The most important point for the success of LCM pill is the
displacement procedure takes into account the loss rate such
that LCM pill is not bullheaded while placement.
ii. During waiting on LCM pill, the hole filling may be done only
intermittently based on discrete observation of level of well
through different time intervals in view of well safety.
Alternately, level of fluid in well can be measured through Echo
meter.
8. Pump and place the pill slowly against the loss zone and pull out to
casing shoe.
9. Allow time (~4 hours) for healing of fracture by bridging materials in
the pill.
10. Circulate above LCM pill at slow SPM to consolidate the LCM Bridge
until the pill volume is exhausted. Repeat the above steps.
11. Restart circulation at reduced pump rates and circulate for one or two
cycles.
12. If loss is controlled, run back to bottom and resume controlled drilling
preferably at less than 10 m/hr.
13. Ensure that all further tripping and casing operations are carried out
100
very slowly and smoothly to avoid pressure surges which may

otherwise aggravate the problem.
14. In case above bridging material fails to seal the loss zone; other
advanced LCM material such as polymer cross-linked pills, high fluid
loss squeeze slurry such as Diaseal-Metc may be used. In other than
pay zones, Diesel Oil Bentonite (DOB plugs) or diesel oil bentonite
cement (DOBC plugs) may also be used.
15. If the above plugs also fail, pump appropriate quantity of specially
designed cement slurry to seal the loss zone.
Ø
High filtration squeeze
· A high filtration squeeze is also used to combat severe losses in
fractured formations. The squeeze requires highly packed
dehydrated solids to seal the loss zone.
· The maximum pumpable density of high filtration slurry using calcium
carbonate is 14.0 ppg (1.68 SG).
High-filtration squeeze procedure
•Spot the slurry against the loss zone
•Close BOP
•Squeeze the pill by hesitation method.
Ø
Gunk squeeze
Gunk Formulations
The following mixtures will produce about 1.4 bbls of pumpable volume
for each 1 bbl of base oil (diesel) mixed. Recommendation would be to
only use the 1:2 cement ratios as this mixture sets firm to hard, will
support significant differential pressure, and will allow further operations
to continue for a significant period of time.
Bentonite to Oil
Add 400 lbs Bentonite to 1 bbl. base oil (or diesel)
Bentonite& Cement to Oil 1:1 ratio
Add 215 lbs Bentonite and 215 lbs cement to 1 bbl. base oil (or diesel)
Bentonite& Cement to Oil 1:2 ratio
Add 145 lbs Bentonite and 290 lbs cement to 1 bbl. base oil (or diesel)
1. Set mixture in the mud lab using a water bath. set the Bottom Hole
Static Temperature to determine the expected setting time for the
cement.
2. Position bit at casing shoe or 100 ft. above loss zone if the location is
definitely known.
101
3. Rig up to place one cement pump on the annulus and one cement
pump on the drill pipe.
4. Do not open the PBL sub if there is one in the BHA.
5. Prepare 50 bbl. in a batch mixer or 100 bbl. in the slug pit.
6. Pump 50 bbl. drill water (the intension and expectation is for most of
this to get circulated above the drill pipe)
7. Pump 10 bbl. base oil (can use 5 to 7 bbl. in 5" or smaller DP)
8. Pump the Bentonite and cement slurry (use the same pump & flow
path as the base oil. The objective of the base oil is to flush all water
from the suction manifold and pump ahead of the gunk mixture to
prevent premature setting)
9. Pump 10 bbl. base oil (can use 5 to 7 bbl. in 5" or smaller DP)
10. Displace base oil to above the bit, close BOP.
11. With cement pumps, displace the gunk mixture out of the drill pipe at
4 bbl./min. simultaneously, begin pumping water based mud or
seawater down the annulus at 2 bbl./min.
12. When a pressure increase of 200 psi is noted, begin a “hesitation
squeeze” procedure by pumping 2 bbls down drill pipe and 1 bbl
down annulus. Shut the pumps down and wait for 10 minutes, Repeat
cycle until all of the bentonite-cement is displaced out of the drill
pipe. Ideally the pressure would increase to as much as 500 psi.
13. Open BOP POOH 10 stands. Circulate 2x bottoms up while rotating
the BHA.
14. Wait for the cement to set in the water bath, RIH and drill out the plug.
15. Increase flow rate to maximum flow rate required to drill and monitor
for losses. This would be considered a dynamic leak off test. A static
leak off test can also be done to provide more confidence.
16. If required repeat the job.
Advantages
1. Will not set in the drill pipe, unless the base oil spacer is too short.
2. Have plenty of time to perform a hesitation squeeze to more
effectively seal the loss zone
3. Uses inexpensive materials available on the rig without special
ordering.
4. Uses existing rig equipment
5. Can be pumped through drilling and MWD/LWD tools as it has no
large particle size solids.
102
Disadvantages
1. Cannot be used in a potential reservoir zone as it causes extreme
formation damage which is permanent due to the Bentonite
2. High molecular weight polymers can be used as a substitute for the
Bentonite in reservoir intervals. This is less effective than Bentonite,
but it will break down with time and is therefore less damaging to a
reservoir.
Pump pill as follows:
§Pump base fluid as preflush to cover appprox.150 m of drill string.
§Pump gunk squeeze to cover approx. 2 times open hole volume.
§Pump base fluid as after flush to cover approx. 150 m of drill string.
§Displace the pill to the bit.
§Close BOP.
§Pump simultaneously from drill pipe and annulus in equal volume
until squeeze pill & spacer are displaced from the drill pipe.
§Maintain equal pressure on drill pipe and casing.
§Most important precaution: Before placement of gunk, the lab
composition is to be pilot tested on the rig to decide final composition
and pumping rate from drill pipe and annulus.
Ø
Baryte Plug
It is used to control internal blow out and control loss/ activity
situations. pH should be maintained after addition of Sodium Acid
Pyro Phosphate (SAPP)/CLS but before addition of Baryte.
Recommended height of plug is 100M.
Table-7: Baryte Plug
3
Required Slurry composition per M of water
Specific
Gravity
CLS SAPP pH Baryte Slurryyield
3
(Kg) (Kg) (MT) (M )
1.8 2.0-2.5 1.2-2.0 9 1.4 1.33

2.0 2.5-3.0 1.5-2.5 9 1.9 1.45
2.2 3.0-3.5 2.0-3.0 9 2.52 1.60
2.4 3.5-4.0 3.0-4.0 9 3.27 1.78
2.6 >5.0 >5.0 9 4.2 2.00
103
v) Troubleshooting Oil Base Mud Issues

Problem: Insufficient Viscosity
Cause Treatment
Under treatment of viscosifier ? Add organophilic clay
Lack of proper particle size ? Add Gelling agent (Rheology
distribution modifier)
Low water content ? Add water (brine)
New mud, lack of shear ? Shear through bit or shear unit
Gas stripping ? Increase mud weight
? Add wetting agent
? Add primary emulsifier & lime
Problem: Excessive Viscosity

Cause Treatment
High water content ? Dilute with base oil
(saltwater flow) ? Add primary emulsifier and lime
? Add wetting agent
Incorporated drill solids ? Centrifuge/solids control
1. High solids (% volume) ? Use dilution
? Add wetting agent
2. Fines solids problem ? Centrifuge/solids control
? Use dilution
? Add wetting agent
3. Water-wet solids ? Add wetting agent and primary
emulsifier
High-temperature instability ? Add wetting agent and primary
emulsifier
? Decrease water content
? Reduce solids content
Acid gases ? Add lime
? Add primary emulsifier and
wetting agent
? Increase mud weight
Overtreatment ? Dilute with base oil
104
Problem: Increase In HTHP Filtration

Cause Treatment
Weak emulsion ? Add primary emulsifier
? Add lime
Lack of proper particle size ? Add Gilsonite, a naturally occurring
distribution Asphalt
? Add Amine treated Lignite
? Add Oil base thinner
? Add weight material or bridging
agent
High-temperature instability ? Add primary emulsifier and wetting
agent
? Add lime
? Add Gilsonite or Amine treated
Lignite
Problem: Water in HTHP Filtrate (If Undesirable)

Cause Treatment
Weak emulsion ? Add primary emulsifier
? Add lime
High-temperature instability ? Add primary emulsifier and wetting
agent
? Add lime
? Add Gilsonite or Amine treated
Lignite
Problem: Water-Wet Solids

Cause Treatment
Super-saturation § Add emulsifier and wetting agent
§ Add water sparingly
Excessive solids § Use solids control and dilution
§ Add wetting agent
Undertreatment § Add primary emulsifier and
wetting agent
Problem: Shale Shaker Screen Blinding
Cause Treatment
Water wet solids ? Add wetting agent
? Add primary emulsifier
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Problem: Water Flow

Indicator Treatment
Decrease in O/W ratio (water ? Increase mud weight
intrusion)
Decrease in mud weight ?
Increase mud weight
?
Add primary emulsifier & wetting
agent
?
Add lime
?
Add base oil to adjust O/W ratio
?
Add salt to adjust brine salinity
Problem: CO 2 Contamination
Indicator Treatment
(POM) decrease ? Increase mud weight
? Add lime
Rheology increase ?
Add primary emulsifier and wetting
agent
?
Add oil for dilution
?
Increase mud weight
?
Add lime
Problem: Hydrogen Sulfide Contamination

Indicator Treatment
POM decrease ? Increase mud weight
? Add lime
? Add primary emulsifier and wetting
agent
? Add zinc-basedH2Sscavenger
Foul odor ? Increase mud weight
? Add lime
agent
? Add zinc-basedH2S scavenger
Mud turns black ? Increase mud weight
? Add lime
agent
? Add zinc hydrogen sulfide scavenger
Drill pipe turns black ? Increase mud weight
? Add lime
agent
? Add zinc-basedH2Sscavenger
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Problem: Lost Circulation

Cause Treatment
Overbalanced hydrostatic ? Reduce mud weight (if possible)
pressure ? Use LCM pills
? Set casing
Excessive annular pressure ? Decrease rheology and gel strengths
loss ? Decrease circulation rates
Mud turns black ? Increase mud weight
? Add lime
agent
? Add zinc H2Sscavenger
?
Problem: Lost Circulation
Cause Treatment
Surge pressures ? Decrease rheology and gel strengths
? Break gel at regular intervals while
tripping in hole
? Reduce tripping speed
? Use LCM pills spotted in hole
w) General Guidelines for Operation of Solid Control Equipment
Ø
Decanting Centrifuges:
•Do not operate the centrifuge without rotating assembly shroud and
belt guards fastened in place.
•Rotate the bowl by hand first to ensure “free” (no drag) movement.
•Do not operate if unusual noise or vibration develops
•Lubricate bearings as per supplier’s recommendation (typically every
8 hours of operation).
•Allow the unit to attain desired rotational speed prior to starting the
feed pump.
•Do not overfeed (“crowd”) the centrifuge.
•Heavily weighted and viscous fluids require lower feed rates and
higher dilution rates.
•Ensure proper agitation is available at the centrifuge pump suction
and in the Baryte return tank.
•Remember to turn off the dilution liquid after the centrifuge has been
shut down.
If a problem develops that is not understood, call a centrifuge technician
107
before attempting to repair. Symptoms of malfunctioning of centrifuge

are:
i. Safety torque coupling frequently disengages.
ii. Unit packs off rapidly.
iii. “Excessive” amount of weight material in the overflow.
iv. “Wet” solids discard from unit.
Ø
Maintenance and Trouble Shooting of Desanders and Desilters
(Improper operation and probable causes)
•No wet solids discharge at the apex (bottom)
§Bottom opening (apex) plugged:Turn unit off. Loosen bottom
adjustment. Push a rod up through the bottom opening to break
up dried or caked mud. If this is not successful, remove top of
hydrocyclone and take out object plugging apex. Make sure the
shale shaker is not bypassed. Re-adjust bottom and replace top
of hydrocyclone.
§Feed pressure (head) too high:Adjust to proper head pressure,
or 75±5 ft, using accurate pressure gauge.
§Mud is free of all particles that hydrocyclones can remove:If
drilling is very slow or if the unit is running during a trip, removal
can approach zero at the underflow and unit should be shut
down and run only periodically.
§Worn inlet nozzle, vortex finder or hydrocyclone ID: Remove
hydrocyclone and inspect for excessive wear. Replace
hydrocyclone if required.
§Hydrocyclone improperly installed: Remove and inspect
hydrocyclone and re-install according to manufacturers’
instructions.
•Flooding liquid out of apex bottom or Roping
§Feed pressure (head) too low
- Check pump suction for restrictions, inadequate liquid level
for pump suction or air entering suction.
- Check pump impeller blades for wear and proper size.
- Check pump discharge for correct manifold routing to only
one hydrocyclone solids-control unit.
- Check condition of pump packing and alignment-clearance
of pump impeller.
108
- Be sure the pump suction compartment is bottom-equalized

to overflow discharge compartment downstream.
§Hydrocyclone inlet plugged resulting in inadequate feed
pressure
- Remove hydrocyclone and inspect.
- Remove any objects plugging inlet.
- If feed plugging occurs frequently,carefully inspect if shale-
shaker is bypassed or shaker screens are torn.
- Install a suction screen on the centrifugal pump.
§Vortex finder plugged, resulting in back-pressure on
hydrocyclone.
- Remove hydrocyclone and inspect
- Remove any objects plugging inlet.
- If feed plugging occurs frequently,carefully inspect if shale-
shaker is bypassed or shaker screens are torn.
- Install a suction screen on the centrifugal pump.
§Worn inlet nozzle, vortex finder or hydrocyclone ID.
- Remove hydrocyclone and inspect for excessive wear
- Replace hydrocyclone if there is any doubt regarding
hydrocyclone condition.
§Hydrocyclone improperly installed.
- Remove and inspect hydrocyclone and re-install according
to manufacturers ’instructions.
•Hydrocyclones plugging
§Feed header (feeding hydrocyclone inlets) plugged.
- Stop feed pump.
- Remove blind Victaulic cap from the inlet header end and
remove obstruction.
- Replace the blind cap and restart pumpafter checking
suction screen.
- Do not bypass shale shaker.
§Hydrocyclone overloaded (roping).
- More solids-control capacity needed.
- Solids removal system cannot handle excessive drilling rates
and/or solids loading.
109
•Inlet head fluctuating

§Restricted pump suction.
- Check for plugging, gas-cut mud or foam at the pump
suction.
- Inspect general condition of pump and piping.
x) Gas/water influx-detection and control

If formation pressure (Pf) exceeds pressure exerted by the column of
drilling fluid (Pm), formation fluids, hydrocarbons or water, may flow into
the well bore. Upward moving gases expand tremendously due to
reduction in pressure on top and unload in very large volumes at surface.
This situation is known as “Gas Influx.”. In case of water influx, mud weight
& viscosity reduction is experienced at shale shaker and after degasser.
The following steps are recommended for detection and control of Gas
Influx during drilling operation.
•Check for increase in flow rate in the return line and mud volume in
active tank, an increase shall confirm influx.
•Keep a strict watch on specific gravity and viscosity of mud while
drilling through a permeable formation like sand stone, lime stone
etc.
•Measure specific gravity of out coming mud more frequently, if gas
influx is anticipated.
•A sudden rise in viscosity of the out coming drilling fluid with an
enhanced flow rate at the shale shaker indicates gas influx.
•Check if the pump rate is same or increased. Same pumping rate
reconfirms the gas influx.
•Immediately stop drilling ahead &start the degasser.
•Stop circulation
•Check self-flow.
•If well flowing, shut in pipe rams of Blow out preventer and record
shut in drill pipe pressure.
•Discuss and decide on well killing method with drilling Engineer and
follow the exact guidelines on kill mud weight requirement in terms
of specific gravity and volume of the kill mud required.
•Calculate required kill mud weight and prepare kill mud in the fastest
possible time.
110
•Once the kill mud is ready coordinate with the drilling Engineer of the
rig for its proper pumping and placement in the well to kill the well.
•Once the high pressure gas influx is controlled by killing operation,
resume mud circulation with a higher specific gravity (approx safety
margin 0.02 SG + Trip margin (0.03 SG)=0.05 SG) which must be more
than formation pressure (i.e. Pm new > Pf)
•Continue circulation with new higher specific gravity drilling fluid for
one or two cycles, stop circulation intermittently and check for self-
flow.
•If no self-flow or gas influx, resume normal drilling operation with
new higher specific gravity mud.
•It is mandatory to keep kill mud of maximum MW ready in the
reserve tank as indicated in the GTO for that section, while drilling
an exploratory well.
y) Well Conditioning for Casing Cementation

Drilling fluid is required to provide a gauged and stable borehole for
proper cementing job.
The following points are recommended from drilling fluid’s angle while
preparing a well for cementation job:
•Circulate and condition the drilling fluid after the casing pipe has
been lowered to the desired depth for 2-3 cycles.
•In the first cycle ensure that the casing open hole annulus gets
cleared off all debris / caving, or left over cuttings from the annulus by
suitable mud Rheology / hydraulic combination in new annular
geometry.
•In the next one or two cycles treat the drilling fluid with suitable
quantities of deflocculant/ pre-mix and fluid loss control additive to
ensure that drilling fluid has low plastic viscosity and yield point
values.
•Once the desired drilling fluid parameters are achieved, start
cementation without delay.
z) Well Conditioning for Logging Operation

The following points must be taken in to consideration while preparing
well for logging operation.
•Circulate and condition the drilling fluid to ensure that all cuttings/
debris are out.
111
•The rheology should be optimum to keep the well bore intact.

•Treat the drilling fluid with proper lubricant to facilitate smooth
lowering of logging tools.
•Special precautions for MDT run: In view of the likely sticking of MDT
tool, the open hole may be placed with a high lubricating pill of
running mud treated with 2% lubricant.
aa) Well conditioning for Hermetical Test

The following procedure to be followed while preparing well for
hermetical testing.
•Run in scraper. Circulate and condition the drilling fluid at least 2-3
cycles depending on the hole trajectory to ensure that all cuttings/
debris are out.
•Displace mud with water having a 50 bbls (7.5 m3) spacer of 8-10%
pre-hydrated bentonite suspension to prevent Baryte
contamination and settling.
•Conduct hermetical testing to desired pressure.
•Displace water with mud having a 50 bbls (7.5 m3) spacer of 8-10%
pre-hydrated bentonite suspension to prevent Baryte
contamination and settling.
•Circulate and condition the drilling fluid at least 2-3 cycles depending
on the hole trajectory to ensure homogeneity and hole cleaning
before pulling out scraper.
•In case of any anticipated delay, scraper must not be allowed to stay
at bottom without intermittent circulation and reciprocation.
Note:
i. In case the hermitical test is done in 2 stage displacement, the same
procedure as described above is to be followed for each stage.
ii) In High pressure wells with more than 1.5 SG mud, hermetical test
may be done with OEDP run without scraper in hole.
bb) Hydrogen Sulphide (H2S) Control

Hydrogen Sulphide Hazards
•Hydrogen sulfide gas has an offensive, rotten-egg odour at low
concentrations and cannot be smelled at higher concentrations.
112
•This colorless, highly reactive acidic gas is hazardous to workers and

detrimental to drilling equipment, even at low concentrations.
•H2S is heavier than air and when released will accumulate in low-lying
areas. Closed compartments and storage tanks are particular
hazards.
•H2S can even accumulate in the top portion of mud pits when there is
little wind or air movement.
•Lethal concentrations can accumulate above mud pits or in tanks
even when the concentration of H2S is so low that it might be
considered trivial.
•Whenever H2S is present or thought to be a possibility, all rig
personnel should be warned not to bend over, or reach down into,
the mud pits.
•The gas is highly flammable and forms an explosive mixture with air.
Even short periods of exposure to hydrogen sulfide can kill or
seriously injure humans and can cause catastrophic failure of steel
tubulars.
•The maximum safe level for repeated worker exposure, the threshold
limit, is only 10 ppm H2S.
•The accepted industry standard is to wear respiratory protection for
concentrations greater than 10 ppm.
•The hazardous limit, or the concentration that may cause death, is
250 ppm/hr.
•Unconsciousness occurs after short-term exposure to a
concentration of 500 ppm, then breathing stops and death occurs if
the condition is not quickly treated.
Hydrogen sulphide scavengers
Following additives may be used for the removal of H2S
•H2S is soluble in both water and oil base drilling fluids.
•High alkalinity drilling fluids with excess lime are preferred for
buffering and pH neutralization.
•In solution, H2S gas ionizes depending on pH. H2S dominates in lower
pH range. At higher pH range H2S is ionized into less harmful hydrogen
sulfide (HS) and sulfide (S) ions.
•At pH of 11; 99.99% H2S is converted to HS and S ions.
113
•pH neutralization is reversible and if pH falls below 11, these HS and S

ions convert into H2S.
•At atmospheric pressure, even high pH fluids liberate H2S if sulfide
concentration is excessive.
•So, alkalinity alone should never be relied up on to control H2S and
detectable sulfide contamination should always be immediately
treated with scavenger chemicals.
•Zinc Oxide is most preferred for most cases and can be used in both
oil and water base drilling fluids. A 1lb/bbl treatment can
theoretically remove 1100 mg/l sulfide but actual removal occurs in
the range of 200-800 mg/l.
•Basic Zinc Carbonate is a complex compound containing Zinc
Carbonate and Zinc hydroxide. Treatment of 1lb/bbl can remove
about 500 mg/l sulfide.
•Iron Oxide is most effective at low pH, where H2S is the predominant
species. Recommended dose is 10-20lb/bbl .Because of pH
sensitivity, it is advisable to use a Zinc based scavenger in
combination with Iron Oxide.
•Because these scavenger are high density chemicals so good
rheology of drilling fluid is essential to keep them in suspension.
•As a suspended solids, these scavenger chemicals can be removed by
solid control equipment.
114
APPENDIX
I. Recommended drilling fluid properties in different hole sizes
Properties Top Section Intermediate Final Section

Sections
Problems to be Hole cleaning Reactive formations Formation
tackled &seepage loss damage
Mud Weight Minimum to avoid Provide 5- 10 % Same but as
mud loss. margin over pore low as
/collapse Pressure required.
but less than fracture
Pr.
Plastic Viscosity As Low As Possible (ALAP)
Yield Value Just sufficient for hole cleaning and cutting removal. Most
2
optimum range:20-30 lbs/100ft
Gel0 The most important parameter with respect to Hole
2
Cleaning. Optimum range 8-15 lbs/100ft based on Hole size.
2
Gel10 In general maximum 30 lbs/100 ft for most applications.
LSRV 1. Maintain Fann 3 rpm reading at least 12 -15 and 6 rpm
reading 1.1 times hole diameter
2. LSRV=2Q3 – Q6 where Q3 and Q6 are 3 and 6 rpm
readings respectively .
3. LSRV=0.4-0.8 X well diameter” (Normal case)
LSRV=Well diameter” (Critical situation)
Water loss API No Control 6-12 4-6
Filter Cake Sufficient to As thin and compact as possible to
support well bore support well bore and control water
loss.
Solid Content Optimum % for drilling fluid system used with maximum
HGS =(SG value -0.9) x 30
pH As per drilling fluid system used.
II. Stacking and Handling of Chemicals

1. Never exceed the recommended weight limit when lifting the pallets
of chemicals by a lift. If shifting is required in a pallet whose weight is
more, then extra sacks should be transferred to another empty pallet
prior to lifting by fork lift.
2. Chemicals like Bentonite, Ethogel, CMC, PAC, PHPA, XC-Polymer etc.
are potentially slippery, when wet. Hence spillage of these chemicals
in the sack store and hopper area should be cleaned up at the
earliest. Any torn bags should be taken out and stacked separately for
use at the first opportunity.
3. Acid tanks when taken on board should be transferred with care and
115
covered with proper lids and never left uncovered. If slippage takes
place wash with plenty of water immediately and neutralize with
lime, Soda or Calcium carbonate.
4. Addition of caustic soda directly in to the hopper should never be
done. It should be preferably be added as an aqueous solution
through a tank wherever available. Canvas gloves are not
sufficiently protective specially when wet, for handling caustic
soda. Use safety goggles, rubber apron and PVC gloves while
handling Caustic soda.
5. Use dust masks when adding chemicals like Bentonite, Baryte,
Cement, FCLS and other such finely powdered chemicals.
6. Hopper area should be adequately ventilated and illuminated.
7. While diluting acids, never add water to concentrate acid in
the tanks. Splattering may take place. Always add the acid to water.
8. Some surfactants, defoamers, corrosion Inhibitors etc. can produce
irritation of the skin and the vapours can irritate the eyes. When
handling such chemicals, wear appropriate personal protective
equipment like gloves, aprons and goggles. If spilled on the skin
wash the area with plenty of water and soap and seek medical
advice.
9. Eye washing stations should be provided with fresh potable water at
all places where drilling fluid handling is done, viz. drill floor, shale,
shaker, mud pit room, hopper/mixing area. Such a facility should also
be provided near the cementing unit.
III. Key Safety Precautions While Handling Chemicals

•MSDS for all the chemicals on board or at rig should be available and
must be read / understood properly.
•Proper PPE must be used while handling the chemicals.
•Avoid contact, inhalation or ingestion of the chemical.
•In case of any of the above occurrence, emergency first aid
procedures should be immediately followed.
• The safe exposure limits for various chemical should be known in
advance.
• In case of release of toxic gas like Hydrogen Sulphide etc. escape in
opposite to wind direction or cross wind at height, so as to be away
from source of leakage. Chemicals for scavenging H2S must be
116
available in the stock such as Zinc Carbonate/ ironite sponge for use
at the site especially in known H2S prone field or exploratory
locations.
•The inventory for each chemical should be known in advance.
•In case of release of flammable chemicals, all ignition sources must
be removed.
•Any confined space entry where chemicals are handled must be done
with a valid work permit.
•Spillage of chemicals must be avoided. In case of any spillage, sweep
clean spilled substances, wash away remainder with large amount of
water,
(Extra personal protection – breathing apparatus set).
IV. Emergency First- Aid Procedures

Inhalation : Fresh air, half upright position and transport victim to a
Hospital.
Skin : Remove contaminated clothes, rinse skin with plenty of
Water or shower and send the victim to a doctor.
Eyes : First rinse with plenty of water of 15-20 minutes and
then Transport the victim to a doctor.
Ingestion : Rinse mouth, give plenty of water to drink then
transport the victim to a doctor.
117
Casing Operations
6 Casing
Operations
The basic purpose of casing is to prevent the drilled section of well from
collapse, for zonal isolation, to prepare the well to sustain pressures from
formations to be drilled subsequently and for providing a conduit for
taking production. The casing operations need elaborate planning and
execution to successfully run and cement a string of casing/liner capable
of meeting the specified pressure requirement and geological objectives.
In view of utmost importance of casing operations in successful
completion of each phase of the well, the procedures outlined in this
chapter need to be adhered strictly.
This chapter covers the following aspects of casing operations:
a) Casing Plan
b) Casing preparation at site
c) Hole preparation prior to casing lowering
d) Rigging up for lowering casing
e) Casing lowering Procedure
f) Casing Landing Practices
g) Phase wise checklist/ running procedures for all casings/ liners
a) Casing Plan
The foremost requirement prior to stacking and lowering casing is the
casing plan complete with details of casing such as
•Casing specifications like grade, nominal weight, end connections,
depth interval for different grade/ppf casings.
•Use of short casing pipe to be mentioned in the plan for validation of
depth through logging.
b) Casing preparation at site

While receiving and unloading casing pipes at Drill Site, the following steps
are to be undertaken:
1. Casings which are to be lowered last into the well are to be stacked
first.
119
2. Place rafters (wooden plank) or thick casing line below each row of
casing pipes at three places.
3. Visually inspect pipes and reject pipes with damaged threads/ having
dents/ovality or any other damage.
4. Measure and write serial number & length of casing pipe on its body
with paint while stacking.
Note :
i) Marking may be done with different colour paint for casing of
different grades and ppf.
ii) It is recommended to use steel measuring tape. Damaged
measuring tape should not be used. Correctness of length should
be rechecked initially before measuring all casings.
iii) For buttress thread casings, length should be measured from the
top of coupling to the base of triangle mark on the pin end.
5. Prepare the tally of casing pipes of first row giving serial number
length, grade, weight and type of connection.
6. Place subsequent casing pipes in rows one by one. Measure and
prepare the tally of all the casing pipes. Casing tally should be re-
checked.
7. Clean pin and box end threads.
8. All Casing pipes should be go-gauged if threads are OK. Reject all the
pipes through which go-gauge cannot pass.
Note : Size of go-gauge should correspond to the drift diameter of
casing.
9. Re-install thread protector on the pin end of casing.
Note: Ensure that all the rows of the casing are properly secured at
both ends to prevent rolling.
10. Before making up, float shoe and float collar should be visually
inspected for any damage to body, threads and ball.
11. Check the type of the shoe: NRV type/self-filling differential type. For
NRV shoe, check for correct NRV function for any leakage by carrying
out water integrity test.
12. Clean threads and apply thread locking compound and make up
casing shoe with the casing pipe up to the base of triangle for casing
with buttress threads.
13. In case float collar is used, it should be made up with thread locking
compound on the second casing pipe (or as per plan).Shoe and float
120
Casing Operations
collar should be made up in advance and kept ready.

14. No welding should be done on N-80, P-110 and above grade casings.
15. In case of larger size of casings i.e. 20" and above, weld shoe after
making V-cut on pipe.
c) Hole preparation prior to casing lowering

The following steps should be taken for preparing the hole during final bit
trip prior to lowering casing:
1. The mast should be centred after mast up and prior to spudding. In
case centering could not be done prior to spudding due to technical
reasons, DIC must ensure that the mast is centered properly prior to
final trip for lowering surface casing.
2. Do not try to push through tight spots. Ream all the held-up zones.
3. Prove the hole with minimum 2 stabilizers in Bottom Hole Assembly
(BHA) and ream till there are no tight pulls or held ups.
4. Circulate and condition the mud at same SPM as during drilling and
ensure the hole is free of cuttings.
5. Pull out to last casing shoe. In case of intermediate/production
casings, lay down the extra drill pipes to reduce the static load on the
rig floor and provide additional working space.
6. Inspect draw works braking system.
7. Slip and cut casing line, if required
8. RIH to bottom, circulate and condition the mud and POOH to lower
casing.
9. Once the bit is inside the casing, mud pumps should be checked to
ensure their reliability during the cement displacement.
10. Prior to pull out of hole for casing lowering, complete all the prepara-
tions so that casing lowering can be immediately started after pulling
out.
11. Break all such assemblies as drill collars, reamers, stabilizers or any
other item with large OD which cannot be handled after casing has
been lowered.
d) Rigging up for lowering casing

1. Once pullout is complete, cover the rotary.
2. Close blind ram and replace pipe rams with rams of casing size being
lowered.
121
3. Keep spinning manila ropes (7-8 pieces) ready, in case spinning tong
breaks down.
4. Keep chisels and files of different types and 2 lb and 5 lb hammers
ready for repair of casing threads if required.
5. Keep wire brushes, Baryte, cotton waste and diesel at the derrick
floor for cleaning the threads of the casing.
6. Keep ready the arrangements for welding and gas cutting at the
derrick floor.
7. Rig up the single joint and side door elevators, slips and power tongs
to lower casing.
Note : Hook up single joint elevator with the help of 16/19 mm wire
rope of sufficient length so that it can be latched on the casing pipe
with the casing elevator just on top of rotary table.Longer length of
sling results in loss of time.
8. Rig up hydraulic casing tong and attach torque gauge suitable for
appropriate tong lever length (25" or 48").
9. Rig up back-up tong with safety line only.
10. Hook up casing fill up line.
11. Change the cull bushing into the rotary opening if required.
12. Thread lock compound should be used for the first 3 joints.
13. API Casing thread dope should be used for the remaining casing
joints.
14. Prepare manila rope piece for controlling casing swing of pipes on rig
floor and keep 4/5 extra pieces as replacement for wear and tear.
15. Prepare 2 slings for lifting pipes from pipe rack to rig floor.
16. For heavier casings or at rigs with high structures the crane is used for
placing the casing pipes on the inclined ramp/ V-door.
17. It is recommended to clean box end threads and apply thread dope at
V-door only to avoid dropping of any unwanted material into casing.
e) Casing lowering Procedure

1. Latch casing elevator on to the first casing pipe and slowly lower the
casing pipe in the well.Rest the casing pipe on the slip and install
additional single joint elevator for safety before unlatching side door
elevator.
2. Lift the block and latch the single joint elevator onto the next pipe.
122
Casing Operations
Use quick-operating cam type casing thread protector to avoid

damage to threads.
3. Remove the protector from the pin end of the next pipe with float
collar, clean pin end threads on rig floor and apply thread-lock
compound and make up the float collar joint to shoe joint using
hydraulic tong.
Note: Thread lock compound should be used for making up shoe,
float collar or all joints in between.
4. Use both the tongs to make up first few joints up to the required
torque to avoid rotation of bottom casing pipes.
5. In case of buttress thread casings the joint should be tightened up to
the base of the triangle mark on the pin end.
6. Block speed should be low when elevator is nearing rotary table to
facilitate attaching single joint elevator on the next casing joint.
7. Checking the floating equipment
Shoe: Most important precaution for NRV function
a) Check there is no mud inside casing.
b) Fill shoe joint with mud. Raise joint up and lower back to rotary
table. Observe mud flow on return line and level drop inside pipe
indicating proper flow through NRV which ensures proper
functioning of NRV in shoe.
Float Collar : After first two casing pipes having float shoe and float
collar have been lowered into the well, run one more single of casing
above float collar and lower up to rig floor. Follow the same test
procedure as b) above for float shoe.
8. Casing fill up
a) Initially for first few joints, fill each joint with mud till sufficient
hook load is attained.
b) In case of NRV type casing shoe, subsequently casing should be
filled after lowering every 5 joints.
c) A good practice is to fill each casing joint while the next casing
joint is being picked up.
d) In case of the self-filling shoe, the casing is automatically filled
while being lowered and this is indicated by rise in hook load.
9. Install centralizers as per plan with stop collar.
10. Continue lowering casing up to the desired depth.
Note: Casing Make-Up:
123
1. Ensure visually that the stabbed pipe is vertical before making-

up.
2. In case of BTC threads, first 5 to 10 joints should be tightened to
the base of the triangular mark and torque should be noted.
Remaining joints may be tightened to the average torque with
occasional checks for the triangular mark.
3. While making-up joints with hydraulic tongs, first use high gear
for initial make-up followed by low-gear for final make-up.
4. In case of any problem during initial make-up of casing joint, pipe
should not be tightened further which may damage threads on
both the pipes due to cross threading causing heating up of the
joint. In such cases, open the joint, clean and check the threads of
both pin and box ends, apply dope and make up again.
5. If threads are damaged badly, reject both the pipes.
f) Casing Landing Practices

Selection of proper casing landing procedure is important to avoid
excessive and unsafe tensile stresses at any time during the life of well. In
arriving at the proper tension and landing procedure, consideration
should be given to factors viz. well temperature, pressure, temperature
developed due to cement hydration, mud temperature & change in
temperature during production operations.
Note : In view of safety, after cementation, all activities such as
unbolting and lifting of BOP must be done only after ensuring surface
sample of cement is set (at temperature as close as possible to Bottom
Hole Circulating Temperature) as any unexpected annular activity during
setting of cement will be a safety threat.
One of the following casing landing methods should be adopted:
1. Casing should be landed in such a manner that the casing at the top of
cement is either in tension or completely balanced so far as tensile
and compressive stresses are concerned.
2. Where excessive specific gravity of mud is used, casing should be
landed with top of freeze point (Top of cement) in tension. In this case
free air weight of the casing above the freeze point is considered for
calculating the weight for setting the slip in the well head.
124
Casing Operations
g) Phase wise checklist/ running procedures for all casings/ liners

1) 20" Casing Lowering
§Check list for 20" casing
S. Equipment Size/ Qty Remarks
N. capacity
1. Elevators Side Door 20”/150T 2 no.
Single Joint 20” 2 no.
2. Casing Slips 20” 2 no.
3. Casing Cull Bushing 20” 2 set
4. Casing Power Tong Set 20” 1 set With 2 set of 20”

jaws
5. Hydraulic Power Tong 20” 1 set
6. Circulating Head 20” 1 no. Ensure it has same
threads as casing
7. Casing Dope 25 kg 2
(API modified) bucket
8. Casing drift Gauge For 20” 1 No. As per the drift
casing diameter of casing
9. Clamp-on thread 20” casing 2 Nos
protector
§Running of 20" Casing:
1. R/Up Casing running tools to run casing as per “Casing Lowering

Procedure” at section d) above.
2. Pick up the shoe joint with crane to the rig floor through V-door. Lift
the joint carefully without damaging the shoe.
3. Test shoe & run 20" casing as per plan. Fill all the joints while lifting
the next pipe.
4. Fill with mud after every joint.
5. Make up cementing/ circulating head, connect rig pump and circulate
mud prior to cementing.
6. Reciprocate casing during circulation.
7. Carry out cement job as per plan.
8. Incase only guide shoe without NRV is used, then after displacement
keep the circulating head valve closed till surface sample of cement
sets.
125
Note:
In case of any held up during casing running, try to clear the same by
reciprocation without pushing down/excessive pull on the casing. Instead,
pull casing out of hole. Probe the hole with minimum 2/3 stabilizers in
Bottom Hole Assembly (BHA) based on well conditions and ream till there
are no tight pulls or held ups. Pull out of hole completely and rerun casing.
2) 13-3/8" Casing Lowering
§Check list for 13-3/8" Casing
S Equipment Size/ Qty Remarks

N capacity
1. Links 350/500T 1 set
2. Elevator Side 13-3/8”, 2 Nos Capacity of side door
Door 150/250T elevator to be decided as
per length of casing.
Single 13-3/8” 2 Nos
Joint
3. Spider Elevator and 13- 1 set To be used in case of
slip 3/8”/350/5 longer & heavier weight
00T string.
4. Casing Slip 13-3/8” 2 Nos.
5. Casing Cull Bushing 13-3/8” 2 set
6. Casing Power Tong 13-3/8” 1 set With 2 set of 13 -3/8”

Set jaws
7. Hydraulic Casing Jaws for 1 set Hydraulic Power Unit with

Tong (5”-20”) 13-3/8” Hoses and spare sets of
Dies
8. Circulating Head 13-3/8” 1 No. Ensureit has same threads
as casing
9. Cementing Head 13-3/8” 1 No. Top & bottom plugs to be
installed prior to cement
job with proper check.
10. Casing Dope (API 25 kg 2 bucket
modified)
11. Thread lock As per requirement
compound
12. Casing drift 13-3/8” 2 no. As per the drift diameter
Gauge(s) casing of casing(s)
13. Centralizers 13-3/8” - As per plan.
x17-1/2”
14. Clamp-on thread 13-3/8” 2 Nos
protector casing
126
Casing Operations
§Running of 13-3/8" Casing

1. R/Up Casing running tools to run casing as per “Rigging up for Casing
Lowering” at section d) above.
2. Dress rotary table for 13-3/8" casing.
3. Run 13-3/8" casing as per plan following “Casing Lowering
Procedure” at section e) above.
4. Change from side door elevator to slip type elevator/spider before
going into open hole as
a) It can handle heavy loads as it holds the casing at pipe body
b) It facilitates working on casing in case of held up
5. Make up cementing head and circulate mud as per plan.
6. Reciprocate casing string if possible.
3) 9-5/8" Casing Lowering
§Check list for 9-5/8"casing
S.N. Equipment Size/ Qty Remarks

capacity
1. Links 350 T/ 1 set 500 T link required for
500 T each deep wells
Elevator Side Door 9- 2 Nos. Capacity of side door
2. 5/8”/250 elevator to be decided
T as per length of casing
Single Joint 9-5/8” 2 Nos.
3. Spider Elevator and 9- 1 set To be used in case of

Spider slip 5/8”/350 longer & heavier weight
/500T string.
4. Casing Slip 9-5/8” 2 nos.

5. Casing Power Tong Set 9-5/8” 2 set
6. Hydraulic Casing Tong Jaw 1 set Hydraulic Power Unit
(5”-20”) 9-5/8” with Hoses with spare
dies
7. Circulating Head 9-5/8” 1 no. Ensure it has same
threads as casing
8. Cementing Head 9-5/8” 1 no. The top and bottom
plugs to be installed
prior to cement job with
proper check.
9. Casing Dope 25 kg 2
(API modified) bucket
127
SN Equipment Size/ Qty Remarks

capacity
10. Thread lock compound As per requirement
11. Casing drift Gauge (s) For 1No. As per the drift
9-5/8” diameter of the casing
casing
12. Centralizer 9-5/8” x - As per plan.
12-1/4”
13. Clamp-on thread 9-5/8” 2 Nos
protector casing
§Running 9-5/8"Casing:
1. Change rams to 9-5/8" casing rams.
3. Dress rotary table for 9-5/8" casing.
4. Run 9-5/8" casing as per plan following “Casing Lowering Procedure”
at section e) above.
5. Change from side door elevator to slip type elevator/spider before
going into open hole as
a) It can handle heavy loads as it holds the casing at pipe body
b) It facilitates working on casing in case of held up
6. While lowering casing, break gel for 30 minutes at last casing shoe.
7. Based on formation characteristics, if the open hole is around 1,000 m
or more, an open hole gel break may be considered for minimum
period (5-10 minutes).Consider additional Gel Breaks if poor returns
are observed while lowering casing.
8. Make sure that the 9-5/8" casing joint coming across the well head
area is free from any ovality as this is going to give a pressure seal with
the slip assembly.
9. Calculate optimum discharge for circulation after casing lowering for
maintaining the same annular velocity as during drilling against drill
pipe.
Optimum Circulation rate=
Discharge during drilling* Annular capacity between hole and casing/
Annular capacity between hole and drill pipe
11. While running casing, ensure mud tanks have sufficient space for mud
displaced by casing and cement volume.
128
Casing Operations

4) Production Casing in Final Phase (5 ½ “/ 7”Liner in 8 ½ “ Hole)
§Check list for 5-1/2" Casing/7"Liner
SN Equipment Size/ Qty Remarks

capacity
1. Links 350 T 1 set
Elevator Side 5-1/2”/7” 2 no. Capacity of side door
2. Door 150/250T elevator to be decided
as per length of the
casing.
Single 5-1/2”/7” 2 no.
Joint
3. Casing Slip 5-1/2”/7” 2 nos.
4. Casing Power 5-1/2”/7” 1 set

Tong
5. Hydraulic Casing Jaw-5- 1 set Hydraulic Power Unit
Tong (5”-20”) 1/2”/7” with Hoses with spare
dies
6. Circulating Head 5-1/2”/7” 1 no. Ensureit has same
threads as casing
7. Cementing Head 5-1/2”/7” 1 no. Top & bottom plugs to
be installed prior to
cement job with proper
check.
8. Casing Dope 25 kg 2 bucket
(API modified)
9. Thread lock As per requirement
compound
10. Casing drift Gauge For 5- 1no. As per drift diameter of
(s) 1/2”/7”casi the casing
ng
11. Centralizer 5- - As per plan.
1/2”/7”x8-
1/2”
§Running of 7" Liner

1. R/Up Casing running tools to run liner as per “Rigging up for Casing
2. Change rams to 7" liner.
3. Hold Toolbox meeting on rig floor to advise all concerned rig
personnel of the objectives, summary of the running procedure, and
to discuss any particular care or safety concerns.
129
4. Make up landing collar as per tally.

5. Run in liner as per tally and install spirolizers and/or centralizers as
per plan.
6. Keep thick gel of waste oil mixed with grease ready at rig floor.
7. Pick up the Liner Hanger assembly very carefully to avoid right hand
torque.
8. Make up liner wiper plug with slick joint.
9. Make up hanger packer assembly with liner.
10. Ensure that setting tool and all connections are properly made-up.
11. Fill Tie Back Receptacle (TBR) with oil and grease gel before running in
hole.
•Pull slips and lower assembly through rotary and set DP slips on
the setting tool extension at the top of the running tool.
•While running in liner on drill string
•Drift all the tubulars in liner lowering string with appropriate
rabbit size.
•Apply pipe dope as little as possible with a paint brush on DP pin
end connections only to avoid excess dope falling down and
choking the ports.
•There must not be any jerk or rotation (Mechanically lock the
rotary).
•Take extra care while making up with Top Drive System (TDS).
Ensure no slippage of back up tongs.
•Held up should be cleared by circulation and reciprocation only.
Take care of pressure limit.
• Lowering speed should be 1.0 to 1.5 minutes per stand as the
annulus space between liner and casing/ open hole has very
narrow clearance.
12. Run first stand of drill pipe carefully and slowly when hanger is
passing through BOP and well head area.
13. Circulate to check for leaks and to confirm return.
Note: This is a very important step to check the sealing of pack off
bushing of liner hanger. Any flow of mud from within the liner
thorough the pack off appearing from top of TBR/ Running Tool
indicates lack of pressure integrity and may cause problems for
subsequent setting of hanger.
130
Casing Operations
14. At any time, do not exceed maximum circulating pressure limit to

avoid premature hanger setting which can result in well
abandonment. Maximum circulation and pressure limit is based on
the Liner Hanger shear setting value.
15. Record pick-up and slack-off weight of liner.
16. Resume further running in of liner with drill pipe stands.
17 Fill up after every 10 stands of drill pipe.
18. In deep wells where mud weight, viscosity, temp, etc are too high fill
up every 10 stands with the help of TDS/Circulating Swage and
continue to pump for 5 minutes after getting return.
19. With the liner assembly shoe at the last casing shoe:
a) Break circulation and check free circulation through the liner
assembly. Circulate at least volume of Liner + Drill Pipe
capacities. Do not exceed pressure limit.
b) Closely monitor for static and dynamic losses and record.
c) Record the up and down weight.
20. Resume further running in to bottom/target depth carefully.
21. In open hole, keep the string under reciprocation while filling.
22. Wash down last stand and tag bottom/reach target depth gently. Tag
bottom with no more than 5-10 T (~10-20 kips).
23. The liner must be set at least about 0.5 m from bottom. Keep pup
joints of various lengths ready to adjust the length.
24. Do not use mud with LCM in any case.
25. Circulate at bottom for at least one cycle.
a) Record the up and down weight of string.
b) Pick up to back off point/hanger setting depth and mark the pipe.
c) Drop ball and set hanger. Continue to circulate for ten minutes
after ball seat shearing. The pressure after ball seat shearing
should be same or more than the earlier pressure and in no case
should be less.
d) Rotate the string at 20-30 rotations to back off setting tool. Note
torque readings.
e) Stop rotation, pickup only about 1/2 to 1 m to confirm back off.
Note: If picked more, polished nipple will come out of pack off and
may lead to serious complications in cementing.
f) Space out and rig up cement head.
131
g) Make sure swivel is used on the end of the cement hose to the
cement head and hose weight is correctly supported.
h) Flush cementing hose before connecting it with cement head.
26. Circulate and cement as per cementing plan.
27. During displacement, run extra supercharger or mixing pump to get
better efficiency.
28. Remove cementing head and set hanger packer
29. Disengage Liner Hanger Running Tool and pull out 2-5 stands of drill
pipe depending on well profile.
30. Reverse and/or direct wash as per cementing plan. Direct wash for
cleaning drill pipe bore.
31. POOH Liner Hanger Running Tool.
§ Running of 7"/ 5-1/2" casing
1. Change rams to 7"/5-1/2" casing.
3. Run 7"/5-1/2" casing as per plan following “Casing Lowering
Procedure” at section e) above.
5. Based on formation characteristics, if the open hole is around 1,000
m or more, an open hole gel break may be considered for minimum
period (5-10 minutes).Consider additional Gel Breaks if poor returns
are observed while lowering casing.
6. Make sure that the 7"/5-1/2" casing joint coming across the well head
area is free from any ovality as this is going to give a pressure seal with
the slip assembly.
7. Calculate optimum discharge for circulation after casing lowering for
maintaining the same annular velocity as during drilling against drill
pipe.
Optimum Circulation rate=
Discharge during drilling* Annular capacity between hole and casing/
Annular capacity between hole and drill pipe
9. While running casing, ensure mud tanks have sufficient space for
mud displaced by casing and cement volume.
132
Cementing Operations
7 Cementing
Operations
Cementation is the one of the most vital operation for integrity, safety and
enhancement of the life of the well. Proper cementation is required to
ensure that long term zonal isolation and safety of the well are achieved
along with casing support. Since the cementation is mostly one time job,
meticulous planning and execution are of utmost importance to achieve
the best results.
This chapter covers the following aspects of cementing operations:
a) Preparation Prior to Spudding of the well
b) Operational aspects during lowering of casing/ liner
c) Plan and Execution of Casing cementing Job
d) Plan and Execution of Liner Cementation Job
e) Multi-stage Cementation
f) Subsea Well Cementation
g) Secondary cementation
h) Cement squeezes procedures
i) Well abandonmentprocedures
j) Salient points of different types of Casing Cementation Jobs
k) Cementing consideration for HPHT wells
a) Preparation Prior to Spudding of the well

1. Check rig bulk handling system is properly placed and installed if it is
part of the rig.
2. Check Cement bulk handling plant (CBHP) to provide stone free and
dry cement free of moisture to various rigs.
3. Stacking of Cement and Cement additives at CBHP should be in line
with the godown specifications.
4. Air dryer should be installed at CBHP to ensure dry air supply.
5. Check facility for storage of optimum cement and cement chemicals
quantity is available.
6. For rain prone areas and particularly during monsoon season, cement
133
and dry cement chemicals

storage should haveraised and
covered platform with dry
wooden planks flooring.
7. Ensure there is provision for
supply of water/mud/
chemical treated water from
mud tanks to cementing unit
with appropriate connections.
8. Ensure provision of cement slurry line from cementing unit to well. If
permanent cementing line is a part of drill site, ensure it is in place
and anchored.
b) Operational aspects during lowering of casing/ liner

Ø
Lowering of casing
1. Make final casing tally such that the casing can be landed preferably
within 2-3 m off bottom.
2. Check float function of shoe/ collar before make up with casing. Keep
bottom side up and fill with water, if water is not coming through
float, the float function is OK. Replace same if found leaking. Use of
defective float collar/shoe results in well to be kept under pressure
after cementation, which leads to micro-annulus development.
3. Use preferably same type and make of float shoe and float collar in a
casing. In general, use float shoe and float collar two joints apart.
4. In case of differential float equipment, check the availability of
correct size ball before casing lowering as it is required for actuating
float equipment before circulation. (Otherwise differential to be
converted to conventional ones before casing lowering).
134
5. Use centralizers as per simulated program to have Minimum 67%

stand off both in vertical and deviated wells. All centralizers to be
fitted with stop rings.
6. Run casing at controlled speed in the open hole to prevent fracturing

and lost circulation.
Based on formation characteristics, if the open hole is around 1,000
m or more, an open hole gel break may be considered for minimum
period (5-10 minutes). Consider additional Gel Breaking if poor
returns are observed while lowering casing.
8. Last casing joint should be spaced out such that cementing head can
be installed conveniently above rig floor after casing is landed at TD.
9. After casing is lowered, start mud pump slowly to break gel and
establish circulation. Check for mud returns.
10. In case of differential float (Intermediate/ production casing
cementation), drop ball and continue circulation.
11. Circulate and condition mud (preferable annular velocity of 1.3m/sec
to 1.8m/sec)for homogeneity and to bring down mud parameters as
per cementing program.
12. Reciprocate casing till the end of cement displacement if well
condition permits.
In addition to the above common points, some specific points must be
considered for:
Ø
Lowering of surface casing
Depending upon the casing policies for different well conditions,
135
20"casing, 18-5/8"casing, 13-

3/8"casing and sometimes 9-
5/8"casing falls under the category of
surface casing.
1. For large diameter surface
casing, use float shoe instead of
guide shoe.
2. In specific condition, for large
size casing (20"/ 18-5/8")
cementation if shoe depth is
more than 500 m, use stab-in
shoe/ collar preferably for faster
surfacing of cement due to
reduced displacement time and
to avoid cement contamination.
Alternatively tail pipe of suitable
length may be used.
Ø
Lowering of Intermediate casing
Depending upon the casing policies for different well conditions, 13-
3/8"casing, 9-5/8"casing and sometimes 7"casing falls under the category
of intermediate casing.
1. Use float shoe and float collar two joints apart. Long length casing
beyond 3000m should have a shoe track of three joints.
2. Always use one centralizer each for first five joints and minimum one
number per four joints uptothe planned cement top.
3. If any zone of interest is there, use one centralizer each for first five
joints and minimum one number per alternate joints upto150 mts
above the top most zone.
4. Use sufficient numbers of spirolizer/ swirlers against caved/ enlarged
hole section for local turbulence to remove mud properly as required
for quality cementation.
Ø
Lowering of Production casing
Depending upon the casing policies for different well conditions, 9-5/8"
casing, 7"casing, 5-1/2" casing and sometimes 5" casing with combination
of 5-1/2" casing falls under the category of production casing.
1. Use float shoe and float collar at two joints apart. For long length and
small diameter casings, place float collar and shoe preferably three
joints apart.
136
2. Floatcollar depth also to be decided based on sump required for the

bottommost pay zone against the casing.
3. Use centralizers as per simulated program to have minimum 67%
standoff both in vertical and deviated wells.
4. In case simulated centralizer program is not available, always use
ü
one centralizer each for first five joints,
ü
minimum one number per joints against pay zones and
ü
minimum one number per alternate joints between the gaps of
zones of interest and upto150 mts above the top most zone.
5. Use sufficient numbers of spirolizer/ swirlers against caved/ enlarged
hole section for local turbulence to remove mud properly as required
for quality cementation.
6. In a well with narrow pressure window that restricts displacement in
turbulence, use sufficient spirolizer/ swirlers at top and bottom of
each object to induce local turbulence for proper mud removal
required for quality cementation in Production casing cementation.
Ø
Lowering of Liner
General point for lowering of casing is applicable in case of liner. However,
certain additional points must be followed in case of lowering of liner as
follows:
1. Length of liner to be decided based on well
requirement subject to limitation as per
manufacturer specification.
2. Liner shoe and landing collar should be placed at
two joints apart.
3. Ensure before connecting Liner Cementing Head
to drill pipe that:
i. Liner wiper plug and dart-plug are of the
same size and make.
ii. Ball is in Ball Dropping Sub (BDS) and spindle
of BDS is in retrieved and in locked condition.
iii. Dart dropping rod is inside the bore and in
locked condition. Thereafter, load dart in the
head.
iv. Liner / cementing head to be serviced before and after every job.
Spindle and flapper to be checked for free movement before the
job.
137
4. Carry out further operation under

supervision of Liner Hanger expert.
5. Before setting the liner hanger, circulate
the hole for 1-1/2 to 2 cycles for
homogeneity of mud and also to bring
down mud parameters to minimum
possible values.
c) Planning and Execution of Casing

Cementation Job
1. Identify bottom cement plug with flexible
diaphragm and hollow aluminum core.
Identify top cement plug with solid
aluminum core.
2. Plan with the established mud pump
displacement efficiency to work out total number of corresponding
mud pump strokes to complete cement displacement.
3. For calculating the efficiency of mud pump consider the reference of
previous primary cement job in the same rig.
4. Check total mud volume in all the tanks before cementation to work
out as a reference for mud loss if any, during cementation with due
consideration of volume pumped by cementing unit.
5. Plan for testing cementing line prior to start of cementation at 1.5
times the maximum plug bumping pressure. Plug bumping pressure
is 50 kg/cm2 over differential pressure limited to 70% of casing burst
pressure rating.
6. It is preferable to use chicksan line for cement pumping and
displacement. If high pressure rubber hose is to be used ensure
regular replacement of same in time to prevent any problem due to
blockade out of rubber pieces.
7. Plan for testing of displacement line upto cementing head at a
pressure of 500 psi above the final expected displacement pressure.
138
8. Calculate the slurry volume using caliper log (preferably four arm
caliper log) for all important casing/ liner cementation jobs to achieve
desired cement rise. In absence of caliper log, use prior field
experience to assume the Annulus Caving factor.
9. A detailed cementation plan duly discussed by all concerned well-site
in-charges to be circulated prior to the operation.
10. Calculate the displacement volume up to float collar (Landing collar in
case of liner) and half the shoe track volume.
11. Coordinate with mud logger for monitoring displacement volume,
total strokes, expected pressure rise, loss or gain etc.
12. To confirm from well site chemist for available well site water salinity
and coordinate for sweet water tanker if salinity is more than 1.0 GPL.
13. Ensure that the pumpable quantity and supply rates of pre hydrated
Bentonite gel/ cementing chemical solution, weighted spacer and
water for cementation job are sufficient for uninterrupted operation.
14. Circulate the hole for 1.5 to 2 cycle for homogeneity of mud.
15. Incase fresh mud is required for production casing cementation, it
should be prepared in advance with good water loss control and
rheology.
16. Prepare pre-flush for water base mud below 1.40 SG.
17. For high pressure (HP) wells, if mud weight is higher than 1.40 SG,
prepare weighted spacer with density equal to average of mud and
cement slurry density.
18. For all HP wells and critical job, always plan for density of cement
slurry > density of spacer > density of mud
19. Also, always plan for Yp(cement) >Yp(spacer) >Yp(mud)
20. Prepare spacer/ pre-flush volume equivalent to 8-10 minute of
contact time at the planned/ desired displacement rate, subject to
limitation of the formation fracture pressure (for spacer) and pore
pressure (for pre-flush)
21. In case of Oil base mud system, use combination of spacer and pre-
flush comprising of surfactant/emulsion breakers and water wetting
agent along with viscous spacers.
22. Spacer should be compatible both with mud as well as cement slurry.
139
In addition to the above common points, the following points are to be

considered depending on the type of casing to be cemented:
Ø
Surface casing cementation
1. Conduct tool box meeting prior to the job.
2. Connect cementing line to cementing/ circulating head. Ensure
cementing line is properly secured/ anchored.
3. In view of safety, cordon off and restrict access to high pressure
cementing line during pressure testing and cementation job.
4. For pressure testing line, pump water equal to line volume and
thereafter close cementing head valve after receiving proper signal
from I/C cementing operation. Test cementing line prior to start of
cementation at 1.5 times the maximum plug bumping pressure.
5. Pressure test the displacement line upto cementing head at 500psi
above the final displacement pressure.
6. Once pressure testingis OK, open cementing head valve after
receiving proper signal from I/C cementing operation and pump pre-
flush followed by cement slurry.
7. During cement mixing, coordinate with site chemist for
measurement of cement slurry density and collection of cement
slurry samples.
8. After getting confirmation from I/C cementing operation that cement
slurry pumping is over, change over the line from cementing unit to
mud pump.Open the required valve for displacement. Ensure that no
other valve is open.
9. When float collar is not used, ensure that minimum 15 m cement plug
is planned to be left inside casing above the shoe. If top rubber plug is
not used, plan for minimum 50m of high viscous gel plug after cement
slurry and carry out displacement accordingly.
10. Displaceby mud at pre-determined pumping rate, slow down (during
end of displacement) and thereafter stop displacement at strokes
calculated with 100% efficiency.
11. Check flow channel returns carefully both during cement pumping
and displacement to assess loss behaviour of well.
12. If float shoe is used, check floats function by releasing pressure
slowly. Release the pressure through properly secured and anchored
line.
13. If float is holding, keep the cementing/circulating head valve open to
140
avoid pressure build up due to thermal expansion.

14. If float is not holding(also when only guide shoe is used), keep the
well under pressure of differential head for 6 to 8 hrsto avoid back
flow of cement slurry.
15. During WOC (with or without pressure), monitor the well for any
activity or pressure build-up in well/annulus.
16. All swivels, chicksans, hammer unions, cementing/liner head and low
torque/weco valves should be properly serviced after each job for
smooth working subsequently. Ensure same again before each job.
17. All High Pressure flexible hoses should be new, tested and in good
condition. Replace the same periodically to avoid blockage by rubber
chunks from ruptured hose.
Ø
Intermediate/ Production Casing Cementation
1. Conducttool box meeting prior to each job.
2. After ensuring that the well mud is conditioned, pump sufficient
quantity of fresh mud (if planned for the production casing
cementation job).
3. Make up cementing head to casing. Anchor/ secure the same.
4. Ensure minimum time is taken between switching from final mud
circulation and start of cementation. This will prevent gelation/
settling of mud solids (mud sagging) which is detrimental for efficient
mud removal by spacer/ cement slurry. If feasible double plug
container (cementing head) should be used to avoid such
phenomenon in case of casing cementation.
5. In case of Single Plug Container
a. Check that bottom cement plug is dropped inside casing before
connecting cementing head.
b. Ensure that stopper rod is inside and in locked condition,
thereafter load top cement plug inside cementing head.
6. In case of Double Cement Plug Container,
a. Check that bottom cement plug is loaded first at bottom position
of cementing head with lower stopper rod inside under locked
condition.
b. Check that top cement plug is loaded next at top with upper
stopper rod inside under locked condition.
141
7. Replace the cementing head cap in position and hammer tight the
same.
8. Connect cementing line to cementing head.
9. In view of safety, cordon off and restrict access to high pressure
cementing line during pressure testing and cementation job.
10. For pressure testing line, pump water equal to line volume and
thereafter close cementing head valve after receiving proper signal
from I/C cementing operation. Test cementing line prior to start of
cementation at 1.5 times the maximum plug bumping pressure.
11. Pressure test the displacement line upto cementing head at 500psi
above the final displacement pressure.
12. Once pressure testing is OK, open cementing head valve after
receiving proper signal from I/C cementing operation and pump
preflush and/ or spacer.
13. In case of double plug container, drop bottom cement plug by
retrieving the bottom stopper rod and thereafter the stopper rod to
be kept in locked position in retrieved condition. Confirm same with
plug dropping indicator.
14. Prepare and pump cement slurry. During cement mixing, coordinate
with site chemist for measurement of cement slurry density and
collection of cement slurry samples.
15. After getting confirmation from I/C cementing operation that cement
slurry pumping is over, drop top cement plug by retrieving stopper
rod (upper one in case of double container) keeping all the valves
closed to avoid suction of air into the well. Confirm from plug
dropping indicator that top plug is released.
142
16. Change over the line from cementing unit to mud pump, open the
required valve for displacement of cement slurry. Ensure that no
other valve is open. Carry out displacement.
17. Check flow channel returns carefully both during cement pumping
and displacement to assess loss behaviour of well.
18. Displace with mud at pre-determined pumping rate, slow down
displacement after 95% of calculated strokes are pumped and
thereafter bump the plug gently.
19. If bumping pressure is not holding, stop pumping immediately.
20. If the top plug fails to land on float collar, number of extra
displacement strokes over the calculated strokes should not exceed
50% of calculated shoe track volume to ensure cement around shoe.
21. Check floats function by releasing pressure slowly. Release the
pressure through properly secured and anchored line.
22. If float is holding, keep the cementing/circulating head valve open to
avoid pressure build up due to thermal expansion.
23. If float is not holding, keep well under differential pressure for 4 to 6
hours or as per plan.
24. During WOC (with or without pressure), monitor the well for any
activity or pressure build-up in well/annulus.
25. All swivels, chicksans, hammer unions, cementing/liner head and low
torque/weco valves should be properly serviced after each job for
smooth working subsequently. Ensure same again before each job.
26. All High Pressure flexible hoses should be new, tested and in good
condition. Replace the same periodically to avoid blockage by rubber
chunks from ruptured hose.
d) Planning and Execution of Liner Cementation Job

1. After circulation is over, drop the ball by pushing the ball dropping sub
inside the liner head bore and thereafter ball dropping sub is
retrieved back. Confirm same with sub indicator position & lock
same.
2. In case of Conventional Liner hanger, plan cement rise of 50m above
liner hanger top. For deviated/horizontal hole, use extra height above
liner hanger top.
3. For Expandable Liner Hanger, cement top is to be planned only as per
well requirement.
143
4. After setting of liner

h a n g e r, s t a r t t h e
cementation job.
5. During cement mixing,
coordinate with site
chemist for measurement
of cement slurry density
and collection of pumped
cement slurry samples.
6. After slurry pumping is
over, change over the
liner head line from
cementing unit to mud
pump keeping the valves
closed during line
changing to avoid suction
of air into the well.
7. Once the line from mud Plug Dropping Liner cementing Head
pump is connected to
cementing head, drop the dart by retrieving the stopper rod and
thereafter open the required valves for displacement of cement
slurry from top inlet. Ensure that no other valve is open.
8. Displace with running mud at pre-determined pumping rate and
strokes, slow down temporarily before shearing the wiper plugand
shear the same.
9. Continue displacement at predetermined rate and slow down
displacement after 95% of calculated strokes are pumped and bump
the plug slowly.
10. Hand over to Liner hanger expert (to back off for conventional liner or
to drop ball for expansion of liner hanger in expandable liner hanger
system followed by back off etc.)
11. Pull out hanger running tool minimum 100m above liner top.
12. After pulling out, reverse circulate cement slurry by pumping 1.5
times drill pipe volume or till cement is cleared out.Direct circulate
1.5 times minimum if mud weight is more than 1.6 gm/cc. In high
angle wells pull out at least 12 stands and direct wash.
13. Pull out of hole (POOH).
14. R/I with bit and tag cement after WOC.
144
e) Multistage Cementation
In multi-stage cementing, first stage is conventional with placement of
cement slurry around the lower portion of the casing string. In next stages,
placement of cement slurry at successive upper stage is carried out
through ports of stage collar. Most stage cementing is in two stages,
although additional stages are possible.
1. Plan to maintain a
minimum gap of 100m
between top of cement
of 1st stage and stage
collar position
2. Plan stage collar depth
atleast 50m below first
zone of interest being
covered with stage
collar.
3. The first stage slurry
thickening time includes
the traveling time of
bomb, opening of ports
and one cycle circulation
through stage collar
ports in addition to slurry pumping and displacement time and safety
factor.
4. It is essential that, the first stage cement slurry needs to be in liquid
condition until stage collar is opened and circulation is established.
5. Check the stage cementing collar before it is made up on the casing,
the size of the trip plug/ freefall plug/ opening bomb, I.D.of the
opening sleeve and closing sleeve and the size of the seats provided in
opening & closing sleeves.
6. Caution must be exercised in initial handling of the stage collars, as
the equipment is manufactured to close tolerances. Rough handling
can misalign the moving parts, causing job failure.
7. The first-stage displacement plug must fit and seal against the float
collar. Keep baffle plate/ baffle collar over float collar, as
recommended by manufacturer.
8. Stage collar should be made up by locking the tongs only at the
designated place on the outer sleeve of the stage collar.
145
9. One centralizer each to be fitted above and below the stage collar.
10. Run casing with the stage collar to the desired depth. The stage collar
should preferably be placed against the shale/clay section.
11. During displacement in first stage cementing, slow down pump
temporarily when 1st stage closing plug is about to cross the stage
collar to avoid any damage.
12. After completion of first stage cementation, drop the opening plug or
bomb and allow it to reach the stage collar. Opening plug velocity is
approximately 1m/sec in normal mud. To open the ports, slowly
build-up pressure usually approx. 1,200 to 1,500 psi (refer
manufacturer’s spec). Rating of the stage collar for opening and
closing of ports must bechecked prior to lowering into the well. A
sudden drop in pressure and return from annulus will indicate
opening of ports.
13. In case of hydraulic stage collar, after bumping of 1st stage plug,
increase pressure slowly to port opening pressure. A sudden pressure
drop and return of mud from annulus will indicate the opening of
port. If port does not open at recommended manufacturer’s
maximum pressure plus 500 psi, drop stand-by opening bomb and
open the ports conventionally.
14. Circulate the well for 2 cycles through the stage collar ports to flush
out any contaminated cement (from the first stage) and
conditionmud for the second stage.
15. Start 2nd stage cementation after 2 cycles of circulation if formation
fracture pressure at bottom permits hydrostatic head of both cement
columns. If not, circulate for 6-8 hours from completion of 1st stage
cementation to start the 2nd stage job.
16. Complete pumping of cement, release shut-off plug, and displace
cement in line up to rig floor behind the shut-off plug.
17. By this process, at the end of 2nd stage cementation, release closing/
shut off plug in such a manner so as to have some cement slurry over
it. This will ensure cement outside the stage collar and minimize the
hazards of displacement fluid outside the stage collar. Further
cement above shut off plug will help in drilling it out.
18. For closing the cementing ports, approximately 1,500psi pressure
(refer manufacturer’s spec) in excess of second stage cementing
pressure is to be built up slowly over the shut off plug. Confirm the
closure by bleeding off.
146
19. In case hydraulic stage collar is used, restrict circulation and

displacement pressure during 1st stage to safe value (refer
manufacturer’s spec) below port opening pressure.
f) Subsea well Cementation

1. In case of offshore, ensure the proper working of air dryer. Otherwise
bulk transfer lines of silos and surge tanks may get clogged affecting
free flow of cement.
2. Ensure mandrel, used for connecting subsea top and bottom
plugshave been serviced immediately after the last cementation.
3. Subsea cementing head is common for all casings. Service the head
immediately after each job for proper functioning of ball releasing
sub, dart holding sub, release indicator rod and locking mechanism
4. Prior to a casing cement job, cementing head may be made ready well
in advance as follows:
4.1 Load the ball (for releasing bottom plug) in cementing head and
ensure that ball release sub is in retrieved position and is in
locked position.
4.2 Before loading the dart (for releasing top plug) in cementing
head, ensure that dart release rod is inside the cementing head
bore and is in locked position.
5. After dropping of the ball from cementing head for releasing bottom
plug, retrieve the ball release sub and lock the same after checking
indicator.
6. Drop the dart to release top plug.
7. In case of subsea primary cementation, casing hanger is rested on
well head prior to cementation and hence reciprocation is not
recommended.
8. Ensure that all substitute/X-over in the drill string above casing
hanger have ID sufficient enough for easy passage of ball and dart by
using recommended size of the rabbit recommended by manufacture
of subsea plug used.
g) Secondary Cementation
1. Use 5" drill pipe with diverter tool
a. In hole size of 12-1/4" and more
b. In 9-5/8" casing or larger
147
2. Avoid diverter tool if pressure

limitation is expected during
reverse circulation after cement
placement which may induce loss
in the well.
3. In case direct circulation is
planned with OEDP or diverter
tool, to reduce pressure losses,
the string must be in continuous
reciprocation and rotation to
avoid stuck up of pipe due to cement on the lower side in an inclined
hole.
4. Check that drill pipe elevator is not worn out as any delay in operation
may lead to stuck up in cement.
5. In case of smaller size hole/casing, use combination string (preferably
with 3 ½” or 2 7/8" drill pipe) with tail pipe of 2 7/8" tubing.
Minimum length of tail pipe should be twice the intended length of
cement plug to be placed.
6. Consider cement volume in excess for deviated hole.
7. Calculate the height of cement column with drill pipe/tubing inside
cement slurry and displacement volume accordingly.
8. Length of cement plug preferably be kept at minimum particularly in
slim holes with narrow annulus clearance.
9. For displacement of cement slurry, use cementing unit for accurate
volumetric displacement.
10. Check for displacement volume at cementing unit by manually
counting the number of tanks and recording tank volumes.
11. Keep lines/valves ready before start of cementation to facilitate
immediate reverse circulation after plug placement& pulling out
without loss of any time. This is required also for circulating out
cement slurry in case of emergency.
12. For large/deviated hole, rotate the string (during cement pumping
and displacement) to increase the chances of cement plug
success.String should be kept in rotation while pulling out also.
13. Ensure timely supply of displacement mud from designated tank to
cementing unit.
14. Monitor hook load continuously throughout cementing operations
148
including pulling out of string for reverse wash. In case of increase in

hook load, POOH fast as far as possible and immediately carry out
direct washat full SPM to avoid any complication.
15. In normal case, after pulling out about 6 stands above plug top, carry
out reverse wash. Pulling out speed should not be more than 10-15
m/minute while string is in cement and thereafter at high speed.
16. In all the cases of direct or reverse circulation, proper thickening time
should be taken into consideration in anticipation of actual job
scenario with contingency.
17. During cement plug/squeeze, job should be planned and executed
for minimum possible operational times.
18. After carrying out the reverse wash / squeeze operation, ensure the
opening of BOP through physical inspection and accordingly lift the
string as required.
19. In case of problem in closing pipe ram for reverse circulation (after
cement placement and pulling out), resort to direct circulation with
reciprocation to flush out residual cement to avoid any complication.
20. In case of problem in opening of pipe ramafter reverse out, continue
reverse circulation till cement is completely cleared.
21. In case of any problem in pulling out from bottom after cement
placement, resort to direct/reverse circulation to flush out entire
cement plug to avoid any complication.
22. Keep cementing unit in readiness, after cement pumping also for any
pressure application in case circulation could not be established after
pulling out.
23. In case, pressure shoots up during initiation/process of reversing out,
apply pressure through drill string by cementing unit upto the safe
limit of the minimum rating of running string components.
24. In case cement plug is required to be repeated, ensure that previous
cement cuttings are cleared and flushed out of hole properly (if
required, use viscous sweep). Otherwise large chunk of cement
cuttings are likely to block drill pipe in subsequent job resulting in well
complication.
25. In very deep wells with high mud weight to increase the chances of
successful placement of cement plug, mechanical separation may be
done using sponge ball to avoid the contamination and thereby
cement plug failure.
149
26. To avoid the chances of stuck up of pipe with cement during cement
plug placement in very deep wells with high mud weight,fibre tubing
may be used @ two times the cement plug length. This will help in
case of a stuck situation to snap the fibre tubing from metal tubing
/drill pipe and thereby saving the well as fibre tubing can be drilled
out later.
27. In case of a secondary job in a well with brine solution which is likely to
accelerate the cement setting time, sufficient care should be taken to
avoid stuck condition. Sufficient amount of preflush and after flush in
proportion ( minimum 100m ) to be pumped ahead and behind slurry
to avoid contamination. If brine weight is more than 1.09 sp gravity (9
ppg) used in the well for job it should be replaced with mud to avoid
acceleration of slurry.
h) Cement squeeze procedures

1. In case of squeeze jobs, injectivity must be checked before taking up
the job.
2. If an attempt is to be made to squeeze cement into perforations or
into a casing leak etc., and the cement opposite the place of squeeze
is to be drilled out later, injection rates should be established before
cement is squeezed. This should be done using a solids free fluid eg.,
water or brine. Acid may be spotted ahead of a squeeze job to break
up plugging mud particles.
3. Establishment of the injection rate is less important if the well is to be
abandoned and cement will not be drilled out afterwards.
4. If injectivity is not there, try to improve injectivity by acid wash
against perforated areas. Injectivity should be minimum 100 L/min at
1,000 psi in general.
5. In mud filled or partially plugged perforations where the injectivity is
very poor, one of the best ways to insure a uniform deposit of cement
is to pump weak hydrochloric or acetic acid solution ahead of the
cement as suggested by WSS expert. The acid shrinks the clay
particles and allows the cement slurry to penetrate farther.
6. High squeeze pressures which may induce formation breakdown
must be avoided, particularly in the vicinity of faults and stacked
reservoirs, in order to prevent zonal communication via vertical
fissures. The formation closure pressure should never be exceeded,
unless specific written orders to do so.
150
7. When a packer has been set just above the perforations or zone to be
squeezed off, the bottom hole pressure must be kept below 80 % of
the collapse pressure of the weakest casing in use. Changing the
setting point of the packer or applying back pressure may help to
increase the allowable squeeze pressure.
8. Annular back pressure should be applied in all cases having a
differential pressure across the packer greater than 1 500 psi.
9. The hesitation squeeze technique should be used in lost circulation /
high pressure zones to aid bridging of the cement solids.
10. Apply squeeze pressure in stages to achieve the desired squeezing
pressure. (shown in fig)
11. The simplest way to carry out a squeeze is to spot the cement
andsqueeze it by applying pressure while the annulus is kept closed.
However, a packer must be used if the pressure during the squeeze
will exceed the maximum allowable pressure at any point above the
planned depth of the cementation.
12. For small size of casings, plug length should be 100 m (preferably) to
avoid contamination.
13. In vertical wells 25 m plug above the perforation should be there after
squeeze, in case of horizontal wells it should be 50 m.
14. If predetermined top of cement plug is desired, after cement
placement and pulling out, OEDP may be placed at that depth and
cement may be reversed out accordingly. However appropriate
safety to be maintained to prevent cement stuck-up considering size
of hole/casing, thickening time etc.
151
Requirements
1. A consistent slurry gradient is particularly important in the case of
(small) cement plugs. The cement must be batch mixed or dumped
until the correct gradient is achieved.
2. Thin slurries with low fluid loss of less than 50 ml/30 min are used for
regular squeeze cementing jobs, to reduce premature slurry
dehydration during placement.
3. Thixotropic cement slurries may be used in zones where losses are
encountered.
4. Slurries designed for use in remedial cementation operations, will be
formulated such that:
Pumpability Time = Mixing Time + Slurry Displacement Time +
Circulating Out Time + 60 mins (Safety margin)
The laboratory will allow for the higher pressures applied.
Preparations
•In deviated wells with less than 30° hole angle, a viscous pill of
approximately150 ft length can be used as a bottom for the cement.
•If there are any perforations below that need to be protected from
the squeeze pressure and/or cement that might work its way down
the hole, a drillable bridge plug must be set approximately 20 ft below
the interval to be squeezed off.
Block cementation using a Cement Retainer
The following procedure should be adhered to when preparing for block
cementation (Circulation squeeze using a cement retainer):
•Perforation should be at least 25m above and below form the area to
be squeezed,
•Set a drillable cement retainer on drill pipe approx. 50 ft above lower
most the perforations to be squeezed off.
•Use preflush and after flush between slurry.
•Displace the batch-mixed cement until the first spacer reaches the
end of the stinger.
•Stab back into cement retainer immediately.
•Squeeze/ circulate away the cement at a constant bottom hole
pressure (BHP) 70% of the slurry.
•Pull out drill pipe from cement retainer approximately 50 ft. above
the upper perforations
152
•Reverse wash the string.

•POOH
Notes :
PUMP not more than 75 % of the total available slurry
In case mud weights measure more than 1.8 gm/cc block cementation not
to be attempted.
i) Well Abandonment Procedure

Well abandoning procedure is recommended to prevent pressure build up
or cross flow in the well and its surroundings in future. Abandonment shall
also prevent contamination of fresh water aquifers and leakage of any
well bore fluid to the surface.
There are two types of abandonment
1. Permanent
2. Temporary
Permanent Well Abandonment
Permanent abandonment is to be followed in the wells
1. Completed as a non-productive well
2. Ceases to produce hydrocarbons
3. No longer operated
•Bottom Abandonment Plug
•Open Hole Abandonment (Take extra height of cement plug to
ensure minimum plug length as below)
a. With Oil /Gas/Freshwater Zone
i. Place cement plug such that it covers
- minimum 30m below the bottom-most zone &
- 30 m above the topmost zone.
ii. If a caliper log is available, correct volume of cement plug should
be calculated and placed to cover the predetermined length of
cement plug.
iii. Tag the cement plug, load test with 8 MT of weight and pressure
test with 1,000 psi or upto LOT equivalent pressure at exposed
shoe.
iv. Place thereafter another cement plug such that minimum 30m
below the shoe and 30 m above shoe is covered.
153
b. With No Oil / Gas / Freshwater Zone:

i. Place cement plug such that minimum 30m below the shoe and
30 m above shoe is covered.
c. For Expected / Known Loss Zone:
i. Bridge plug is to be set 15m to 30m above last shoe followed by
50 m cement plug above.
•Cased Hole Abandonment
Place preferably 100m cement plug such that minimum 30 m above
the top of topmost perforation is covered after cement is set and
squeezed.
§Cased Hole Abandonment (earlier producing one):
a. Place preferably 100m cement plug such that minimum 30m
below the bottom of bottommost perforation to 30 m above the
top of topmost perforation is covered after cement is set.
b. If perforation interval is too big, isolation of all zones are required
or not, to be decided. If required place more than one plug.
c. Top most object in all cases is to be isolated by squeezing cement
slurry. Squeeze can be combined with cement plug placement
while isolating top most object.
d. If completion packer is not retrieved, perforation interval below
the packer is to be isolated first by squeezing cement through
packer and thereafter leaving a cement plug of minimum 30m
above packer.
•Intermediate Abandonment Plug
•For Well With Liner Cementation
In case well is completed with liner cementation in the final
phase, place 100m cement plug such that minimum 30m below
the liner hanger top to 30 m above the liner hanger top is
covered after cement is set.
•For Well with Retrieved Casing Leaving A Stub:
If casing is retrieved leaving a stub inside the previous casing,
place 100m cement plug such that minimum 30m inside stub
and minimum 30 m above the stub is covered after cement is set.
•For Offshore Well (additional safety):
In offshore exploratory well, place 100m cement plug in
production casing at 1,000m – 1,500m depth. Alternatively
154
bridge plug is to be set if top zone is already isolated by cement

plug/squeeze.
•Surface / top abandonment plug:
•For Onshore Wells:
Place 100m cement plug in such a manner that top of the cement
plug is within 60m below the mean ground level of that area.
•For Offshore Wells with Surface BOP:
Check 203 x 13-3/83 annulus and 13-3/83 x 9-5/83 annulus for
any activity. Fill both annuli with mud. Perforate 9-5/83 and 13-
3/83 casings 25m above 203 shoe position with 8 shots per
foot. Place a balanced cement plug of 100 m and closing BOP as
well as both the annuli, squeeze slurry up to 1,000psi. Retrieve 9-
5/83 , 13-3/83 and 203 casing from MLS.
Place preferably 100m cement plug in such a manner that top of
the cement plug is within 60m below the mud line level.
•For Offshore Wells With Subsurface BOP:
When well head is not retrieved and annuli are sealed by
energization, place a cement plug of 100m length such that top
of cement plug is at about 100m below well head.
Ø
Temporary Well Abandonment
•Place a bridge plug or minimum 100m cement plug at the base of last
casing string. Avoid open hole cement plug.
•Put another plug with top of plug not more than 300m below
wellhead / mud line. This plug may be any of the three types
1. Retrievable Bridge Plug / packer
2. Permanent Bridge Plug
3. Cement Plug of 100m
•Testing abandonment cement plug and others
For both permanent and temporary abandonment
Tag the cement plug, load test with 8 MT of weight and pressure test
with 1,000 psi wherever possible
The bore hole including the space between the cement plugs shall be
filled with drilling fluid of sufficient specific gravity and other
properties so as to enable it to withstand any subsequent pressure
which may develop in the bore hole.
155
j) Salient points of different types of Casing Cementation Jobs

Description Surface Casing Intermediate Liner Production
18-5/8” and 13-3/8”/ Casing (Intermediate/ Casing
above 9-5/8” Casing Production)
Shoe Type Float Type Float Type Float Type Float Type Float Type
(with side
ports)
Float collar For 20” size: Float Type Float Type Float Type Landing collar
Stab-in F/C for of same liner
casing shoe > hanger make
500m
(alternatively
stinger &
F/shoe may be
used)
Shoe track 15m cement Two casing 2 joints apart 2 joints apart
(distance to be left joints (3 joints for smaller size csg in
between inside above preferably deep well)
F/C and shoe
shoe)
Wiper Plug Preferably top Both top and Both top & Liner dart & Both top &
plug to be bottom plugs bottom plugs wiper plug of bottom plugs.
used preferably same liner (Two bottom
hanger make plugs & one
top may be
used for
critical job)
Annulus •
Annulus Caving Factor to be •
Slurry •
Slurry volume to be calculated
Caving taken as per earlier job volume: as as per caliper + 10%-20%
Factor (to experience in the same field per caliper •
Preferably four arm caliper
be •
Or else 10- 20% caving may be with 10% should be recorded
considered considered for surface rise. excess
for slurry •
If caliper is
volume not taken,
calculation) caving to be
considered
as per earlier
job
experience
in same field
or else
around 20%
over ideal
annulus
156

above 9-5/8” Production)
Casing
Centralizer 4-5 nos to be used ? 1 centralizer ?
Use centralizers as per
per joint for program ensuring minimum
first 5 joints 67% standoff.
&then
? 1 centralizer
after every
fourth joint
up-to
cement top.
Spirolizer Nil To be used to To be used to induce local
induce local turbulence against
turbulence ? caved section
against caved ? top and bottom of each zone
portion of interest
Mud N/A Rheology (Pv, After casing lowering, Pv, Yp and

properties Yp) to be filtration loss should be
(after maintained to maintained at minimum
casing optimum possible.
2
lowering) values Preferred Yp< 25 lbs/100ft
Gel break/ Only Circulation and ? Gel break for ? Gel break for 30 mins at the
Circulation/ conditioning for bottoms up. 30 minutes previous csg shoe.
Mud at the ? Additional gel break (5-10
conditioning previous min) if OH > 1000m.
casing shoe. ? Additional gel break (5 -10
? Final min) if poor returns are
circulation at observed during casing
bottom lowering.
? Final circulation at bottom (1 -
2 cycles)
Reciprocati N/A Preferred To be done for To be done
on of casing expandable till end of
Liner Hanger displacement
(Not feasible for
conventional
Liner Hanger)
?
3
Fresh Mud N/A In case of Oil Around 30 -35 M of freshly
based mud, prepared mud having the
entire annulus same drilling mud properties
volume may be to be used.
replaced with ? In case of Oil based mud,
fresh water entire annulus volume may
based mud be replaced with fresh water
based mud with fluid loss/
rheology control before
cementation
Pre-flush/ Water ? Pre-flush/ weighted spacer in water base mud
Spacer type below 1.40 SG.
? Weighted Spacer if mud weight > 1.40 SG.
? A set of spacers and pre -flush to be used in Oil
base mud system which should also change the
wettability of the formation and casing from oil -
wet to water-wet.
157

above 9-5/8” Production)
Casing
3 3
Pre-flush/ Water: For 7”csg/ liner: around 14.0 M (min 10.0 M )*
3 3
Spacer 6.0 m3 for 20”/ 18-5/8” For 5-1/2” csg : around 20.0 M (min 14.0 M )*
Volume 3.0 m3 for 13-3/8”/ 9-5/8” * subject to formation fracture pressure and pore
pressure limitations.
Major At the rate equivalent to that At maximum At desired rate to achieve
Displaceme used during drilling possible rate turbulence, depending on the
nt rate subject to size of casing/ liner and hole size
formation subject to formation fracture
fracture and pressure
pump pressure Desired minimum rate (for
limitation gauged hole):
> 3.0 m3/min for 9-5/8” csg
> 2.3 m3/min for 5½” csg
> 1.7 m3/min for 7” L/ csg
> 1.0 m3/min for 5” csg
WOC Decide WOC needed by the time required to Decide WOC needed by the time
attain 500 psi compressive strength of cement required to attain 2000 psi
slurry (as per UCA test for the cement slurry compressive strength of cement
used for the actual BHP/ BHST) slurry (as per UCA test for the
cement slurry used for the
actual BHP/ BHST)
k) Cementing Considerations for HPHT wells

Cementation of HPHT wells encounters a wide range of unique
challenges. The most common HPHT definition is when bottom hole
temperature exceeds 300°F (150°C) and/ or bottom hole pressure
exceeds 10,000 psi (69 MPa).
High temperature gives a sensitive effect to the cement slurry, especially
to the thickening time and cement rheology. The Plastic Viscosity and
Yield Point will decrease with an increase of temperature.
As the well depth increases, hydrostatic pressure will increase and so the
ECD (Equivalent Circulating Density) & vice versa and rise of temperature
will reduce ECD due to thermal expansion. In HPHT wellbore, it’s
suspected that high-temperature variation will give effect to expansion
and contraction of casing and plastic formation leading to crack in set
cement.
The cement design should consider a combination between silica,
retarders, weighting agent, extender, expanding additive, fluid loss agent,
casing eccentricity, mud removal and laboratory test, which will lead to
the objective of providing proper zonal isolation over the life of the well.
Following steps needs to be carefully planned/ executed:-
1. The Planning Process
158
2. Slurry Design
3. Spacer Design
4. Integrated Job Design
5. Good Cementing Practices— execution
In addition to the above mentioned broad features, following areas needs
careful attention:-
• Basic materials quality and suitability
• Equipment selection
• Liner Systems, hangers and running toots
• Cement Mixing
• Slurry Placement/mud displacement
• Contingency planning:-
Ø
in case of problems during the job
Ø
in case the job fails to secure the objectives, eg shoe leaksetc
1. The Planning Process
1.1 Equipment
1.1.1 Compressed air supply for bulk cement handling: –
Check that the air driers are working properly. Moisture
introduced into the bulk cement can seriously compromise the
slurry design and lead to very confused lab results because of
differences between rig samples and lab held samples which
have not been through the same exposure. This is particularly
true for blends, ie G+35%.
1.1.2 Cementing Unit
Ensure that cementing unit is ready for the operation. If
required, necessary service/ up gradation of fluid end to be
done.
1.1.3 Batch Mixture
Critical/ High density slurries should be batch mixed. Batch
mixture capacity should be sufficient to accommodate slurry
volume. Plan the pumping of the slurry accordingly.
1.1.4 Tool/ Kit
Darts, Plugs, liner hangers, running tools, sealing surfaces,
Packers, elastomers, etc, all require extra attention.
159
1.2 Hydraulics
Carry out simulation studies incorporating the well data and certain
assumptions to evaluate the effect of ECD during final circulation.
Optimization of volume and displacement rate to be done to
maintain the ECD within safe limit as per available formation data.
1.3 Casing Eccentricity
a) Proper Directional survey and four arms caliper are recommended
to determine a proper centralizer placement in critical wells.
b) Generally, for casing centralization, 70% standoff is considered
as the minimum requirement to have good cement bond as per
the latest guidelines.
c) Although, higher casing eccentricity does not significantly
increase the max von Mises stress in cemented wellbore casing
when using high-thermal property cements , but for low-thermal
property cements, it increase the maximum von Mises stress. It is
important to note that, casing eccentricity leads to reducing
cement shear stress and tensile stress, but on the other hand, it
increases cement compressive stress.
1.4 Temperature estimation
In high temperature wells, the standard API temperature equation for
determining cement circulating temperature (BHCT- the lab testing
temperature) from bottom hole static temperature (BHST) should be
viewed with caution.
API equation is not appropriate when the thermal gradient exceeds
1.9 DegF/ 100 ft (35 DegC/km). Therefore it is recommended to use
temperature simulator to predict cementing test temperatures
(BHCT) for HT wells where BHST> 300 DegF, (149 DegC) and/or the
thermal gradient >1 .9 degF/100 ft (35 degC /km.)
In exploration wells where thermal gradients are less certain,
computer modelling should also be used to interpolate logged
temperatures back to BHST. The more data and modelling, the better
the most likely temperatures can be bracketed and the appropriate lab
designs chosen.
1.5 Mud Removal
Mud removal planning is crucial in achieving proper cement
placement and strong cement bond in HPHT wells. The plans include
the
a) Conditioning of drilling fluid before cementing to remove gas
160
and cuttings, break the muds gel strength, and lower the mud
viscosity. For Bingham Plastic fluids, the higher the
dimensionless shear rate, the better circulation efficiency.
b) The important factors to achieve a good mud removal are: (a)
Improving pipe stand-off, (b) increasing Pv/Yp ratio, (c)
decreasing mud gel strength, and (d) increasing flow rate.
c) Use of preflush/ chemical wash/ spacer ahead of slurry to act as
a buffer between possibly incompatible mud and cement. To
avoid slurry contamination, at least 650 ft (200m) of spacer
ahead and 170 ft (50m) behind cement slurry to be maintained
for separation from mud during displacement. Difference
between spacer and mud densities and cement and spacer
densities should be around 10%.
d) To get effective turbulent flow, minimum of 1.33 m/sec annular
velocity should be considered.
e) Around 10 minutes contact time is recommended.
f) Use of mud removal tools such as scratchers.
1.6 Cementing Computer Program
Cementing operation could be optimized by simulating it first in
cementing computer program. It will give an overview of the proper
flow pump sequence, pumping schedule (include stage timing, flow
rate, volume for each fluid, worse depth scenario regarding collapse
and burst), and centralizer placement. It also gives ECD predictions
and the efficient displacement rate. The program can give
illustrations of pore and fracture pressure window, which help in
deciding the best slurry density, drilling fluid conditioning, spacer,
lead or tail slurry etc.
In critical well conditions, set cement sheath characteristics should
be analysed using advanced software. The software can quantify the
risk of wellbore set cement sheath failure by applying stress analysis
and sensitization criteria. The software analysis of radial and
tangential stresses can determine cement sheath performance in
compression, tension or both, enabling the design of the set cement
behind the casing.
1.7 Contingency Planning:
Make sure that contingency slurries are developed as the well
progresses. Setting any casing at deeper depth can have a profound
effect on the slurry design due to increased temperature and
161
pressure condition and may take a week of lab testing if pilot studies
are not already underway.
As contingency plan, Lab testing to obtain a suitable Kick-off plug/
plug designs for shoe squeezes should be made available
2. Slurry Design
Cement slurry system, pre-flush and spacer should be designed and
tested in the laboratory to fit the objective of the cementing job. When
mixing slurry, laboratory testing needs to be run to ensure that slurry
show the right properties at surface and down-hole conditions. Mixing
sequence/ technique need to be followed since some of the additives are
sensitive to shear. Laboratory tests simulated at appropriate period of
ambient pressure and temperature to provide proper mixing energy. The
slurry should be tested ± 50°F from targeted BHCT (Bottom Hole
Circulation Temperature).
Key areas to be considered in designing an HPHT cement slurry are:
• Bulk cement sampling
• Temperature
• Cement selection
• Additive selection:
Ø
Retarder
Ø
Fluid Loss Aid
Ø
Silica
Ø
Weighting Agent
Ø
Gas Migration Control
Ø
Other additives
• Slurry Sensitivity
2.1 Bulk Cement Sampling:

HT wells will require silica, most commonly dry blended silica flour.
For lab testing, samples should be collected from three sources viz.,
(i) individual samples of cement and silica,
(ii) sample taken from the bulk blending plant and
(iii) samples brought back from the rig
The samples should be properly packed (Containers must be
moisture proof and airtight, full and uncontaminated by anything)
with the lids marked with well name, date etc.
162
2.2 Temperature
2.2.1 Bottom hole circulating temperature
Bottom hole Circulating Temperature (BHCT) is the
temperature that influences the thickening time or
pumpability of the cement slurry. The BHCT is normally
calculated from a set of temperature schedules published in
API RP 10B.
However, for cementing deep wells, temperatures should be
verified by some form of actual down hole measurement,
preferably during the circulation phase.
2.2.2 Bottom hole Static Temperature
Knowing the bottom hole static temperature (BHST) is
important for designing and assessing long term stability or
rate of compressive strength development of a cement slurry.
Determining BHST is especially important in deep well
cementing—where the temperature differential between the
top and bottom of the cement can be high and cement slurries
that are designed for safe placement at times may be over
retarded at top-of-cement (TOC) temperatures, resulting in
poor compressive strength development. Generally, if the
BHST at the top of the cement column exceeds the BHCT, over
retardation is not expected.
2.3 Cement selection
High temperature cementing jobs are generally performed with API
Class G or Class H cement. Wherever possible in HPHT cementing, a
recognised high quality well cement with a track record at such
conditions should be used.
Cements with non-linear response to retarder concentration should
be avoided.
The API Specification does not address suitability for HT conditions.
For slurry density > 2.1 SG (17.5 ppg) at BHST above 300 DegF (149
DegC), the reactivity of some cements can make the slurry very
difficult to retard at high temperature and difficult to disperse
thereby affecting slurry rheology and amount of weighting agent
required to create a pumpable slurry.
163
2.4 Additive Selection

2.4.1 Retarder (Thickening Time)
Proper amounts of retarder must be blended with the cement.
In deep wells, differential static temperature between top and
bottom of cement column can exceed 100°F (55 DegC).
Retarder has varying sensitivity levels to temperature. Hence,
small temperature difference can cause significant changes in
thickening time. Higher dose may delay the setting process
which in turn may lead the entry of gas into the cement in high
pressure wells. For extreme temperature conditions,
thickening time should be measured with ± 10% of the
retarder concentration.
A lignosulphonate high temperature retarder or synthetic high
temperature retarder is usually used. In general, for wells
where the BHCT exceeds 230 DegF (110 DegC) and the use of
highly refined or synthetic or chemical retarders is preferred.
For HPHT wells recommended Thickening Time Policy is
maximum of:
• Job time + 2 hrs
• Job time x 1.5
• 8 hrs
(Thickening Time does not include batch mixing time)
2.4.2 Fluid Loss Control
Maintaining constant fluid loss in HPHT well is necessary to
preserve the chemical and physical characteristic of the
cement slurry, especially due to differential pressure on top
and bottom-hole in deep wells. On the other hand, it needs to
prevent the development of filter cake that could cause
bridging in the annulus. Fluid loss is crucial, especially in deep
wells having long string casing due to narrow clearance
between wellbore and liner.
For high temperature application, the latex based fluid loss
additives are widely used, the advantage being that latex does
not viscosify adversely.
164
The design criteria for fluid loss control for HPHT cementing
operation are linked to dynamic filtration rather than static
filtration. Conditioning with stirred fluid loss cell is mandatory.
Recommended API Fluid Loss (For HTHP wells) < 50 ml/ 30min
2.4.3 Silica
Above 230°F (110 degC), commonly used Portland cement
may shrink, lose strength, and gain permeability, which can be
minimized/ prevented by adding at least 35 % silica.
In HPHT wells, changes in down hole temperature and
pressure in later stage can crack or even shatter the cement
sheath; radial pressure/temperature fluctuations can create a
micro annulus. To avoid such failures high temperature
flexible cement having lower Young’s modulus should be
used. Use of combination of Class G cement with 40% silica
flour, prevents mechanical strength retrogression and also
provides retardation property.
Two forms of silica are normally available:
• Silica flour (fine)
• Silica sand (coarse)
The minimum concentration of silica added to cement should
be 35%. However studies have shown advantages when using
silica sand (coarse) of raising this to 50%.
Silica flour must be pre-blended with the cement. Where large
slurry volumes are to be pumped, pre-blended silica is only
practical option. Where slurry volume permits batch mixing,
use of sand in tote bins is preferred to minimise the risk of
sampling and ensuring accurate silica content in the final
slurry pumped.
Pre-blending of silica with cement adds a significant risk as the
bulk is often not fully homogeneous and sampling errors can
occur. With subsequent transfers, the blend becomes more
homogeneous. However, it may undergo some changes
(aeration) due to moisture in the compressed air transfer
system. Therefore, samples taken from a blend at the yard
may not match those taken at the rig. A 5% variation in the
165
flour content of a blend can have a substantial impact on the

retarder response and requirement.
2.4.4 Weighing Agents
It is crucial to maintain hydrostatic pressure in the well to
balance or exceed the formation pressure. Cement slurry with
density over 16.5 ppg (1.98 SG) require a weighing agent.
Effectively there are three possible weighing agents:
a) Barite (4.15 SG)
White powdery Barite requires additional water to wet its
particles. Slurries with densities up to 19.0 ppg (2.28 SG) can
be prepared with Barite. Barite is the most readily available
and lowest cost but is not suitable due to particle size and
usual chemical impurities.
b) Haematite (4.90 SG)
Red crystalline granules Haematite is very efficient weighting
agent, it could overcome many of the shortcomings of barite.
Dispersant is often used to prevent excessive hematite slurry
viscosity. Haematite is used to prepare slurries with density as
high as 22 ppg (2.64 SG). However, the density difference and
coarseness of the haematite requires careful slurry design to
prevent haematite differentially settling from the slurry.
Where slurry volumes permit the use of batch mixing, the
haematite should be added to the batch mixer instead of pre-
blending with cement. Where pre-blending has been used,
separation of haematite during pneumatic transfer has been
observed and obtaining a representative sample of a 3
component dry blend presents a further difficulty.
c) Manganese tetroxide (4.68 SG)
Reddish-brown powder Manganese Tetraoxide is of very small
size particles (average 5 µm), significantly greater particle
surface area than other weighting agent, provide a better mix,
especially when well control is one of the issues. It has lesser
tendency to settle than hematite and can be added directly to
the mix water without severe settling.
Combination of Haematite and Manganese tetraoxide can be
166
prepared to have slurries densities as high as 22 ppg (2.64 SG).

Slurries containing manganese tetraoxide typically develop
higher compressive strength than other weighting materials,
but sometimes with short thickening time.
2.4.5 Gas Migration Control:
It is very important to control the flow of influx after
cementing for deeper high pressure oil and gas wells. Most of
the gas channelling in cement column occurs during a
transition period from liquid to solid, adding latex additives
help to delay cement pore pressure drop and shortened
transition time between liquid and solid stage.
To prevent gas migration, slurry modification could be done by
decreasing fluid loss, extend zero gel time, reduce transition
time adding gas influx preventing material and increase slurry
compressibility. Job design changes could be done by
decreasing effective column height, increasing overbalance
pressure, interfering with gelation process and drilling a larger
diameter hole.
2.4.6 Other Additives
Other additives used in HPHT slurry designs include:
• Dispersants (for mixability and rheology)
• Anti-foam (to reduce air entrainment during mixing)
• Anti-settlement aids(to prevent solid and/or liquid
separation
• Synergistic additives (which may support other
additives e.g. retarder aids)
2.5 Slurry Sensitivity
In most cases additives for HPHT slurries are being used at the upper
end of their design limits. As a consequence the slurry properties are
much more likely to be influenced by changes in:
• temperature
• mixing/shear
• additive concentrations
• Slurry Stability
167
• density
• additive order of addition
• contamination
• Sensitivity testing (additional TT test to the expected conditions)
The impact of each of these on the slurry design should be assessed.
2.5.1 Sensitivity to Temperature:
Once BHCT has been determined, the thickening time of slurry
should be obtained for 15 DegF (8.3 DegC) hotter than BHCT.
The compressive strength should also be determined for a test
temperature 15 DegF (8.3 DegC) lower, or at liner top BHST
whichever is cooler. If no set is seen in 36 hours retarder
selection should be re-addressed.
2.5.2 Mixing / Shear
Cement slurry properties can be affected by both the time
they are held on surface after mixing and the mixing energy
they receive.
When a slurry is designed for an HPHT application, it should be
mixed and then held at room temperature and pressure
simulating the holding time expected on surface (during batch
mixing). Some cements have been shown to have 6 hour pump
times at high temperature but to exhibit significant viscosity
rise when held at low temperature and pressure. Any rise in
consistency above 30 Bc during this surface conditioning
should be redesigned.
2.5.3 Additive Concentration
The thickening time should be determined for retarder
concentrations ± 5% of that in the expected design.
Acceptable slurries have:
•Pump times which decrease with less retarder and
increase with more retarder.
•with 5% less retarder Pump time > job time
•with 5% more retarder Pump time < 2 x base slurry TT
If the slurry is to be mixed continuously, it is advisable to use a
cement batch tank to prepare the mix water, unless assurance
can be obtained on cleaning the pit and lines to prepare mix
water.
168
2.5.4 Cement slurry Stability

• Conditioning in HPHT consistometer or cured in HPHT
curing chamber
• If well deviation is below 15 deg - Free Fluid test is run
vertical
• If well deviation is above 15 deg - Free Fluid test is run at 45
deg
• Free Fluid = Zero
• (Static) Sedimentation test: less than 5 % deviation from
theoretical cement slurry density
• Dynamic Settling Test: The SG of cement is measured from
the top, middle and bottom of the consistometer cup after
the cement has set.
• Go/ No-Go Test - Consistency spike after motor shut off:
below 70 Bc, Also simulates dropping the top plug or the
shutdown period prior to sting-out of the liner and
circulate/reverse circulate.
2.5.5 Density
Slurry density is critical for both well control and slurry
performance. Pumping the slurry light may increase the
susceptibly to settlement of the weighting agent, pumping it
heavy may reduce the thickening time. The slurry should be
pumped after checking with a pressurised mud balance
(calibrated at the appropriate range).
2.5.6 Additive Order of Addition
Slurry sensitivity has been shown to be affected by different
orders of addition of additives. To prevent this affecting
performance, the laboratory should document the order used
during slurry design and this should be included on the slurry
recommendation&followed when preparing mix water in the
field.
2.5.7 Contamination
The impact of contamination by mud and/or spacer can have a
substantial impact on slurry pumping time and rheology. The
thickening time of the slurry should be confirmed with a 10%
contamination of both mud and spacer.
High solids content of high density spacers can reduce pump
169
time of the slurry even at low levels of contamination. If this

occurs in the lab, it is recommended that a similar
concentration of retarder is included in the spacer.
In case of liner, if the mud has a dramatic effect on pumping
time, spacer should be pumped ahead of and behind the plug
to prevent mixing. Additionally, care must be exercised when
pulling out from the top of liner to minimise fluid mixing.
2.5.8 Sensitivity testing (additional TT test to the expected
conditions):
• At maximum BHCT
• Minimum BHST for the CS at top of the liner
• Minus 5% retarder concentration or 0.02 gps whichever is
greater (Same for retarder aids)
• Plus 5% retarder concentration or 0.02 gps whichever is
greater (Same for retarder aids)
• Plus 0.25 Ibm/gal slurry density
• Minus 0.25 lb/gal slurry density
3. Spacer Design
On HPHT wells, both water and emulsion spacers (with OBM) have been
used. The main areas of concern with spacer design are:
• spacer stability
• selection of weighting agent
• rheology
• compatibility
3.1 Spacer Stability
The ability of the spacer to support the weighting agent on surface
and under down-hole conditions should be confirmed. This is
particularly critical where pore and fracture gradient margins result
in spacer density being very close to mud weight. The ability to
support the weighting agent at surface should be confirmed in the
laboratory by leaving a volume of spacer static for 2 hours in a
measuring cylinder using the Free fluid procedure used for testing
Well Cements (API Specification 10B). (Prior to pumping, the density
should be confirmed with a pressurised mud balance).
The stability down-hole should be assessed using the BP settlement
tube and determining any free fluid after leaving for a minimum of 4
hours under down-hole conditions.
170
3.2 Spacer Rheology

In many cases the ability to achieve turbulent flow of the spacer, or a
density hierarchy between the spacer and the drilling fluid is
compromised, due to the small difference between pore and
fracture pressures, rheology of the spacer and pipe movement will
be the only available methods for achieving good mud displacement.
To optimise spacer rheology it should be determined at simulated
down-hole temperatures (along with the mud) to ensure effective
mud displacement. Surface rheology measurement should also be
taken to provide a quality control step on the rig.
3.3 Spacer Contact Time
The time the fluids are in contact with a section of casing and
formation will directly influence the displacement process and the
amount of drilling fluid displaced. The minimum recommended fluid
volume and contact time vary somewhat according to specific
conditions. Generally, total contact time of all displacing fluids should
approach 10 minutes, with the displacing fluids pumped at the
highest velocity possible while still maintaining well control.
When weighted, water-based drilling fluids are used, reactive flushes
and spacers can help control gas leakage, bonding, and lost
circulation problems. For oil-based drilling fluids, a set of spacer/ pre-
flushes is recommended.
3.4 Spacer Compatibility
It is critical that the compatibility of the spacer is confirmed with both
the mud and the cement. Using a range of mixtures (as a minimum
95/5- 75/25- 50/50- 25/75- 5/95), the rheology should be
determined at BHCT (or 190 degF/ 88DegC if BHCT not practical).
10 minute gels should also be included. If the 100 rpm is 25% greater
than the highest 100 rpm reading of the uncontaminated fluids, the
spacer design should be reviewed. If plastic viscosity/yield point or
10 minute gels suggest the slurry may become unpumpable, or
separate into one or more phases, the spacer design should be
changed. In addition, the thickening time of the cement with spacer
contamination as described in above must be determined.
Compatibility problems have occurred occasionally with heavily
treated water-based drilling fluids. Oil-based drilling fluids pose
additional problems during cementing operations because they
frequently exhibit poor interfacial compatibility with water-based
171
fluids. There is a potential to form interfacial mixtures that can be

extremely viscous and non pumpable. An oil film remaining on the
pipe surface from the drilling fluid can hinder a good cement-to-pipe
bond.
General
1. STANDARDS GIVEN IN THE OSID STANDARD MANUAL (175) MUST BE
FOLLOWED WHEREVER APPLICABLE .
2. Cement job simulation software must be run for the production
casing cementation to determine the following:
a. Optimization of centralizer program.
b. Effective design and use of preflush and spacer .
c. To know the limits of Dynamic and static well security.
d. To engineering the displacement rates.
3. Practice of conducting extended LOT in deep / HP wells and in well
with narrow pressure margins.
4. Mention about conducting of pre-job safety meeting on every
pumping /testing job using cementing unit in addition to cementing
jobs.
172
Installation of Well Head
8 Installation of
Well Head
A wellhead is the equipment installed at the surface of an oil or gas well

that provides the structural and pressure-containing interface for the
drilling and production equipment.
The primary purpose of a wellhead is to provide the suspension point and
pressure seals for the casing strings that run in the well.
After cementation, casing head is fitted on the surface casing. It is the first
well head component to be installed on a conventional well and serves as
a connection between surface casing and BOP stack during drilling and
then to other well head components fitted subsequently. It has a bowl to
accept a casing hanger to suspend the intermediate casing.
This chapter covers the following aspects of well head operations :
a) Installation of casing head(Section-A)
b) Installation of casing spool (Section-B and C)
c) Pressure Testing of Well Head
a) Installation of casing head (Section-A)
There is fixed clearance between rotary beams and ground level in a
drilling rig which is required to accommodate all well head sections, BOPs,
adaptor flanges, drilling spools and riser nipple. Hence, installation of the
surface casing head (Section-A) at appropriate height within cellar pit is of
utmost importance as any improper cut may lead to complication in
accommodating other wellhead and BOP components.
The following procedure is to be adopted for land rigs:
1. Remove false conductor.
2. Cut surface casing at a measured height from the bottom of the
cellar pit. The height is calculated as follows:
Measure heights of all the well head components except the tubing spool
and make a mark on the surface casing measuring from the top of the
cellar pit. First make a rough cut approximately 10cm above the mark, and
then the final cut can be made for dressing and chamfering.
173
C-Section Z
H
B-Section Y
X
A-Section
Point of final cut
on surface casing
Surface Casing
To be cut Bottom of cellar pit
Typical 4-CP Wellhead Hook-up

For example, considering a 4-CP well head, length of the casing to be cut
from top of the cellar pit can be obtained from the following formula:
H=X+Y+Z
Where;
H- Height of the casing to be cut from top of the cellar pit
X- Height of Casing Bowl section 'A'
Y- Height of Well head section 'B'
Z- Height of Well head section 'C'
3. The marks are put all around the casing at a number of points and
then a circular mark is put all around.
4. Cut casing and chamfer properly on the inside,
•The weld-on housing of the casing head (Section-A) is placed on
the cut casing and is kept perfectly horizontal using spirit level
and welded from both inside and outside after preheating using
the recommended high pressure welding electrodes.
Note: Use low-hydrogen arc-welding rods #E7018 or #8018-C3 when
welding API H40, J55 or K55 casing to the casing bowl. Use low-hydrogen
arc-welding rods #8018-C3 when welding API L80 casing to the casing bowl
174
5. The welded casing head housing is allowed to cool normally (Do not
use water to cool casing).
Weld OnFlange
Inner Welding Lap
Test Port
Top of
final
cut casing
Outer Welding Lap

Sectional View of Weld On Type Casing Head
showing Inner & Outer Welding Lap
Table-1: Types of casing heads (Section-A)generally available

Size top flange of Working Used with casing
casing head Pressure PSI
(Nominal bore)
8" 2,000 7-5/8" or 8-5/8"
3,000
10" 2,000 9-5/8" or 10-3/4"
3,000
5,000
12" 2,000 11-3/4" or 11-3/8"
3,000
13-5/8" 5,000 11-3/4" or 13-3/8"
16" 2,000 16"
3,000
21-1/4” 2,000 20” or 18-5/8”
3,000
175
Slip on welded bottom casing head housing is shown below:

This type of housing is equipped with a
socket weld preparation which slips
over the casing and has provision for
welding the top of the casing to the ID of
the housing and also for welding the
bottom of the housing to the OD of the
casing. Same housing can be used over
all the weights and grades of a particular
size casing. Test port is provided to test
the integrity of welding. Housing/bowl
flange should be aligned with respect to the cellar pit.
Outlets on the Casing Head Housing
Outlets are provided on the casing head housings for access to the
annulus. Threaded outlets, flanged outlets or a combination there of are
available. Either one or two outlets can be provided.
b) Installation of casing spool (Section-B and C)

Once intermediate/final casing is run and cemented, after WOC following
activities are to be performed :
i. Unbolt and lift BOP
ii. Land casing and set slip
iii. Lay down 21-1/4” BOP (Only in case of 4-CP wellhead)
iv. Installation of primary and secondary packer
v. Install casing spool (section-B/C)
In view of safety, after cementation, all activities such as unbolting and
lifting of BOP must be done only after ensuring surface sample of cement
is set (at temperature as close as possible to Bottom Hole Circulating
Temperature) as any unexpected annular activity due to setting of cement
will be a safety threat.
i. Unbolt and lift BOP
1. Have 2 heavy duty hammers available on the rig.
2. Use correct size of hammer wrench for opening nuts of flange
connections in criss-cross pattern and store nuts in a safe place.
Hammer wrench of mm size should not be used on inch size
nuts and vice versa.
176
3. Ensure BOP is lifted without jerk with slings and shackles of rated
load capacity that are in good condition.
4. Ensure that BOP is secured properly in a tripod.
ii. Land casing and set slip
1. Make sure that casing is centered. Place the slip around casing
pipe using all 4 eye bolts carefully so that it remains at the same
level to avoid jamming of slip and eccentric setting.
2. While using housing type slip, Allen bolts should be loosened just
enough to make sure that dies are moving just freely.
3. While setting the slip, ensure that uncemented casing pipe
remains in tension after setting slip (Refer Section-(f) 'Casing
Landing Practices' in Chapter: 'Casing Operations') and the slip is
set properly with top of the slip at same level all around the
casing.
4. Rough cut on casing should be made about 15” above the top of
flange and remove the cut pipe.
Slip Seal Casing Hanger Casing Slips

(Type BCMBFNS) (Type BCMBNS)
Courtesy : BHEL
iii. Lay down 21-1/4” BOP (Only in case of 4-CP wellhead)

1. 21-1/4” BOP is installed only in 4-CP wells and is to be laid down as the
next phase requires 13-5/8” BOP stack.
2. Take extra care to lay down 21-1/4” BOP with crane with special
attention on slings as breaking of slings may result in injury to rig crew
and damage to BOP.
177
iv. Installation of primary and secondary packer

Installation of Primary Seals
1. Make final cut on the casing such that:
Height for final cut= Total height of both the pressure plates with
secondary lip seal in between in the assembled positions above the
top of flange.
2. Remove burrs and chamfer the top of cut pipe.
3. Install the lower pressure plate with the flat face at the bottom over
the casing and into the body counter bore.
4. Thoroughly clean and lubricate the casing with oil and install lip seal
with proper care. Care must be taken to avoid damage to the lips of
the rubber packing.
5. Drive the packing down until it is flush with the lower pressure plate.
6. Install the upper pressure plate with flat surface facing up.
Installation of Secondary Seals
Upper Steel PressurePlate
Secondary Rubber LipSeal

Packer
Lower Steel Pressure Plate
Secondary Packer Assembly

1. Install the lower pressure plate with
the flat face at the bottom over the Secondary Packing Support
Secondary Lip Seal Packing
casing. Secondary Packing Support
2. Install the secondary seal with its lip

face up over the casing.
3. Thoroughly clean and lubricate the
casing with oil and install lip seal with
proper care. Care must be taken to
avoid damage to the lips of the
rubber packing.
Primary Packing Support
4. Drive the packing down until it is Primary Lip Seal Packing
flush with the lower pressure plate. Primary Packing Support
178
5. Install the upper pressure plate with flat surface facing up.
v. Install casing spool (section-B/C)
1. Carefully lower the casing spool over the secondary lip seal to avoid
damage to lip seal
2. Install all studs with nut and tighten in criss-cross pattern to
recommended torque. Do not use oversize hammer wrench as it may
round off nuts at edges.
c) Pressure Testing of Well Head:

§Testing – Weld on Bowl
1. Remove the ½” LP plug from the casing bowl.
2. After cooling of welding joint, the welding seal is to be tested
preferably with N2 through the test port to the minimum of:
o maximum anticipated surface pressure from the next phase or
rated working pressure of the flange or
o 80% of the casing collapse pressure.
§Testing- Casing spool/ Tubing Spool
1. Casing spool or tubing spool is tested by connecting test pump to
the test port on the lower flange of spool.
2. Carry out pressure test at rated working pressure of lower flange
of spool or 80% casing collapse pressure whichever is less.
§Testing of Primary and Secondary Seals
After installing different parts of a well head, testing is carried out to
determine the pressure integrity of the field installed seals and
connections.
The testing should consist of
1. Primary pressure holding period
2. Followed by bleeding off pressure
3. Secondary pressure holding period.
The pressure holding period should be 5 min.
The maximum allowable test pressure should not exceed the lowest
pressure determined from the following:
(A) Rated working pressure of lower flange of connection.
(B) Rated working pressure on primary seal.
(C) Collapse pressure of casing pipe after taking into consideration
safety factor.
179
Casing spool Tubing Spool
Test Port
The two flanged connections of well head equipment are joined together
with studs and nuts with a steel ring gasket in between. The test port is
provided in the lower flange of a casing or tubing spool to pressure test
the sealing area of the ring gasket, the primary packing group and the
secondary packing group. 1/4" NPT ball check valve is installed behind
1/2" NPT plug to allow the safe removal of 1/2" pipe plug when checking
for a leak between cross over seals.
Note : The above test procedure is for BHEL well heads. The
manufacturers' manual may be referred for other make of well heads.
Test Procedure
1. Remove 1/2"plug and check valve provided at the outlet of the test
port and make connection of the test pump at the test port.
2. Open valves in the annulus of the casing head housing or casing head
spool as the case may be.
3. Start pumping water with the help of hand operated hydraulic test
pump.
4. Carry out low pressure (300 psi) and high pressure test at rated
working pressure of lower flange of spool or 80% casing collapse
pressure whichever is less.
5. Hold the pressure for 5 minute after pressure stabilization subject to
maximum drop of 5% of the test pressure. If so, the test of primary and
secondary seals and the steel ring gasket is considered OK.
6. If there is drop in pressure, check for the leakage point:
•
If the leakage is in between the flanges, ring gasket is not holding
and the flanges should be retightened and tested again. If leakage
persists, change ring gasket. Test again.
180
•
If the leakage is observed from the
side valve in the annulus of casing,
the primary seal is not holding, the
flanged connection should be
separated out and the seal and the
sealing surface to be checked.
Replace the seal if damaged. Test
again.
•
If the leakage is observed from the
top, visible on seeing with the help
of a torch, the secondary seat is
not holding, the flanged
connection should be separated
out and secondary seal and the
sealing surface to be checked. A Typical 3-CP Well
Replace the seal if damaged. Test Head Configuration
again.
A Typical 4-CP Well Head Configuration
181
Directional Drilling
9 Directional
Drilling
Directional drilling is the process of drilling a curved well, in order to reach

a target that is not directly beneath the drill site. Directional drilling is
employed in circumstances where the area above the targeted deposit is
inaccessible such as reservoirs that exist under shallow lakes, protected
areas, railroads, or any other area on which the rig cannot be set up. It is
also useful for long, thin reservoirs which are not efficiently produced
with a vertical completion. Horizontal entry into the reservoir allows it to
be drained more efficiently. Directional drilling is especially useful for
offshore locations where cost of offshore drilling rigs can make it
uneconomical to drill a single well. With directional drilling, the offshore
rig can gain access to deposits that are not directly beneath the rig and
many wells can be drilled from a single location, making it much more cost
effective to drill offshore and also onshore.
This chapter deals with various tools and techniques utilized in directional
drilling as follows:
a) Conventional direction drilling survey tools
b) Positive Displacement Mud Motors (PDMM)
c) Measurement While Drilling (MWD)
d) Rotary Steerable System (RSS)
e) Time Drilling for Sidetrack
183
a) Conventional Direction Drilling Survey Tools
Mule shoe used for

alignment of bent direction.
Universal Bottom Hole

Orienting sub (UBHO)
used for Orientation
Bent sub used for

deviating the well from
vertical in conjunction
L1 L2 with mud motor
Angle of bent sub
Tan b = ( L 1 -L 2 )/d
d =OD of bent sub

b
b) Positive Displacement Mud Motors (PDMM)

PDMM is a tool which converts hydraulic energy of drilling fluid into
mechanical energy and rotates the drill bit to drill and deviate the well
bore without rotating drill string above it.
184
PDMM Basic Design
Top Sub
Power section
Transmission assembly
Surface Adjustable bend
Bearing section
Drive Shaft
PDMM are denoted as “a:b” lobes and “n” stages where “a” is lobes in
rotor and “b” is lobes in stator and “n” is no of stages, for example 4:5
lobes and 3.4 stage
•More lobes = More torque, Lesser RPM
•Lesser lobes = Higher RPM,Lower torque
•More stages = More torque, More pressure drop across motor
•Lesser stages = Lower torque, Lower pressure drop across motor
•Torque is proportional to pressure drop and RPM is to discharge.
185
In order to get the best performance and optimum life of mud motors, the
standard procedures mentioned below should be followed during
operation. Slight variations may be required with changes in drilling
conditions and drilling equipment, but efforts should be made to follow
these procedures as closely as possible.
Assembly Procedure & Surface Check Prior To Running in Hole
Preliminary checks should be completed without a bit attached to avoid
potential damage to bit, motor and BOP. A thread protector should be
installed in the bit box of the motor whenever handling the motor on
surface but must be removed before flow testing.
1. The lift sub supplied with the mud motor should always be used for
handling and making up of the motor. Also make sure the
connection between the lift sub and the motor is tight.
2. To lift the motor to the rig floor, use a winch line secured to the lift
sub if crane is not available. Pick up the mud motor with the
elevators and set it into the slips of the rotary table. Install the dog
collar/safety clamps.
3. Apply rig tongs only on the designated areas of the mud motor. All
connections marked “NO TONGS” on the motor are torqued in the
service shop. Further make-up on the rig floor is not necessary and
if attempted may cause damage to it.
4. Remove the lift sub and connect the Kelly to the mud motor,
remove the safety clamp, and lift the motor out of the slips.
Remove the thread protector from the bit box of motor and inspect
the threads for any damage.
5. Always put a screen in the DP/X-O box before connecting Kelly.
6. Lower the mud motor until the dump sub ports are below the
rotary table, yet visible.
Caution: The dump sub valve will remain open until there is
enough fluid pressure to close it. Therefore, the mud motor should
be lowered until the ports are below the rotary table before
starting pump. This will prevent the initial flow of drilling fluid from
splashing on the rig floor.
7. Slowly start the pumps and ensure drilling fluid is flowing out of the
dump sub ports. Increase the flow rate until the dump sub ports
close and drilling fluid stops flowing outof dump sub ports. Record
the circulation rate and standpipe pressure.
186
Caution: Do not exceed maximum recommended flow rate for this

test.
8. Lift the mud motor until the bit box of motor becomes visible. It
should be rotating at a slow and constant speed. Listen to the
bearing section of the motor for excessive bearing noise, especially
if the tool has been used previously without being serviced.
9. Before stopping the pumps, the mud motor should be lowered
below the rotary table and check that drilling fluid flows out of the
dump sub ports after shutting down the pumps. It is possible that
the dump sub valve remains closed after this test due to a pressure
lock. If this occurs, no drilling fluid will flow out of the ports. To
remove the pressure lock, bleed off some stand pipe pressure and
the valve will open.
10. After this surface check, the bit should be attached to the motor
using a bit-breaker under the guidance and presence of service
company engineer and directional drilling engineer.
11. If the mud motor has been used previously, an overall inspection
should be completed. Inspect for seal integrity by cleaning the area
above the bit box and visually checking for lubricating oil leakage or
seal extrusion. General visual inspection of the entire motor
should be carried out to check for housing damage or loose
connections.
12. Non Magnetic Drill Collars (NMDC) are to be tightened only upto
the exact torque value. Excessive tightening and also prolonged
jarring result in magnetic hot-spots in tool joint area.
13. The adjustable assembly or bent sub is set to the desired bend.
Break joints with tong Lift adjusting ring Match angle and tighten lock housing
187
14. Check the bearing condition and note down the gap of thrust
bearing for wear. Acceptable bearing wear tolerance are as
below
Hang the PDMM freely, measure distance D1 between lower end
of bearing housing and drive sub. Set PDMM down on the rig
floor measure the same distance as D2. Calculate (D1-D2)
Table-1: Tool Size (OD) and Maximum Tolerance

Tool Size OD Max Tolerance
(inch) (D1-D2)
mm inch
2-3/8 1.68 0.066
2-3/4 2.49 0.098
3-3/4 3.99 0.157
4-3/4 3.99 0.157
6-1/4 5.99 0.236
6-3/4 5.99 0.236
8 8.00 0.315
9-1/2 8.00 0.315
11-1/4 8.00 0.315
Tripping with PDMM

1. The drill string should be tripped with the travelling block hook
unlocked and special care must be taken when passing through BOP,
casing shoe, liner hanger top , bridges and while nearing bottom.
188
2. Tight spots should be cleared by starting the pumps and reaming

slowly at manufacturer’s recommended RPM for the motor and bent
setting. Great care should be taken during these operations.
3. When tripping to deeper depths, or where hole temperatures are
high, periodic gel break circulation is recommended. This prevents
bit plugging , aids in cooling the mud motor and high temperature
damage.
4. Mud circulation through a mud motor inside casing should be
avoided while using PDC bit, as this may damage the bit cutters and
casing.
Drilling
After the assembly has been tripped to the bottom of the hole, mud
motors should be operated in the following manner:
1. With the bit 1-2 meters off bottom, start the pumps slowly and
increase to desired flow rate. Do not exceed the maximum rated flow
rate for the mud motor.
2. Record flow rate and the total pump pressure. Note that the pressure
may exceed the calculated off bottom pressure due to some side load
effects between the bit and the bore hole.
3. Torque can be affected by poor hole cleaning and it should be
thoroughly cleaned prior to orienting. Hole fill may be cleaned by
slowly rotating the mud motor full circle. This prevents ledge buildup
and side tracking.
4. Orient the drill string as desired, lock rotory and lower the bit
carefully to bottom and slowly apply further weight onto the bit.
Pump pressure will rise as the weight on bit is increased. Record the
change in system pressure between the off bottom and on bottom
values. This will be the differential pressure. Try to drill with steady
differential pressure by keeping a steady flow rate and constant
weight on bit.
5. Adding weight on bit will cause both the differential pressure and
torque to increase. Similarly, reducing weight on bit will reduce both
the differential pressure and the torque. Therefore, the rig pressure
gauge enables the operator to monitor the performance of mud
motor.
6. Applying excessive WOB may cause damage to the on-bottom thrust
bearings. Similarly, applying excessive tension while being stuck may
cause damage to the off-bottom thrust bearings. Follow the
189
instruction of the engineer or refer to the manufacturer

specifications for the recommended maximum loads for these
conditions.
7. Optimum differential pressure can be determined by monitoring
motor performance, penetration rate, and drilling requirements.
Also, maintaining a constant differential pressure assists in
maintaining orientation of the drill string.
Reactive Torque in PDMM
1. Mud motors drive the bit with a right-hand (clockwise) rotation. As
weight is added to the bit, reactive torque acting on the drilling motor
housing is developed. Therefore, this reactive torque must be taken
into account when orienting the drilling motor from the surface in the
desired direction. As a rule-of-thumb 5" drill pipe will turn about
20/100 m depending upon depth, hole profile, lithology etc.
2. At shallower depth the entire string may start rotating anticlockwise
due to bit getting stuck in formation or motor getting stalled due to
more WOB , therefore keep the rotary locked to prevent reverse
rotation
Stalling of Mud Motor
If the differential pressure exceeds the motor design, the motor will stall.
An increase in standpipe pressure will occur and bit rotation will cease.
If a stall condition occurs the following procedure should be followed as
soon as possible:
1. Release trapped torque in controlled manner.
2. Lift the bit off bottom
3. Stop pumps, if necessary.
Drilling Fluids: Limitations with PDMM
Drilling fluids with a pH below 4 or above 10 can cause damage to the
stator. Continuous circulation through the power section can lessen this
damage and should therefore be employed when operating in drilling
fluids close to the limits of this pH range. Allowing the drilling fluid to be
idle will aggravate the problem.
Chlorides in drilling fluids can reduce rotor and stator life due to corrosion,
especially at elevated temperatures. Particular attention should be paid
to the internal coatings when the chloride concentration is in excess of
30,000 PPM. The motor should be flushed and serviced as soon as
possible if it has been exposed to chlorides.
190
Drilling mud with a density of more than 16.7 PPG (SG =2) will cause
abnormal erosion of motor internals due to suspended particals in these
muds.
The percentage of solids should be kept to a minimum. Large amounts of
abrasive solids in the drilling fluid will dramatically increase the wear on a
stator. It is recommended that the sand content be kept below 2% for an
acceptable operational life. Solids content greater than 5% will shorten
rotor and stator life considerably.
Well-mixed fine to medium Lost Circulation Material (LCM) can be used
without plugging or causing motor damage. If coarse LCM is to be used, a
PBL circulating sub should be installed above the motor assembly to
bypass the motor.
Hydraulics
The use of a PDMM in the drill string changes the hydraulic calculations.
Various factors have to be taken into account. These are:
1. Range of allowable flow rates: Each size and type of PDMM is
designed to take a certain range of volumes of fluid.
2. Pressure Drop across the Motor: When mud is pumped through a
mud motor which is rotating freely off-bottom (i.e. doing no work) a
certain pressure loss is needed to overcome the rotor/stator friction
forces and causes the motor to rotate. This pressure loss and motor
RPM are proportional to flow rate.
3. Stall-out Pressure :There is a maximum recommended value of
motor differential pressure. At this point, the optimum torque is
produced by the motor. If the effective WOB is increased beyond this
point, motor will stall.
c) Measurement While Drilling (MWD)

MWD is the process by which certain information such as directional data,
formation characteristics, drilling parameters, are measured near the bit
and transmitted to the surface without interrupting normal drilling
operation.
In MWD, sensors are installed in a special down hole tool. A transmitter in
the down hole tool sends signals to the surface via various telemetry
systems like mud pulse, hard wired pipes, electro-magnetic, acoustic.
These signals are detected at the surface, decoded and processed by
surface equipment. The required information in a convenient and usable
format is displayed at driller’s console.
191
Most common form of transmitting Information is through mud pulse

telemetry. Usually it is either positive pulse or negative pulse.
Positive Pulse
Restrictor valve is
operated by hydraulic
actuator which increases
stand pipe pressure due
to temporary restriction
in flow. To transmit data,
valve is operated several
times creating a series of pulses. Surface transducers detect pulses and
are decoded by surface computer. Surface computer initially detects a set
of reference pulses followed by data pulse. Message is decoded by
detecting the presence or absence of a pulse within a particular time
frame.
Negative Pulse
Restrictor valve is
operated by hydraulic
actuator which
decreases stand pipe
pressure due to
temporary bleeding
off mud from drill pipe
to annulus. To transmit
data valve is operated
several times creating a series of pulses. Surface transducer detects pulses
and is decoded by surface computer. Surface computer initially detects a
set of reference pulses followed by data pulse. Message is decoded by
detecting presence or absence of a pulse within a particular time frame.
Pulse generated in due course is affected by vibration and fluctuation in
pump pressure. These problems have to be identified and rectified to
ensure data quality.
d) Rotary Steerable System

A Rotary Steerable System (RSS) is a new form of drilling technology used
in directional drilling. It employs the use of specialized down hole
equipment to replace conventional directional tools such as mud motors.
They are generally programmed by MWD Engineer or directional driller
192
who transmits commands using surface equipment (typically using either

pressure fluctuations in the mud column or variations in the drill string
rotation) which the tool decodes and gradually steers into the desired
direction. This tool is designed to drill directionally with continuous
rotation from the surface, eliminating the need to “slide” as in a mud
motor.
The methods used to direct the well path fall into two broad categories:
-Push-the-bit and Point-the-bit
Push-the-bit tools use pads on the outside of the tool which press against
the well bore thereby causing the bit to press on the opposite side causing
a direction change.
Point-the-bit tools
cause the direction of
the bit to change
relative to the rest of
the tool by bending the
main shaft running
through it. The latter
require some kind of
non-rotating housing
or reference housing in
order to create this
deflection within the
shaft.
193
e) Time drilling for sidetrack

•A minimum of 100m of cement plug should be placed, minimum of
50m above and 50m below the estimated sidetrack point.
•To drill (polish) the cement plug, a “slick” assembly can be used or to
drill faster a PDMM can be run.
•If using a slick assembly to polish the plug, follow the rule of 5’s for
drilling a hard cement plug
§5 Ton WOB, and rotation at 50 RPM, ROP should be
approximately 5min/meter. If polishing with a PDMM,
noticeable weight and differential pressure should be observed,
and ROP should be somewhat close to formation ROP when
originally drilled.
•Drill down 10-15 m to polish the plug while the cement is somewhat
soft to just above the proposed sidetrack or Kick off Point (KOP). If
polishing cement with an MWD system in the hole, care should be
taken to avoid damage and/or plugging of MWD tool. Carefully
monitor samples to determine amount of cement returns – onsite
geologist should be consulted for this information.
•With the directional assembly in the hole, drill last 10-15 m of cement
in stages up to KOP. For high compressive strength formations, a
diamond sidetrack bit should be used. Patience is critical in this hole
section as rushing the process can result in no sidetrack. With the
motor setting set between 1.83º and 2.8º, begin time drilling. The
ideal motor is a medium speed or 4:5 Lobe configurations. The motor
type and motor setting will be dictated by the bit used, formation
hardness and build requirement.
Table-2: Time Drill in a staged approach.

Stage Sliding rate % of formations in cuttings at
shale shaker
1 3-4 min/inch Visually 20-30% Formation
- First 2-3m observed in cuttings
2 2-3 min/inch Visually 50% or moreformation
- Next 2-3m observed in cuttings
3 1-2 min/inch Visually 80% or more formation
- Last 3m or more observed in cuttings, reactive
torque apparent and bit taking on
weight
194
Fishing
10 Fishing
A “Fish” is a length of drill string or tool or any undesirable object or junk

left in the well bore that must be removed before further drilling
operation. The tool required to recover fish is called a fishing tool. Failure
to recover the fish may necessitate side tracking or even abandonment of
the well. Most common causes of fish in a well are:
a) Parting of drill string due to tensile failure, mud cut etc.
b) Twisting off of drill string due to torsional failure.
c) Bit rollers left in the well.
d) Logging tool sticking.
e) Inadvertently dropped metal objects such as dies, bolts, hammers,
wrench etc.
f) Drill string opening due to back-torque.
g) Stuck up and subsequent back off.
The chapter covers the following topics:
a) General Fishing Practices
b) Fishing procedures
c) Margin of Over Pull
d) Determination of Length of Free Pipe
e) External Catch Fishing Tools
f) Internal Catch Fishing Tools
g) Junk Catch tools
h) Milling Tools
i) Accessory tools
a) General Fishing Practices

Ensure that
•Drilling crew has good understanding of the fishing tools (their
strengths and applied stresses) during each fishing operation.
•All fishing equipment are properly maintained and dressed.
•Dimensions and drawing of all downhole equipment are recorded
195
prior to running into hole. It is a good practice to measure OD of

box/pin end of entire BHA to ascertain reduction in OD due to wear.
•All depths and pipe tallies are correct.
•All fishing tools should have provision to accommodate any internal
fishing or back-off tool which may be run to recover fishing tool itself
subsequently. In case of male tap and spear it can’t be ensured.
b) Fishing Procedures
•Prior to engaging a fish, ensure that the following information are
recorded/calculated:
§String up, down and rotating weight with and without circulation
(as applicable for each tool run).
§Free rotating torque of the fishing string.
§Jarring calculations, safe working loads, strengths of fishing
tools, etc.
•Record SPM and pressures.
•Circulate and condition mud prior to fishing.Avoid excessive
circulation to prevent cutting accumulation on top of fish and
washing out the hole around or above the fish.
•Ensure that during the fishing operation, tool joints of drill pipe are
not against Rams of BOP.
•Circulate slowly when locating fish top. An increase in pressure, while
lowering, and/or rotating, will confirm tool is on top of fish (pack-off
rubbers normally good for up to 1,000 psi).
•At this point shut pumps down if required.
•Try & energy fish with recommended procedure.
•Do not pull more than 80% of the minimum yield strength of the pipe
or minimum strength of fishing tool.
•When fish is free, circulate bottoms up.
•Flow check the well.
•In many cases, the pipe may come out full of mud as fish may be
choked. In such cases, following precautions must be taken:
i. The well should be filled continuously through trip tank
ii. Trip tank volume should be closely observed for activity with the
help of trip sheet with closed end volume of string.
196
Fishing
•Avoid circulation while working the fish through tight spots.

•Pick up and set string in slips carefully avoiding any shock loading to
drill string.
•Do not rotate the string with fish while pulling out of the hole.
•While pulling out after a twist off/ wash out, check visually every
connection for wash outs.
•In case of parted string, check at surface bottom part of the pulled
out string to determine as accurately as possible, size, shape and
condition of the fish top in hole.
•When bit cones or similar junk items have been lost on bottom
§It is considered better to fish with Reverse Circulating Junk
Basket (RCJB) in soft/ medium hard formations.
§In hard formations, junk mill with junk sub is better choice.
c) Margin of Over Pull (MOP)

MOP is the desired amount of excess tension above working load (Pw) to
account for hole drag, excess pull capacity in case of pipe stuck situation
MOP = Pt x 0.9 – Pw
Where Pt=Tensile capacity of pipe
Pw=Working load on pipe
d) Determination of Length of Free Pipe (in a stuck string)

The relation between the differential stretch and the length of a frozen
string due to differential pull is:
L= 2.1 x 103x A xe
P2-P1
Where:
L= Length of free pipe (m)
A= Cross sectional area of drill pipe
e= differential stretch (m)
P2-P1= Differential pull (kg)
197
Considering a correction factor of 1.05 for tool joint the equivalent length
( Leq) of free drill pipe is given by:
Leq= 1.05 L
Note:This method is fairly accurate in straight wells.
method of applicable of this technique is as follows:
1. Prior to measuring the differential stretch the string should be
thoroughly worked so as to minimize the effect of residual stress in
the string.
2. A pull (P1) of 10/15T greater than the air weight of the drill string is
applied to the stuck string and a mark is made on the kelly or pipe as
the case may be.
3. This pull is released and equal pull (P1) is applied once again. Another
mark is made on the kelly. The two marks do not coincide due to the
friction in the hole. The mid-point between the two marks is taken as
the upper reference mark A.
4. A pull P2 (P1+ 10/15T) is applied and a lower reference mark B is made
following the steps mentioned above.
5. The distance between the two marks A and B is measured as “e”.
Note : The pull must be within the safe limits of the margin of over-
pull of the string
e) External Catch Fishing Tools

External catch fishing tools engage fish on its OD. These tools help in
recovering fish by using an Overshot with grapple or Die Collar threading
directly to its OD.
Overshots
The different types of over shots are as follows:
1. Full Strength (FS)
Capable to withstand all pulling, torsional and jarring strain. This is
the most widely used overshot in oil industry.
2. Extra Full Strength (XFS)
Engineered for extreme use but with limited catch size compared to
FS.Jarring is recommended.
3. Semi Full Strength (SFS)
Engineered for special hole condition commensurate with max.
198
Fishing
strength and max range of catch size. Jarring is not recommended.

4. Slim Hole (SH)
Meant for heavy pulling strain only. Jarring is not recommended.
5. Extra Slim Hole (XSH)
For pick up jobs only. Jarring is not recommended.
Note :
- Spiral grapples are being used for higher catch size (maximum
catch size for over shot)
- Basket grapples are being used for lower catch size (usually
1/2" less than maximum catch size for the over shot)
Top Sub
Top Sub
Packer
Basket Grapple
Type A
Packer
Basket
Grapple Control Packer
Bowl
Spiral Inner Seal

Graapple
Spiral Grapple Mill
Spiral Control
Graaple Packer
Control Mill Control
Packer
Standard
Guide Guide
Inner Seal
Spiral Grapple
Control
Overshot with spiral Grapple Overshot with Basket Grapple
Spiral Grapple
199
Type A Packer
Oversize Lip Guide
Wall Hook Guide
200
Fishing
Rotary Die Collars

Rotary Die Collars are simplest fishing tools available for engaging a fish
externally. This is not a positive engagement tool and hence jarring is not
recommended.
Wickers:The hardened cutting teeth (wickers) are machined on a shallow
taper to provide an excellent grip. Wickers are plain water tight non-fluted
design if circulation is required below stuck point. Fluted type design also
available to flush cutting while engaging fish.
Length of wicker:The length of wicker is up to 24”. Length larger than 24”
require two piece constructions.
Wall thickness:It should never be less than ¼” to avoid developing
cracks.
Taper per foot (TPF): Standard TPF is ¾”. It should never exceed 1” TPF as it
reduces no of wickers which can engage fish during fishing operation.
Water course:All die collars are furnished with a circulation hole drilled
through the centre.
Selection of Die Collar
Larger wicker I.D: Larger wicker ID should be at least ½” larger than fish
O.D.
Smaller wicker I.D: The smaller wicker I.D should be at least ½” smaller
than fish O.D. The smaller wicker ID should never be less than 1-1/2” due
to boring and wickering operation during manufacturing process.
Operation:
In operation, it is necessary only to run the Die Collar in the hole to the top
of fish, apply less than 1 T weight and rotate sufficiently to embed taper
threads of the Die Collar into the fish till rotation ceases or torque
increases and pull the fish.
Advantage
The principle advantage of a Die Collar is that it is inexpensive and that it
requires virtually no maintenance.
Disadvantage
The disadvantage of a Die Collar lies in the fact that it cannot be
disengaged from the fish in the event that it proves impossible to pull the
fish. Furthermore, it is difficult to gauge the amount of torque required for
its operation. Insufficient torque results in an insecure hold; too much
torque can result in distortion of the fish and damage the tool to such an
extent that engagement might be lost.
201
Rotary Die Collar
j) Internal Catch Fishing Tools

These tools engage the fish in its inner diameter. Similar to External Catch
Tools, this is achieved by a grapple or by threading directly to the fish's
inside surface. These tools are Casing /Drill pipe Spear and Male Tap.
Spears: Common types of spear are:
a) Itco type
b) Full circle
ITCO Type Releasing Spear
•It provides a dependable, inexpensive and simple means of engaging
a fish internally.
•These Spears ensure positive engagement, easy release from the fish
when desired and easy re-engagement after the Spear has been
released. It is ruggedly built to withstand severe jarring and pulling
strains.
•It engages the fish over a large area without damage or distortion of
the fish.
202
Fishing
•The ITCO Type release spear consists of a mandrel, grapple, Release

Ring & Nut.
Full Circle Type Releasing Spear
Full Circle Type Releasing Spears are recommended when fishing for
smaller casing sizes or for thin walled casing or for corroded casing that
might easily be distorted.
The Full Circle Slips, which are completely backed up by tapers on the
Body, contact virtually the entire inner surface of a very long section of the
fish.
Consequently, when a fish is engaged and upward pull is exerted, the
expansion strain is spread over such a large area that there is no fish
distortion. In the larger sizes, the tool employs a Friction Block Assembly
and in the smaller sizes it employs a Friction Spring Assembly. These
assemblies serve the purpose of holding the Slips stationary while the
Body is rotated to place the tool into its engaging or releasing position.
ITCO-type Spear
203
Full Circle Spear
Unitizer
Retainer
Screw
Friction
Retainer
204
Fishing
Taper Taps
Rotary Taper Taps are the simplest fishing
tools for engaging a fish internally when
there is insufficient clearance to permit the
use of an externally engaging fishing tool or
when there is a damaged joint. The taper
tool enters into the bore of the fish and
secure a firm hold on its internal diameter.
This tool is good for straight pull.
k) Junk Catch
Junk catch fishing tools are used to remove
“junk”, from the wellbore and are
categorized as:
1. Junk sub
2. RCJB
3. Magnet.
Magnets and junk baskets are ideal when retrieving a fish that is broken
into pieces or has an irregular shape.
Junk sub
Junk Subs are normally
run just above the drill
bit and have a cup for
catching objects too
heavy to be completely
Never
circulated out of the
apply
hole. This is particularly tong
advantageous in junk here
milling operations. It is
always a good practice to
run a Junk Sub above
scraper to make scraping
jobs more effective.
Note: Never apply tong on the cup body as it may get crushed.
205
Reverse Circulation Junk Basket

(RCJB)
Reverse Circulation Junk Basket

is used to recover all types of
small junk objects from well
bore.
The unique principle of this tool
of reverse circulation ensures
complete recovery of all junk.
A drain through the tool also
eliminates the possibility of
pulling a wet string even though
the inner barrel is plugged by the
core.
It can also be converted into an
fishing magnet and still retain
reverse circulation feature.
A single junk catcher is used in
each assembly.
A lifting sub is provided which
includes a storage space for the
steel ball used in the operation of
the tool.
After reaching top of junk, the
steel ball is dropped into the
valve seat, fluid flows through
the inner passage of the barrel
and moves out the vents in its
lower end. The fluid is directed
outward and downward and
flows in a continuous stream to
the centre of the tool and up
through return ports in the upper
end of the barrel. Cut the core so
the junk is collected into the
barrel above the junk catcher.
Junk catcher does not allow junk
to fall down back into the well
bore.
206
Fishing
Fishing Magnets
Fishing Magnets are used to recover small magnetic objects from well
bore.
Such un-drillable objects like bit cones, bearings, slips, tong pins& dies,
and milling cuttings, hammer can often be retrieved only by magnet.
Fishing Magnets trip is particularly advisable prior to diamond coring.
In a single trip, the Fishing Magnet will completely clean the junk and
protect the bit.
Milling Tools
These fishing tools are used
to mill objects downhole for
a specific reason that
cannot be fished out with
other conventional fishing
tools.
Milling Tools, hard faced
with Itcoloy (sintered
tungsten carbide pieces)
are designed to mill the fish. They are highly resistant to impact loads and
their self-sharpening feature results in maximum useful life. The milling
Tool provides maximum edges for milling.
Pilot Mills
Pilot Mills are used for milling liner hangers top and are also well suited for
milling wash over pipe, safety joints, crossover swages, and washover
shoes.
207
I) Accessory Tools
Accessory tools like Bumper sub, Fishing Jar, intensifier improve the
success of fishing operation.
•Bumper subs provide that extra movement in the drill string when
finding the top of the fish and it helps in disengaging the overshot.
•Fishing jars create the impact and impulse force to free the stuck fish.
•Intensifiers are run in combination with the fishing jar to increase the
jarring impact.
Hydraulic Up Fishing Jar
The hydraulic jar is an easy to use accessory tool
that assists in various operations such as fishing
and washover. This is installed in the string
above fishing tool assembly. It delivers an
upward blow to fishing string below the jar.
Setting or adjustment is not required prior to
lowering in the hole. Hydraulic oil jar is
composed of cylinder and piston assembly.
Piston assembly slides within the cylinder
assembly for jar to give impact. It is a closed
hydraulic system.
Time delay mechanism:
It is designed in such a way that the intensity of
jarring can be varied from a very light impact to
a blow of very high impact by the metering
action of piston assembly. As pull is applied for
the jar to trip, a small amount of oil is leaked
through piston rings in such a manner that the
stroke is delayed until necessary stretch in the
running string is achieved.
Metering stroke:The movement of the piston
assembly from bottom most position to the
internal splines position is called metering
stroke.
Free stroke:Free movement of mandrel from internal splines position to
the top most position of the piston assembly is called free stroke.
Hence Total stroke = Metering stroke + Free stroke
208
Well Control
11 Well
Control
Well control means managing bottom hole pressure against formation

pressure to avoid undesired entry of formation fluid into the well bore.
Primarily the formation pressure is managed by well bore mud
hydrostatic column but still there is a chance to get formation fluid into
the well bore as soon as formation pressure exceeds hydrostatic pressure.
In the event of any imbalance, a kick is experienced, which if not attended
properly may lead to a blowout.
The focus of well control therefore lies on prevention and early
intervention using well control equipment, proper planning & counter
measures. It also requires proper knowledge of principles & procedures
and equipment used in well control. One major feature in all well control
procedures for handling of kick is to maintain constant bottom hole
pressure throughout the procedure while the influx is removed and
balance of pressures restored. Hence, an understanding of standard well
control procedures is of utmost importance for the drilling crew.
The topics covered under this chapter are as follows:
a) Introduction
b) Identification of a kick and precautions.
c) Shut-in procedures
d) Blow out prevention equipment
e) Choke & kill manifolds, BOP Control System, MGS & Diverter
f) Function and pressure testing of equipment
g) Well killing methods-Driller’s, Wait & Weight and Volumetric
h) Common problems during well killing.
i) Stripping procedures
j) Handling of shallow gas
k) Well control drills
l) References
m) Formats: Drills, function and pressure tests
209
a) Introduction
Well control means to have BHP in the well more than formation pressure
all the time. It is classified in to three categories as given below:
Primary Well Control: While drilling maintain mud hydrostatic pressure
more than expected formation pressure.
Secondary Well Control: After losing primary well control and in kick
situation, close the BOP at surface and apply back pressure (SIDPP and
SICP) to keep BHP above or equal to formation pressure. This also involves
killing of well to regain primary control.
Tertiary Well Control: In case secondary control is lost due to BOP failure
then Tertiary Well Control enables regaining secondary control over well
by replacing the damaged BOP stack with the working BOP stack.
Note: Well control manual published by IDT should be available at rig for
ready reference at all times.
b) Identification of a kick and precautions
Influx is the flow of formation fluids into the wellbore. Kick is continuous
entry of formation fluid into the wellbore when BHP exerted by fluid
column becomes less than the formation pressure. Influx may result in a
kick only if BHP is reduced below formation pressure.
Well shows kick sign when INFLUX enters the well bore and increased/
self-flow is noticed by driller during drilling/tripping.
Kick normally is associated with some early warning signs that give
indications to the driller about approaching abnormal/High pressures in
the well. The driller need to be vigilant at all time to notice these warning
signs so that such situation can be managed in a more controlled manner.
210
Well Control
Table 1: While Drilling

Warning signs Responsibility Recommended
action
Drilling break: Driller Stop drilling
Sudden increase in ROP is immediately and
observed have flow check
Back ground gas % increasing Chemist/ MudLogger
to report to driller
Increase in torque & drag with Driller
sudden increase in ROP
Shale density reduced as seen by Geologist
geologist
Mud temperature increasing Mud chemist to
continuously report to driller
Salinity of mud increasing
Large volume of angular shaped
cuttings noticed at shaker
Table-2: Swabbing while Tripping
Most of the kicks occur in wells during pulling out of hole due to swabbing,
which results in hole taking less than the calculated volume. Systematic
recording of the pipe steel volume v/s volume taken by the well is the only
way to detect a kick during POOH. Hence, Trip Sheet must be filled up
during every trip out to avoid well activity. (Trip sheet at Annexure-1)
Warning signs Responsibility Recommended Precautions

action
Based on trip sheet Assistant Shift - Flow Check Do not resume
readings during in-charge • If +ve, shut- tripping out even
POOH if well is taking in the well if no self-flow is
less than calculated • If –ve, run found during flow
volume of mud to back to check. Influx is
top up the annulus, it bottom and already in the well
shows formation circulate and needs to be
fluid is entering in bottoms up removed from
the well bore due to while well prior to
swabbing (Piston monitoring commencing
effect).This reduces the returns. POOH.
Bottom Hole Hole fill should be
Pressure (BHP) of done using trip
well and may lead to tank only to check
more influx if BHP swabbing.
falls below formation
pressure.
211
Above precautions are even more important in case of a very narrow mud
weight window.All above mentioned warning signs are to be taken
seriously and should be responded to in time.
Trip Tank
Trip tank is one of the most important equipment which is used during
tripping operation for early detection of kick/swab. It is the most accurate
way to measure the fill up volumes.
It is a small capacity tank (30-60 bbls) with a low pressure piping to a point
in the annulus below the flow line. Fill up mud can be fed from the tank
into the well by a centrifugal pump called trip tank pump. When lined up
on trip tank, the return flow comes back to trip tank in a closed loop
system.
The dimensions are calibrated so that driller can easily track the fill up or
displacement volumes even in small volume of 0.1 m3or 0.5 bbl.
Procedure for using trip tank
1. Fill trip tank with the mud used during final circulation before pulling
out.
2. Line up trip tank so as the return flow from the bell nipple is coming
back to the trip tank in a closed loop.
3. Run the trip tank pump and check for its functioning and leakage.
4. Record the initial reading on the calibrated indicator at rig floor.
5. Prepare Trip Sheet(with
calculated metal volume)
6. Start pulling out and fill up
reading from trip tank in trip
sheet after pullingout every
three or five stands.Record
the deviation between the
calculated volume v/s actual
fill up volume.
7. Run the pump continuously
throughout the pulling out.
This keeps the hole full and
helps in monitoring of the
mud volume taken by the well
during pulling out.
212
Well Control
Flow Check
The first action after getting any warning sign is to go for FLOW CHECK
as per following procedure.
1) Flow Check Procedure for Water Based Muds (WBM)
1. Stop rotary.
2. Pick up Kelly to clear tool joint above rotary table.
3. Stop pump.
4. Check for self-flow for minimum 5 minutes.
a. If flow check is positive,shut in the well.
b. If flow check is negative and everything is normal, resume
pooh.
2) Flow Check Procedure for Synthetic Oil Based Muds (SOBM)
Due to high solubility of gas in SOBM, the flow check procedures and
actions are different as compared to WBM.
1. Stop rotary.
2. Pick up Kelly to clear tool joint above rotary table.
3. Stop pump.
4. Check for self-flow for minimum 15 minutes
5. If flow check is positive, shut in the well.
6. If flow check is negative but presence of dissolved gas is suspected
due to drilling break or change of formation, circulate out the
bottoms up through full choke opening. In case of sudden change in
choke pressure, the choke may be closed immediately for recording
shut-in pressures if any.
7. If bottoms-up does not indicate influx, resume drilling.
Precautions while Drilling with SOBM
1. Gas sensors must be installed.
2. Any change in background or connection gas should be critically
analyzed.
3. All transfer to and from active pits should be done with prior
intimation to driller.
Recording of Slow Circulating Rate (SCR)/Kill Rate Pressure (KRP)
SCR/KRP should be recorded afresh using Drill Pipe Pressure Gauge on
Choke Panel by keeping the string at bottom and circulating at two
reduced flow rates, generally 30 & 40 SPM for both pumps separately for
213
the following cases:

1. At the beginning of each shift
2. Change in bit nozzle and BHA
3. After drilling of more than 150/200 m in the same shift
4. After change of mud weight
5. After change in size of pump liners
c) Shut-in procedures
Line Up for Well Shut–in
In case of self-flow, there are two possible Shut-In Procedures in practice:
§Hard Shut-In: This is most recommended procedure to shut-in well to
minimize influx unless instructions exist for soft shut-in due to
reasons such as Low MAASP value & shallow depth with low LOT
value
§Soft Shut-In : Soft shut-in procedure involves shut in of well in gradual
manner to avoid shock loading to the formation.
Table-3 : Position of Valves during Drilling / Tripping (Hard Shut-In)
Hydraulic valves (HCR) in choke & kill line Closed
Manual valves in choke & kill line Open
All valves between choke line valve & up to choke Open
Hydraulic / Manual choke Closed
Valves downstream of choke and up to Mud Gas Separator Open
(MGS)
Line to MGS & shale Shaker
Choke
Remote
HCR valve
Bleed line
Manual
Gate
valve
Adjustable
Choke
214
Well Control
Table-4: Position of Valves during Drilling/Tripping (Soft Shut-In)

Hydraulic valves (HCR) in choke & kill line Closed
Manual valves in choke & kill line Open
All valves between choke line valve & up to choke Open
Hydraulic / Manual choke 1/3rd open
Valves downstream of choke and up to MGS Open
Line to MGS &Shale Shaker
shakers
Remote choke
HC Bleed line
R
Choke line
Manual
Gate
valve
Adjustable
choke
Hard Shut-In Procedure: (Land & Jack-Up Rigs)

1) While Drilling
1. Pick up and ensure tool joint is 1 m above the rotary table
2. Stop mud pump
3. Close annular BOP or upper pipe rams
4. Open hydraulic valve (HCR) on choke line
5. Record SIDPP, SICP and pit gain
2) While Tripping
1. Set string on slips and install FOSV in open position. Close it.
215
2. Close annular BOP or upper pipe rams

4. Make up Kelly/ TDS and open FOSV.
5. Record SIDPP, SICP and pit gain
3) Recording SIDPP with float
If there is a float in the string, SIDPP will read zero. Therefore, start
pumping slowly into the string until a change in SICP is noticed.
The drill pipe pressure at this point is equivalent to SIDPP.
4) While Lowering Casing
1. Ensure BOP rams are dressed to the casing size to be lowered.
2. Set casing on slips.
3. Close annular BOP or casing rams
4. Install casing to drill pipe X-over
5. Install FOSV in open position and close it.
7. Make up Kelly /TDS and open FOSV.
8. Record SIDPP, SICP and pit gain.
5) While String is out of Hole
When string is out of hole, soft shut in procedures are recommended
2. Close blind / shear-blind rams
3. Close choke
4. Record SICP and pit gain
Recording of Shut-In Pressures
After shut-in, both SIDPP and SICP should be recorded every 5 minutes in
the form of a table till they become stabilized. After stabilization of
pressure, if SIDPP and SICP are further increasing at the same rate,it
indicates that gas migration is taking place.
Driller should maintain SIDPP constant at stabilized SIDPP value by
intermittently bleeding through choke during waiting period.
Interpretation of Shut-In Pressures
Given below is an example of a well that was shut in after a kick and
tabulated values of SIDPP and SICP recorded at an interval of every 5 min:
216
Well Control
Table-5: Recording of SIDPP and SICP
Time (Hrs) SIDPP (psi) SICP (psi)

0600 100 150
0605 200 270
0610 275 370
0615 340 450
0620 400 520
0625 405 525
0630 415 535
0635 430 550
0640 450 570
It is clear from the table above that rate of increase in pressure of SIDPP&
SICP has reduced after 0620 hrs and both SIDPP & SICP are rising by same
amount. This indicates that the pressures have stabilized at 0620 hrs. and
subsequent increase is due to migration of gas in the annulus. Therefore
the value recorded at 0620 hrs i.e. 400 psi is the true SIDPP.
Note:
The proper recognition of Stabilized value of SIDPP is very important as it
is used for calculation of right kill mud weight and formation pressure.
d) Blowout Prevention Equipment

For H2S prone areas, all well control
equipment should be H2S trimmed.
§Blowout Preventer Size
The size of BOP means the Nominal
inside diameter of BOP stack. The
selection of BOP size should be such
that it should allow passage of all the
tools required for drilling operations.
§Connections, Size & Pressure Rating of
Wellhead Flanges Annular Figure
1. BOP & well head pressure rating
should be more than the maximum
anticipated surface pressure.
2. API standard rating flanges are to
be used and BOP stack should have
minimum connections as far as
possible.
Ram block
217
3. Only studded/flange/hub types of connections are to be used in

BOP stack.
4. BOP side outlets should be of the same rating as of BOP stack.
§Classification of Surface BOP Stack
The following BOP stack configuration should be used as per working
pressure classifications. These configurations are in line with API RP
53and OISD RP-174
BOP Stack Configuration for 2,000 psi Working Pressure
ANNULAR RAM PREVENTER

PREVENTER
RAM PREVENTER
DRILLING
SPOOL
DRILLING
SPOOL
ANNULAR
PREVENTER
RAM PREVENTER
RAM PREVENTER DRILLING

SPOOL
DRILLING
SPOOL
RAM PREVENTER
EXAMPLE OF BLOWOUT PREVENTER ARRANGEMENTS FOR 2M RATED

WORKING PRESSURE SERVICE-SURFACE INSTALLATION
NOTE :
1. DRILLING SPOOL & ITS LOCATION IN THE STACK ARRANGEMENT IS OPTIONAL.
2. USE OF DOUBLE RAM TYPE PREVENTER IS OPTIONAL.
218
Well Control
BOP Stack Configuration for 3,000 psi & 5,000 psi Working Pressure
ANNULAR ANNULAR
PREVENTER PREVENTER
RAM PREVENTER RAM PREVENTER
RAM PREVENTER DRILLING

SPOOL
DRILLING
RAM PREVENTER
SPOOL
EXAMPLE OF BLOWOUT PREVENTER ARRANGEMENTS FOR 3M & 5M RATED

WORKING PRESSURE SERVICE-SURFACE INSTALLATION
NOTE :
1. DRILLING SPOOL & ITS LOCATION IN THE STACK ARRANGEMENT IS OPTIONAL.
219
BOP Stack Configuration for 10,000; 15,000 & 20,000 psi

Working Pressure
ANNULAR ANNULAR
PREVENTER PREVENTER
DRILLING RAM PREVENTER

SPOOL
DRILLING
SPOOL
RAM PREVENTER
EXAMPLE OF BLOWOUT PREVENTERS ARRANGEMENTS FOR 10M, 15M & 20M

RATED WORKING PRESSURE SERVICE SURFACE INSTALLATION
NOTE :
1. DRILLING SPOOL AND ITS LOCATION IN THE STACK ARRANGEMENT IS OPTIONAL.
220
Well Control
e) Choke & kill manifolds, BOP Control System, MGS & Diverter
The choke line and manifold provides means of applying back
pressure required on the formation while killing the well and
circulating out influx from the wellbore.
§Recommendation for ChokeManifold and Choke Line
a) Valves, connections and lines between BOP stack and choke
should have a working pressure equal to or greater than the
rated working pressure of the ram BOPs in use and all the
connections should be flanged, welded or hubbed. No
connection should have hammer union with rubber seal.
b) Minimum two valves are recommended in choke line
immediately after the BOP stack with rated working pressure
equal or greater than the rated working pressure of Ram BOP in
use. One of these two valves should be remotely controlled.
c) A minimum of one remote operated choke should be installed on
all choke manifolds and choke manifold above 10,000 psi rating
should have two remote operated chokes.
d) Pressure gauges suitable for operating pressure and drilling fluid
service should be installed so that drill pipe and annulus
pressures may be accurately monitored and readily observed at
the station where well control operations are to be conducted.
e) Manufacturer’s guidelines should be followed for flexible line on
minimum working bend radius to ensure proper length
determination and safe working configuration.
f) The choke line nominal diameter should not be less than 3 inches
and all other components should not be less than 2 inches.
g) The vent/bleed line that bypasses the chokes should be at least
equal to the diameter of choke line.
h) All choke manifold valves should be full bore and should be
either fully opened or fully closed during operation.
§Kill Manifold and Kill Lines
Kill lines are an integral part of the surface equipment required for
well control during drilling. The kill line system provides a means of
pumping into the well bore when the normal method of circulating
down through the Kelly or drill pipe can not be employed.
a) All lines, valves, check valves and flow line fittings should have a
working pressure at least equal to the rated working pressure of
the ram BOPs in use.
221
b) All the connections should be flanged, welded or hubbed.

c) No components should have less than 2" nominal diameter.
d) Two full bore manual valves (one should be remotely operated)
between the stack outlets and kill line.
e) The rig pump line to kill manifold should have a check valve and the
auxiliary pumping line to the kill manifold should have a gate valve.
Bop Control System
BOP control system provides pressurized hydraulic fluid to operate BOP
stack functions promptly and in absence of power as well.
Accumulator Check
Before connecting the system to the stack, the unit should be visually
inspected and the fluid reservoir checked to ensure that no foreign fluids,
other debris are present and pre-charge pressure verification ( Preferably
before spudding) also should be done. Pump closure tests should be
conducted before pressure testing BOP.
§Accumulator Bottle Pre-Charge Pressure Verification
a. Open the bottom valve on each bottle & drain the operating fluid
into the reservoir.
b. Measure the Nitrogen pressure on each bottle (1,000 should be
psi) and charge if necessary.
c. Charge the control unit to its max operating pressure (Example
3,000 psi for 3,000 psi unit) by running electric and pneumatic
pumps. Record time taken for charging the unit (should be within
15 Min).
§Pump Closure Test
a. Position a joint of drill-pipe of minimum size to be used in the
stack.
b. Isolate the accumulator bottles bank from closing manifold and
pumps.
c. Isolate the Electric supply and use only air pumps to charge.
d. Simultaneously close the annular & open the HCR valve.
e. Record the time to close the annular and open HCR.(Max. 2
minutes.)
f. Restore the control to their original position.
g. Repeat the test using the other power source for the pumps.
h. Open the accumulator to the closing unit and pump.
222
Well Control
§ BOP Remote Panel

Two remote panels should be kept at site (one near the driller and
another near DIC/Tool pusher cabin) and the control hose bundle and
pneumatic supply should be connected. The control bundle should
be well protected through a conduit/grating so as to prevent any
damage during the course of well. Ensure pressure gauges are in
working condition.
§ Mud Gas Separator (MGS)
1. A suitable atmospheric mud
gas separator, arranged with
the inlet line from choke
manifold and the vent line
(discharging released gas)
connected to a flare line, must
be provided. The dia. of the
shell should not be less than
36".
2. Vent line should not be less
than 6" nominal pipe
diameter and should be of
sufficient length to end at safe
distance from rig.
3. The Vertical MGS should be
properly anchored to prevent
toppling down while venting
the gas during well killing.
4. During drilling, the MGS should be regularly checked for proper
functioning of all valves and flange connections. MGS should be
regularly flushed with water.
5. Keep drain valve in bottom of MGS in open condition during
drilling.
Diverter Equipment
Whenever GTO indicates possibility of shallow gas, include Diverter in the
top hole drilling plan.
Note : For setting up and selection of diverter WCS-IDT well control
manual available at rig may be referred.
Drill String BOP Valves (FOSV/KellyCock/Inside BOP)
1) The Kelly or Top Drive should be equipped with an upper and a lower
223
Full Opening
Safety Valve
Kelly cock and should be pressure tested. The working pressure of

Kelly cock should be equal to or greater than the rating of the BOP
stack in use. The upper Kelly cock of the top drive should be
hydraulically operated.
2) A spare Kelly cock ie Full Open safety Valve (FOSV) that is compatible
with drill pipe in use should be available on the rig floor at all times in
the open position. It should be equipped with lifting cap with handles
for easier stabbing.
Note: Operating handle of FOSV should be easily accessible near
driller’s console at all times.
3) An Inside BOP Valve (IBOP), with the appropriate connections for the
drill string in use, should be available on the rig floor at all times in
open condition.
4) All required crossovers for connecting the FOSV/IBOP to the drill
collars or tubing in use should be available on the rig floor.
224
Well Control
f) Function and pressure testing of equipment

The BOP Stack and allied equipment should be tested as per the OISD-RP-
174 using chart recorder.
§Function Test
Function test is conducted to ascertain proper functioning of all the
well control equipment including BOP control unit.
§Function Test Procedure
1) Ensure that pressure reading on unit gauges after charging are:
o Accumulator pressure: 3,000 psi,
o Manifold pressure: 1,500 psi
o Annular Pressure: 600-1,500 psi.
2) Cut off pumps.
3) Check if pressure is holding. If not, repair the leakages first.
4) Close all pipe ram & annular with pipe in the hole and open HCR
valve.
5) Check closing response time and pressure after each BOP stack
function
6) For surface BOP stack, closing time should not exceed
o 30 seconds for each ram preventers
o 30 seconds for annular preventers smaller than 18¾”
o 45 seconds for annular preventers 18 ¾” and larger.
7) Operating response time for choke and kill line HCR valves (either
open or close) should not exceed the minimum observed ram BOP
close response time.
8) Record final accumulator pressures after all the functions. It should
not be less than 1,200 psi or minimum operating pressure of any ram
BOP. If found less, check accumulator bottles availability.
9) All the operating levers of gate valves and blow out preventers
should be returned to their original position before resuming
operations and should either be in open or closed position only.
10) All the results should be recorded in the prescribed format and
signed by shift incharge.
Testing Equipment
§ Test pumps
A low discharge high pressure pump should be used for pressure
225
testing. In case the test pump is not available then cementing unit
should be used. Never use rig pump for pressure test.
§Test Plugs
1) While testing BOP stack and other equipment, test plug with O-
rings/seals should always be used to isolate BOP.
Note: Ensure that the test plug being used is compatible with
well head and the bottom plug of the test plug is removed.
2) The annulus valves of the well head should be in open position
before lowering the test plug.
3) Test plug is to be lowered and landed into the well head with a
test drill pipe joint (short S grade drill pipe).
4) To test the blind or shear-blind ram, bottom plug of the test plug
should be installed and test pipe should be removed, leaving the
test plug resting on the wellhead.
§Cup Tester
Cup of the cup tester should be selected on the basis of :
a) Burst strength of upper most part of casing
b) Compatible with the casing size & grade.
c) The tensile strength of the test drill pipe used with cup tester
should be sufficient to avoid failure during testing. “S” grade pipe
is recommended for testing with cup tester.
Test Fluids
Clear water should be used for testing of BOP stack and other well control
equipment.
Test Pressures
All BOP components that are exposed to well pressure should be tested
first to a low pressure of 200-300 psi and then to a high pressure as per
API/OISD-174.
§Low Pressure Test
Low pressure test should be conducted at 200-300 psi on all the rams,
annular preventers, manifolds, lower Kelly cock etc. In case any leak is
observed at low pressure, the corrective remedial measure should be
taken accordingly. DO NOT GO AHEAD WITH HIGH PRESSURE TEST IF LOW
PRESSURE TEST FAILS.
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Well Control
§High Pressure Test

Initial Pressure Test
It is conducted prior to spud or upon installation with Test Pump or
Cementing unit. Pressure chart recorder should be used for pressure
testing.
1) Rams, choke manifold and choke/kill lines should be tested to the
rated working pressure (RWP) of the ram BOPs or to the RWP of the
well head on which the stack is installed, which ever is lower.
2) Annular BOPs may be tested to70% of the RWP or to the test pressure
applied to the ram BOPs, which ever is lower.
3) Lower Kelly cock, upper Kelly cock and drill pipe safety valve should
be tested to the RWP from the well bore direction.
Subsequent Pressure Test
(To be carried out within 21 Days Interval)
1. Subsequent high pressure test of ram BOPs and choke manifold
should be limited to maximum anticipated surface pressure +10 %
margin but not to exceed the RWP of the ram BOPs.
2. The maximum anticipated surface pressure is to be determined using
the formation pressure data given in GTO.It is the formation pressure
reduced by gas column hydrostatic for well depth in terms of TVD at
gas density of 2.5 ppg (0.3 SG).
3. Annular BOPs should be tested to a minimum of
•70% of their working pressure
or
•The ram test pressure as in Point 1 above.
§Test Duration
Hold the pressure for 5 minute after pressure stabilization subject to
maximum drop of 5% of the test pressure.
Test Frequency
§Function Test
All operational components of BOP equipment should be function
tested at least once a week.
§Pressure Test
Pressure test on the well control equipment should be conducted:
a. Prior to spudor upon installation
227
b. After the repair/disconnection of any pressure containments in

the BOP stack, chokeline or choke manifold, but limited to the
affected component.
c. Before exceeding 21days.
§Testing of Kelly Cocks/IBOP:
Arrangement should be made to pressure test Kelly cock/ IBOP from
the well bore direction. Kelly cock should be tested at rated working
pressure using test pump or cementing unit every time the BOP stack
is tested.
g) Well Killing Methods

The main principle involved in all well killing methods is to keep bottom
hole pressure constant.
The various well killing methods are as follows:
1) Driller’s Method
2) Wait and Weight Method
3) Volumetric Method
In the first two methods the influx is circulated out and the heavy mud is
pumped in the well keeping the bottom hole pressure constant. The third
method i.e. Volumetric method is a non-circulating method in which the
influx is brought to the surface & heavy mud is placed in the well bore
without circulation.
•Before starting killing prepare complete plan for killing.
Complete kill sheet based on Shut-In data and well configuration.
•Instruct Mud Chemist to start preparing Kill Mud Weight as per
calculated KMW.
Pump start up for Land rig(or Jack up rig):
Crack open the choke and bring the pump to kill speed in steps of 5 SPM
holding casing pressure constant with a gauge pressure allowance of +69
psi by manipulating the choke opening.Always be cautious not to allow
pressure to shoot up too much or fall below the initial SICP.
If killing could not be started immediately then driller should maintain
SIDPP on the gauge constant by regularly bleeding mud through choke
after a rise of around 50-100 psi on SIDPP gauge.
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Well Control
If SIDPP is not available due to NRV in the string, then to read SIDPP
value:
•Pump very slowly (2-5 SPM) and watch SICP gauge.
•When the SICP gauge deflects then the pressure showing on the D/P
pressure gauge is the required SIDPP value.
Driller’s Method
In this method the well is killed in two circulations.
•First Circulation
a) Crack open and bring the pump up to kill speed in steps of 5 SPM,
gradually opening the choke holding casing pressure constant.
b) When the pump is up to kill speed, maintain drill pipe pressure
constant.
c) Circulate out the influx from the well maintaining drill pipe
pressure constant.
d) When the influx is out, stop the pump reducing the pump speed
in steps of 5 SPM, gradually closing the choke, maintaining
casing pressure constant. Record pressure, SIDPP and SICP
should be equal to original SIDPP.
Note: In case recorded SIDPP & SICP are equal but more than original
SIDPP value, it indicates trapped pressure in wellbore. Whereas if
SICP is more than original SIDPP, it indicates that some influx is still in
the wellbore.
•Second Circulation
a) Line up suction with kill mud.
b) Crack open the choke and bring the pump up to kill speed in steps
of 5 SPM, gradually opening the choke, holding casing pressure
constant.
c) When the pump is at kill speed, pump kill mud from surface to bit
(String strokes + Surface line volume), maintaining casing
pressure constant.
d) Pump kill mud from bit to surface(Total annulus strokes),
maintaining drill pipe pressure constant.
e) When the kill mud reaches surface, stop the pump reducing the
pump in steps of 5 SPM, gradually closing the choke maintaining
casing pressure constant. Record pressures, SIDPP and SICP both
should be equal to zero.
229
Open & observe the well. Add trip margin (0.2-0.3 ppg or 0.025-0.035
gm/cc) before resuming normal operation.
Wait &Weight Method (W & W Method)
In W&W method killing is done directly with Kill Mud Weight in one
circulation.
This method is preferred when open hole volume is more than drill string
volume and pressure safety margin is small. (Pressure safety margin is
initial MAASP – SICP).
While waiting for KMW preparation driller should maintain proper BHP
maintaining SIDPP constant within +100 psi range by frequently bleeding
through choke.
Killing Procedure (Wait and Weight Method)
a) Line up mud pump suction with kill mud.
b) Crack open the choke and bring the pump up to kill speed in steps of 5
SPM, gradually opening the choke, holding casing pressure constant.
c) When the pump is at kill speed, pump kill mud from surface to bit,
maintaining drill pipe pressure as per step down schedule( during this
step drill pipe pressure will fall from ICP to FCP ).
d) Pump kill mud from bit to surface, maintaining drill pipe pressure
constant equal to FCP.
e) When the kill mud reaches surface, stop the pump reducing the
pump speed in steps of 5 SPM, gradually closing the choke
maintaining casing pressure constant. Record pressures, SIDPP and
SICP both should be equal to zero.
Open & observe the well. Add trip margin (0.2-0.3 ppg or 0.025-0.035
gm/cc) before resuming normal operation.
Volumetric Method
It is applicable for Gas influx only in the situations like:
1. All nozzles of Bit plugged.
2. Gas influx is below the bit while tripping.
3. Drill pipe is parted or mud cut above the influx position.
4. Well is closed on Blind ram without string.
Volumetric killing is accomplished in two steps, namely ‘Bleeding’ &
‘Lubrication’.
1. Bleeding
In bleeding operation the influx is allowed to migrate and BHP is
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Well Control
maintained by bleeding mud hydrostatic equivalent to pressure rise. This

brings the influx to the surface in steps.
DIC/Tool pusher has to prepare a plan for bleeding in advance by
calculating the volume to bleed for the working margin pressure.
Calculation in API units for Volume to bleed
Volume to be bled (inbbls) =
Working margin pr(psi) X (OH x Tubular Annular capacity(bbl/ft))
0.052 x Mud Wt(ppg)
Suppose the recorded SICP is 500 psi and calculated volume to bleed is 5
bbls.
1) Allow the casing pressure to increase by pre-decided safety margin
about 100 psi (500+100=600 psi)
2) Allow the Casing pressure to increase further by working margin
about 100 psi (600+100=700 psi).
3) Bleed mud through choke taking returns into a small measuring tank
allowing the casing pressure to drop by working pressure only and
then close the choke (to 600 psi).
4) Allow the pressure to rise back(700 psi) and bleed mud in steps the
same way for total 5 bbls required for decrease of Hyd Pv by 100 psi.
5) Allow the casing pr to raise to 800 psi by migration. then repeat the
procedures of step 1-4.
6) This procedure should be repeated until gas reaches surface.
Thereafter, Lubrication technique is to be used for reducing the
casing pressure.
Lubrication
The lubrication technique is used to kill the well/ reduce the casing
pressure when gas is at the surface so that other operation such as
tripping / stripping can be performed.
Again calculation for volume pump-in to increase the Hyd Pr by working
pressure margin is to be done prior to commencing lubrication.
Volume to pump-in (bbls) =
Working margin pr(psi) x [Cased Hole x Tubular Ann.Cap(bbl /ft)]
0.052x Kill Mud Wt(ppg)
Kill Mud Weight = OMW + SICP/ (0.052 x Ht. of Gas Col. after bleeding)
Height of GAS COLUMN = Total Pit Gain/Annular capacity
231
Suppose for this case the Volume to pump-in for Working pressure Margin
increase is 4 bbls.
1. Slowly pump KMW through kill line while watching casing pressure
and pump till the pressure rises by working pressure margin(100 psi
in this case). Allow the mud to fall or lubricate through the gas. This is
a slow process, but can be speeded up by using a low yield point mud.
2. After sufficient delay for lubrication of mud, bleed gas through choke
until the surface pressure is reduced by working pressure margin
(100 psi in this case). In no case mud is to be bled off.
3. Repeat the process until all of the gas has been bled off and KMW is
seen at choke. Also at this point the casing pressure should read
around ZERO.
Note : During the lubrication process, particularly near the end of the
operation it is normal to decrease the volume of mud pumped. This is
because the annular volume occupied by the gas decreases with each
pump & bleed sequence. Watch the pumping pressure closely and
when it reaches 50-100 psi above the shut in casing pressure, stop
pumping. Measure the volume of mud pumped, calculate the
hydrostatic pressure of that volume in the annulus and bleed
sufficient gas to drop the casing pressure by the amount of
hydrostatic pressure plus any increment of trapped pressure because
of pumping operation.
Volumetric process is applied in cases where no other option is
available for normal killing.
General instructions for crew while killing
1. The Rig Manager/Area Manager should ensure that all Drillers and
DIC/Tool Pusher at rig hold valid well control certificate.
2. Hold pre-job meetings for making the crew aware about their
respective roles during well killing situation.
3. While killing, there should be proper co-ordination between driller at
Drillers console and DIC/Tool Pusher at choke.
4. Mud chemist should monitor mud density in and out, pit level and
ensure correct mud weight is pumped into the well.
5. All abnormal observations should be immediately brought to the
notice of DIC/Toolpusher/Driller.
6. Assistant driller should stand by with driller and co-ordinate for all the
preparedness for killing operations.
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Well Control
7. Rig mechanics should ensure availability of all the equipment

specially hoppers, mud pumps, vacuum degasser and shale shaker.
8. All the Rig men/Top men should assist the mud chemist for
measuring and recording the mud parameters and mud preparation.
h) Common Well Killing Problems
S.N. Indications Problem Action required

1 Rapid pressure increase on D/P and Plugged Stop Pump
Casing gauges. May lead to Choke Close HCR
fracture/loss if not attended Line up other choke.
immediately.
2 Pressure drop on D/P and Casing Choke Wash Stop Pump
gauges requiring repeated choke Out Close HCR
closure to maintain pressure Line up other choke.
schedule. May lead to excessive BHP
drop and additional influx into the
well.
3 Sudden decrease in Drill Pipe and Pump failure Shut-in the well and
casing pressure. Also the Pump SPM ( Electrical) plan for killing with
showing zero reading. May lead to other pump.
excessive BHP drop and additional
influx into the well.
4 Sudden increase in D/P pressure Bit nozzle Stop pump in steps
only. No change in SICP partially of 5 SPM
plugged maintaining casing
pressure constant.
5 Sudden one time drop in D/P Nozzle wash Stop pump in steps
pressure but no change in casing out of 5 SPM
pressure. maintaining casing
pressure constant.
6 Increase in drill pipe pressure is Annulus pack Shut-in the well and
erratic and not responding to choke off analyse.
operation.
7 MVT/PVT showing partial loss Induced loss Reduce pump speed
8 Rotary hose suddenly vibrating Suction Shut-In the well and
problem analyze.
9 Gradual drop in D/P pressure with no Pump/ string Stop pump in steps
change in casing pressure. leakage of 5 SPM
problems maintaining casing
pressure constant.
i) Stripping- in Procedures
Stripping-in is the process of lowering drill string into the wellbore with
BOP closed on kick. Use of Annular Preventer for stripping-in is preferred
because tool joint can be stripped through the closed Annular easily.
233
However sometimes it may be necessary to use two Ram preventers or an

Annular/Ram combination if well pressure is too high to strip-in with one
Annular.
Stripping-in is to be carried out only under strict supervision of Crisis
Management Team.
Table-6: Selection of BOP for Stripping
S.N. Well pressure Length for stripping Preventer

required
1 1,000 psi or less Any length Annular preventer
2 1,000-1,500 psi 1,000 ft Annular preventer
3 1,000-1,500 psi More than 1,000 ft Annular preventer +
Ram preventer
4 1,500 psi or above Any length Ram preventer +
Ram preventer
Stripping-in with Annular Preventer

Pipe completely out of hole and annular preventer closed on open hole:
1. Check that Blind ram preventer below the Annular Preventer is closed
2. Bleed off pressure between Ram preventer and Annular BOP.
3. Open the Annular preventer
4. Lower the bit with NRV and drill collars above the closed ram
preventer.
5. Close the Annular preventer and pressure up to well pressure
between the two closed preventers (preferably by cementing unit).
Once pressure across the blind ram is equalized, open the ram
preventer.
6. Reduce the closing pressure of Annular BOP until a small amount of
leakage is observed between the tubular and seal when the tubular is
stripped in. A rule of thumbs holds that 0.5 to 2.5 barrels of leakage
per thousand feet of stripped pipe, depending on its size. Closing
pressure on the preventer is to be adjusted time to time during the
job so that target leakage rate can be maintained.
7. As the pipe is stripped into the well, bleed mud from the well at
regular intervals to maintain a fairly constant bottom hole pressure,
which should be equal to the closed end displacement of the stripped
234
Well Control
in pipe. Also fill the inside of the stripped pipe at regular intervals,
which should be equal to the inside capacity of the stripped in pipe.
8. When lowering the pipe in the hole, do not exceed 50-60 feet per
minute speed. A slower rate should prevail when passing tool joints
through the preventer with utmost care and adjustment of annular
closing pressures.
9. Proceed with stripping until bottom is reached keeping record of the
mud displaced.
Note: In case the drill string is partially in hole, then start from step
No-5.
Stripping-in using Ram Preventer
1. Strip with lower stripper ram closed until the tool joint is about
midway between the two stripping rams.
2. Stop string movement and close the upper stripper ram.
3. Open the valve on equalizing loop with the bleed off line closed.
4. Allow pressure between the two rams to equalize.
5. Open the lower stripper ram.
6. Close the equalizing loop valve.
7. Strip against the upper stripper ram until the tool joint is below the
lower stripper ram.
8. Stop string movement and close the lower stripper ram.
9. Open the bleed line valve.
10. Allow pressure between the two rams to dissipate.
11. Open the upper stripper ram.
12. Close the bleed line.
13. Repeat the procedure.
While doing this, maintain the casing pressure constant by bleeding
mud from the choke. For most stripping jobs, if gas migration is not
taking place holding casing pressure constant should be adequate. If
the casing pressure starts rising between stands it confirms gas
migration, then follow the volumetric method.
235
j) Handling of shallow Gas:

Shallow gas is defined as quick, unexpected and uncontrolled flow of
gas from top hole with unconsolidated formations wherein BOP
closure may result in fracture around the casing shoe.
§Recommended Procedure to Drill Top Hole
1. Install diverter.
2. Drill a pilot hole of smaller size.
3. Keep sufficient source of water and stock of mud to handle
shallow gas.
4. Drill at controlled rate.
5. Circulate the cuttings out after every pipe connections to avoid
loading of the annulus.
6. Circulate while pulling out through tight spots.
§Shallow Gas Occurrence during Drilling:
1. At first sign of flow, immediately stop rotary, raise the kelly until
tool joint is above rotary.
2. Open diverter overboard line valves depending upon wind
direction.
3. Close diverter packer.
4. Circulate out with available drilling fluid at max possible pump
rate.
5. Evacuate non-essential personnel from the rig.
§Shallow Gas Occurrence while Tripping:
1. Set pipe on slips.
2. Install FOSV and close it.
3. Open diverter line valves depending upon wind direction.
4. Close diverter packer.
5. Connect Kelly or circulating head.
6. Open FOSV.
7. Circulate out with available drilling fluid at max possible pump
rate.
8. Evacuate non-essential personnel from the rig.
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Well Control
k) Well Control Drills
The competence of the drilling personnel to respond to well control

situations and follow correct procedures can be improved by carrying out
emergency drills regularly.
1. Drill should be conducted without prior warning during routine
operation in safe well/hole condition.
2. BOP drills should be conducted once a week with each crew.
3. Drill should be initiated at unscheduled times if operations and hole
condition permits.
4. Responsibilities should be assigned to the persons during emergency
as part of the Rig/ Installation Emergency Response Plan (ERP) to take
care of all emergency operations.
5. While drilling in H2S/Sour gas prone area, detectors must be installed.
sufficient number of Breathing apparatus and Cascade System must
be made available. Crew must be trained to handle situation in this
environment.
6. To conduct a drill, kick should be simulated by manipulating primary
kick indicator such as the pit level indicator or the flow line indicator
by raising its float/paddle gradually and checking for the alarm and
reaction of the crew.
7. The reaction time from float raising to the designated crew member’s
readiness to start the closing procedure should be recorded and
response time should not be more than 60 seconds.
8. Total time taken to complete the drill should be recorded and it
should not be more than 2 minutes.
Following drills should be performed and documented
i. Pit drill
ii. Trip drill
§Pit Drill (On Bottom)
1. Raise alarm by shouting or raise float to set off auto alarm.
2. Stop rotary & pick-up Kelly.
3. Position tool joint for closing BOP.
4. Stop mud pump.
5. Secure brake and ensure designated crew is at assigned position.
6. Check for self-flow.
237
7. Record the response time. (should be 1 minute or less)

§Trip Drill (Drill Pipe in BOP with string in cased hole)
1. Raise alarm by shouting or raise float to set off auto alarm.
2. Position tool joint above rotary and set the pipe on slips.
3. Install full opening safety valve in open position.
4. Close FOSV after installation.
5. Close BOP.
6. Ensure designated crew members are at assigned place.
7. Record response time. (should be 2 minute or less).
Trip drill should be carried out preferably when bit is inside the
casing.
A full opening safety valve with cross overs for each size and type
of connection in the string should be kept open and available on
derrick floor.
Safety valves should be clearly marked for size and connection.
§Trip Drill (Drill Collar in Blowout Preventer)
1. Raise alarm by shouting or raising float to set off auto alarm
2. Position upper drill collar box at rotary table and set it on slips.
3. Connect a drill pipe joint or stand of drill pipe on drill collar tool
joint with change over sub and position drill pipe in BOP.
4. Install FOSV in open position.
5. Close FOSV.
7. Close BOP.
8. Record response time. (should be 2 minutes or less)
Under actual kick conditions (other than drills) if only one stand of
drill collar remained in the hole it would be probably faster to simply pull
the last stand and close the blind ram. If numbers of drill collar stands are
more, then install FOSV with change over sub on drill collar, close it and
close annular preventer.
§Trip Drill (String is Out of Hole)
1. Raise alarm by shouting or raising float to set off auto alarm
2. Close blind/ blind-shear ram.
4. Record response time.(should be 2 minutes or less)
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Well Control
§Strip Drill
1. The stripping drill should be performed by at least one crew on
each well.
2. This drill can be conveniently performed after casing is set and
before drilling out cement.
3. Keep the drill string in the hole, install NRV on drill pipe & close a
blowout preventer
4. Pressurized the BOP at desired pressure.
5. Reduce the operating pressure of BOP to an acceptable value.
6. Assign position of each crew member.
7. Follow an acceptable procedure and the crew should strip
sufficient pipe into the hole to establish the workability of the
equipment and to allow each crew member to learn to perform
their assignments. In addition to establishing equipment
reliability, this will permit the training of at least one crew on
each well.
Note: Over a period of time, all crews should become proficient in
stripping operations.
l) References
1. API-RP 53: Recommended Practices for Blowout Prevention

Equipment Systems for Drilling Wells
2. API-RP 59: Recommended Practices for Well Control Operations
Rig: Project: Date:
Well: Time:
Driller: Trip sheet no.: Depth:
Reason for trip:
No. Of stands up to casing shoe:
3. API-RP 64: Recommended Practices for Diverter Systems Equipment
and Operations
4. API-SPEC 16C: Specifications for Choke and Kill Systems
5. API-SPEC 16D: Specifications for Control Systems for Drilling Well
Control Equipment
6. API-SPEC 16R: Specification for Marine Drilling Riser Couplings
7. OISD-RP-174: Recommended Practices for Well Control
8. Well Control Manual, IDT
239
l) Formats
Trip Sheet
No of Steel Vol. Cum. Steel Cum. Variati Cum. Remarks

stands displ. Pumped displ. Vol. Mud on Variation
p/o Vol. from vol.
In trip tank Filled
Cu.m. Cu.m. Cu.m. Cu.m.
Pull out Tick Displacement 8’’ D/C 6 ½” D/C 5” 5”HWDP

DP
Even Length (m)
Single Cu.m./m
Double Cu.m/std.
Stand
Volume cu.m.
Signature of Shift In Charge Signature of Shift Chemist

Pit Drill (While Drilling)
Rig: Project/Asset:
Well No.: Date:
This is conducted/practiced during the drilling operation. The call for kick
is given by DIC/Tool pusher/Shift in charge by shouting or by lifting the
flow meter flap on the mud return channel. The person at brake takes the
action i.e. stop rotary, lift the Kelly such that the tool joint comes to above
rotary. Stop pump and check flow. Following check to be made:
1. Call by DIC/Shift in charge_________ Shouting / Flap/Float raising

2. Rotary stop___________________________
3. String lifted___________________________
4. Mud pump stopped____________________
240
Well Control
5. Man at flow channel____________________

6. Man at R. panel/ BOP Control unit_________
(for shut in well if required)
7. Response time________________________
(From first call given for readiness
to actual closing of BOP)
Sign:
Name:
Designation:
(DIC/Shift in charge)
Note:
1. Minimum frequency one drill per week per shift during drilling.
2. Please check the hole condition before conducting the drill.
3. Please record in the DPR
4. Response time should be 1 minute or less.
241
Trip Drill (While Tripping)
Rig: Project/Asset:
Well No.: Date:
This is conducted/practiced during the Tripping operation with bit in

cased hole section. The call for kick is given by DIC/Tool pusher/Shift in
charge by shouting or by lifting the pit level sensor in Trip tank. The person
at brake takes the action i.e. Set the string on slip with tool joint 1m above
rotary, stab FOSV and close it and then check for self flow and ready for
shut-in the well:
1 Call by DIC/Shift in charge____________Shouting / Float raising

2. Set string on slip with 1m stick up
3. Stab FOSV
4. Close FOSV
5. Man at R. panel/ BOP Control unit Shut-In the
Ram/Annular BOP
6. Response time___________________
(From first call given for readiness
to actual closing of BOP)
Sign:
Name:
Designation:
(DIC/Shift in charge)
Note:
1. Minimum frequency one drill per week per shift during drilling.
2. Please check the hole condition before conducting the drill.
3. Record in the DPR
4. Response time should be 1 minute or less.
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Well Control
BOP Function Test Format
Asset / Basin: Field: Well No.:

Rig: Date:
1. Specifications
(i) Diverter
Mfg. ………….......……. Model ……....………….. Size ……………..…..
Rating ………..…...…… Volume: Close…….... Open …………….…
(ii) Annular preventer

Mfg. …………….......…. Model …………….....….. Size ……….………..
Rating …………….....… Volume: Close……..… Open …………….…
(iii) Ram preventers

a. Mfg. ………………. Model ………………...... Type ………………..
Size: ………………. Rating ………… Volume: Close…………Open
b. Mfg. ………………. Model …………....…….. Type ………………..
c. Mfg. ………………. Model …………....…….. Type ………………..
(iv) Choke manifold

Mfg. ………….......……. Model ………....……….. Size ………………....
Rating …………….....…
(v) Kill manifold

Mfg. ………….......……. Model ………………....... Size ………………....
Rating ………….....……
(vi) BOP Control Unit
Mfg. ……….......………. Model …………….....….. Capacity…………..
Rating …………….....… Pre-charge pressure ………………................
Operating fluid ……… Operating pressure building time ……sec.
Charging system ………………......................................................……..
Alternate charging system ………………..................................………….
2. Control unit operated:

(i) Rig floor mounted ( )
(ii) Accumulator system ( )
243
BOP Function Test Format
3. Results of Test
S Type of Preventer Function Time in Accumulator Remarks

N / equipment seconds Pressure
Close Open Close Open Initial Final
1. Diverter
2. Annular
preventer
3. Lower ram
4. Middle ram
5. Upper ram
6. Choke line
hydraulic valve
7. Manual valve on
choke line
8. Manual valve on
kill line
9. Blind/ Shear rams
NOTE
i) Observe proper movement of the rams
ii) Ram preventers should also be operated manually and record time
required to close/ open __________________ minutes.
iii) Shear ram is not to be tested. Do not close pipe rams on open hole.
iv) Test should be conducted alternately from accumulator unit / Rig
floor panel.
v) Ram preventers should be tested on each round trip but not more
than once per day. Annular preventer and other equipment to be
tested once a week.
vi) Special attention needed to _______________________________ .
vii) The final accumulator pressure should be at least 200 psi above the
pre-charge pressure.
Signature of S/I Signature of tool pusher

Name: Name:
Designation: Designation:
244
Well Control
Pressure Test Format
Asset / Basin: Field: Well No.:

Rig: Date:
1. Specifications
(i) Diverter
Mfg. ………………. Model ………….……..
Size ……………….. Rating …………...……
(ii) Annular preventer
Mfg. ………………. Model ……….………..
Size ……………….. Rating ………...………
(iii) Ram preventers
a. Mfg. ………………. Model ……………….. Type ……....
Size: ………………. Rating ………........…
b. Mfg. ………………. Model ……………….. Type …….…
Size: ………………. Rating …........………
c. Mfg. ………………. Model ……………….. Type ……....
Size: ………………. Rating ………….......
(iv) Well Head
Manufacturer…………………………………………………………
Section size ……………Rating ………..............………… psi
(iv) Choke manifold
Mfg. ………………. Size ………………..
Rating ……………
(iv) Kill manifold
Mfg. ………………. Size ………………..
Rating ……………
2. Date of BOP stack installation ……………………………………....
3. Test conducted by ………………………………………………...........
4. Test fluid………………………………………..................................
5. Test Plug …………………………………………………………...............
245
Pressure Test Format
6. Results of Test
SN Type of Preventer / Test pressure Period of test Remarks

equipment psi (minutes)
Low High Low High

1 Annular preventer
2. Upper pipe ram
3. Lower pipe ram
4. Blind/ Shear rams
5. Well head
6. Kill line hydraulic valve.
7. Kill line Manual valve
8. Kill line choke valve
9. Choke line hydraulic valve
10. Choke line manual valve
11. Choke manifold
12. Kill manifold
13. Inside BOP
14. FOSV
15. Lower Kelly cock
16. Upper Kelly cock
17. Swivel
Note:
i) Valves on casing head below plug tester should be kept open during
the test to verify leakage through plug tester.
ii) High pressure test should be limited to rated working pressure of the
weakest member exposed to the test pressure.
iii) Record total testing time: _________________________ minutes
iv) Any leakage flange connection / joint found?
Yes ………………………… No …………………………………
If yes, what measures taken and time required to rectify
……………………..
v) Special attention needed to ……………………………………………………
Signature of S/I: Signature of T/P:

Name: Name:
Designation: Designation
246
Wire Rope
12 Wire
Rope
Wire rope plays an important role in all rig operations,mainly hoisting drill
string and casing, material handling, crane operation, making/ breaking
of tubulars etc.
Wire rope consists of a group of strands laid helically around a core. The
strands of a wire rope consist of a number of individual wires laid about a
central wire.
All wire ropes have specific application and performance charactertics. It
is important to select ropes that are best suited for each application. Care,
handling and maintenance of wire rope are of utmost importance for safe
use and longer life.
The chapter includes the following topics:
a) Care while handling the wire rope spool
b) Reeving casing line on blocks before raising mast
c) Replacement of casing line during operation
d) Casing line slip and cut procedure
e) Care of wire rope during service
f) Bending of Casing line wrt sheave diameters
g) Work Done Calculation of Casing Line
h) Attachment of U-clamps on wire rope
a) Care while handling the wire rope spool

1. Do not drop the wire rope spool on any hard or sharp object while
unloading from a truck.
2. Use crow bar only against drum rim for moving the spool and not
against the rope.
3. Protect wire rope spool from mud/water as it may lead to rusting/
corrosion.
4. Store wire rope in properly lubricated condition to minimize the
effects of corrosion on wire rope.
5. Never use wire rope in an arc welding circuit as it damages line.
247
6. Always protect the rope from the flame and sparks while cutting/
welding.
7. Do not lift wire rope spool with wire rope sling wrapped around drum
which may get jammed and crush the wire.
b) Reeving casing line on blocks before raising mast

1. While reeving casing line, travelling block should be placed on
horizontal pipe walk and the mast on small horse.
Casing line is reeved with the help of crane/ mole from deadline
anchor sheave through both blocks to fast end of draw works. Due
precautions should be taken during reeving with MOL or Crane to
avoid kinking of wire rope and damage to wire due to slush during
rainy season.
2. After reeving is complete, ensure fast end and dead end of casing line
are secured properly.
3. Carry out load test by holding the mast inches above horse for some
time.
4. Raise mast to high horse level, change horse to bigger one, fit monkey
board and belly board, make one more load test if required/ not done
earlier before raising the mast.
248
Wire Rope
c) Replacement of casing line spool during operation

1. The travelling block should be hung/ supported in a vertical position
as close to rotary table as possible.
2. Replace the old spool with the new one.
3. Connect the old line to the new line with a snake grip suited to the
particular casing line size.
Note: Check the condition of the snake before use and change if
found damaged.
Snake grip
Note : Never weld the new casing line to the old one.
4. Care should be taken to see that the grip is properly made up.
5. Loosen the dead line anchor and slowly reeve the old drilling line
completely on the draw works drum. At this point, the snake grip is
just near the drum.
Note: When spooling new wire, keep a close watch on weight
indicator to avoid load on the snake which may otherwise snap it and
lead to accident. During this time, new casing spool should rotate
freely.
6. Secure the new line so that it will not run back through the blocks &
remove the snake grip.
7. Remove the old line completely from the drum by reverse rotation
and discard the same.
8. Connect the new line into fast end wedge on the draw works. Reeve
new line on the drum to take load ensuring proper wrapping in the
drum grooves and remove the securing line. There should be 6-9
wraps on drum at this position of block.
9. Check the condition of brass inserts in dead end clamp and replace if
worn.
10. Tighten deadline anchor bolts to recommended torque in proper
sequence (cross tightening). Over-torquing may damage the wire.
11. After anchoring casing line at the dead end, raise the travelling block
and take off the hang off line.
Note: If not reeved properly, lower the block and hook again through
249
the V-door to unreel the line and reeve casing line on drum again
properly.
12. Avoid installing a new casing line just before lowering a heavy casing
string as new rope is more susceptible to crushing than a rope that
has been in service.
d) Casing line slip and cut

Service life of casing line is increased substantially by following a planned
slip and cut program based on work performed. This shifts the bending
points of the wire rope so that wear and tear is spread out uniformly along
the entire length of the rope extending its service life.
It is recommended to slip and cut casing line at casing shoe during RIH as it
gives more time to understand well behavior.
Note: Slip and cut at casing shoe during POOH and with bit out of hole
should be avoided for safety of the well.
The following two slip and cut programs are followed on rigs:
a) Slip and cut casing line at one go.
b) 3 to 4 slips followed by cutting entire slipped length.
Procedure
1. Disengage twin stop / crown-o-matic before slip and cut.
2. Before slip and cut, rest the drill string in slips as low as possible and
with FOSV installed in open position.
3. Hang/ support travelling block in a vertical position as close to rotary
table as possible.
4. Ensure that the casing spool is free to rotate and pay out the wire.
5. Loosen the dead line anchor bolts and slip the planned cut off length
of wire rope in term of no. of wraps on drum using brake lever.
6. Ensure proper spooling on draw works drum by maintaining sufficient
tension on the rope.
7. Tighten deadline anchor bolts to recommended torque in proper
sequence (cross tightening). Over-torquing should be avoided as it
may damage the wire.
8. Put paint mark on dead end wire to check for any line slippage during
operations. Do not use U-clamps for this purpose.
9. Secure the fast line properly before proceeding further so that it does
not accidentally run back through the block.
250
Wire Rope
10. De-reeve the calculated length of wire till cut point is reached by
reverse rotation of draw works and cut the line.
11. Take out the fast end wedge/ clamp from drum.
12. Attach the new (useable) end into fast end wedge/clamp and secure
the same in the draw works.
13. Reeve the wire on drum.
14. Raise the travelling block and disconnect hang-off line.
Note: If not reeved properly, lower the block and hook again through
the V-door to unreel the line and reeve casing line on drum again
properly.
15. Pick up on blocks. Lower the block fast and apply brakes to ensure
both the clamps are secured satisfactorily and tripping can be
resumed safely.
16. Whenever possible, a new wire line should be run under controlled
loads and speeds for a short period after installation as it will help to
adjust the rope to working condition.
17. When following program-B, it is most important to get the first drum
layer full and tight without overcrowding at the ends during
subsequent slips so that it will support the succeeding layers.
Note : Step No-9 to 13 are not applicable in case the wire is only
slipped.
18. Before resuming operations, ensure that twin stop / crown-o-ma are
reinstalled / reset and tested.
e) Care of wire rope during service

1. Never strike the wire rope with hammer or crow bar directly; it may
cause kinks or bruises.
2. Use a wooden block between hammer and rope while hitting wire
line for spooling it properly in the drum grooves.
3. Do not allow the line to rub against any derrick member .
4. Ensure that brass bushings inside wire rope clamp are not worn out
otherwise it may damage the rope.
5. Turn-back rollers on draw works should be in good condition for
smooth change of directions of casing line at the ends of draw work
drum.
6. Application of sudden braking to stop movement of traveling blocks
at excessive speeds may cause severe stresses on wire rope and
damage it.
251
7. Whipping of line causes fatigue in line; therefore, a wire line stabilizer

(Rolly Guide) must be installed on fast line with all rollers in good
condition.
8. Vibration may cause fatigue failure of drilling line shortening its life. It
is most serious at the sheave at crown block leading to deadline.
Stabilizers should be used to avoid whipping of the dead line end.
9. All sheaves should be in proper alignment. The fast sheave should line
up with the center of the hoisting drum.
10. Sheave grooves in the crown and travelling blocks should be checked
periodically with the gauge.
Place sheave gauges in grooves as shown in figure below.
•Detail “A” reflects gauge fit in sheave and is OK.
•Detail “B” reflects gauge “fit” in a worn (tight groove) sheave.
•Detail “C” reflects gauge “fit” in a sheave where the groove is too
large.
Sheave grooves must neither be too small nor too large to avoid
damage to the line.Small grooves cause pinching and overheating
while large grooves allow flattening of the line.
11. Visually check wire line daily to check damages like broken wires,
crushing; kinks etc.
12. A proper slip and cut- off practice should be followed and daily record
of work done by casing line should be maintained
13. Make sure dead anchor drum moves up and down freely on its
bearing at hinge pin and is greased regularly.
14. All sheaves should be properly lubricated to ensure minimum turning
effort.
252
Wire Rope
15. Avoid developing kink due to improper handling that may be caused
by pulling a loop in a slack line. Early rope failure will undoubtedly
occur at this point.
Kink
16. Avoid bird caging caused by sudden release of tension and resultant
rebound of rope from over loaded condition.
Bird caging
17. Wire line tolerances are given below in Table-1:
Table-1: Wire line tolerances
Nominal dia of rope, Undersize, Oversize,

inch inch inch
0-3/4” 0 1/32”
1-3/16”to 1-1/8” 0 3/64 ”
1-3/16”to 1-1/2” 0 1/16 ”
f) Bending of Casing line wrt sheave diameters

1. Bending reduces the amount of load casing line can carry.
2. Bending of casing line over sheaves causes re-adjustment of wires
and strands as well as bending of wires themselves and results in
fatigue failure and breaking of wires due to continuous bending.
3. To minimize the fatigue of the drilling line due to bending, sheave
diameters should be within the following limit:
253
Table-2: Relation between rope and sheave diameter
Rope dia, inch Sheave diameter, inches

Recommended for Minimum for
(6 X19) rope (6 X 19) rope
7/8 39 26
1 45 30
1-1/8 50 34
1-1/4 56 38
1-3/8 62 41
1-1/2 67 45
4. When wire rope is used over sheaves that are too small its service life
is reduced.
g) Calculation of Work Done by Casing Line

1. Excessive wear occurs in a few localized sections where rope makes
contact with travelling block and crown block sheaves at pick-up
points during tripping and on the drum where each wrap of rope
crosses over the rope on the layer below.
Note: If broken wires are seen in these points of critical wear or any
other point, then length of wire rope up to the damaged point should
be discarded.
2. Slip and cut the rope in time otherwise sections of casing line will be
damaged to such an extent that there is danger of failure, injury to
personnel and damage to equipment.
3. Casing line should be cut as per program to optimize rope service life
without compromising on safety of rig operation.
4. For an accurate record of the amount of work done by a drilling line, it
is necessary to calculate the weight being lifted and the distance it is
raised and lowered. On a drilling rig the loads and distances are so
large that we use “Tonne-Kms” for work done calculations in MKS
system. In FPS system, the unit is "Ton-Miles".
Note : The table-4 gives work done by casing line in MKS unit of 103
daN-Km which can be can vested is T-km by multiplying by 1.02.
5. Most of the rigs are equipped with Tonne-Kms/Ton-mile indicator
which displays work done by casing line.
254
Wire Rope
Work Done by a Casing Line during Round-Trip Operations

Work done by wire rope can be calculated as follows:
1. Work done to pull out bit from L depth and running it back to same
depth with new bit,
TL= [pL(L+l)+4L(P+d/2)]10-6
Where
TL = Amount of work done by casing line (in T-Km)
L= Depth of hole (m)
l= Length of a drill pipe stand (m)
d= (BHA weight–Weight of same length of drill pipe) in
mud, Kg
p= Buoyant weight of drill pipe with tool joint in Kg/m
P= Total weight of Traveling block/elevator assembly (Kg)
Work Done by Casing Line during Drilling Operations
Work done in round trip operations from L1 depth = TL1
Work done in round trip operations from L2 depth = TL2
Where L2 is deeper than L1.
Work done to drill from L1 to L2depth = TL1-2= 3[TL2-TL1]T-Km
Work Done by Casing Line during Coring Operations
Work done to core from L1 to L2depth = TL1-2= 2[TL2-TL1] T-Km
Work Done by Casing Line during Casing Operations
Work done by casing line to run casing to L depth is as follows:
TL= ½[pL(L+l)+4LP]10-6
Where
TL= Amount of work done (T-Km)
L= Depth of hole (m)
l= Length of a single joint of casing (m)
p= Buoyant weight of casing along with coupling in Kg/m
P=Total weight of Traveling block/elevator assembly (Kg)
Note: Conversion from daN to T force is as follows:
• 1*103daN=1.02 T
• 1*103daN.Km=1.02 T.Km
255
Table-3: Cut off length and wraps

Cut off length as a function of derrick and mast height and drum diameter
Draw Works Drum Diameter (inch)
Mast Height
20 22 24 26 28 30 32 34 36
(ft)
Cut off length in meters

&
No of wraps per cut off
151 Length 34.6 34.7 34.5 33.9 33
or Wraps 15 ½ 14 ½ 13 ½ 12 ½ 11 ½
mor (1)
e
142 Length 25.9 25.9 25.7 27.5 26.8
to Wraps 13 ½ 12 ½ 11 ½ 11 ½ 10 ½
150
133 Length 24.7 25.5 23.9 23.9 25.7 25.1 24.3
to Wraps 15 ½ 14 ½ 12 ½ 11 ½ 11 ½ 10 ½ 9½
140
120 Length 23.1 21.9 23.9 23.9 23.5 22.7 24.3
to Wraps 14 ½ 12 ½ 12 ½ 11 ½ 10 ½ 9½ 9½
132
91 Length 18.4 18.4 18.2 19.7 19.0
to Wraps 11 ½ 10 ½ 9½ 9½ 8½
119
Note:The cut-off length given is a whole number of drum laps plus one
half laps in order to change rope cross over point, which is apoint of high
wear.
256
Wire Rope
Table-4: Cumulative work done before First Cut off

Total work of casing line before the first cut off
Formation Hardness
Derrick or Mast
1" 1 1/8" 1 1/4" 1 3/8" 1 ½’

Formation
Height, ft
10 daN.Km
10 daN.Km
10 daN.Km
10 daN.Km
10 daN.Km
Ton Mile
Ton Mile
Ton Mile
Ton Mile
Ton Mile
3
3
Very hard 716 500
80
Hard 716 500
to
Medium 716 500
87
Soft 859 600
94 Very hard 716 500 859 600
to Hard 716 500 1,003 700
Medium 716 500 1,146 800
100 Soft 859 600 1,289 900
Very hard 859 600 1,432 1,000
126
Hard 1,003 700 1,575 1,100
to
Medium 1,146 800 1,719 1,200
131
Soft 1,289 900 1,862 1,300
Very hard 859 600 1,432 1,000
133 to Hard 1,003 700 1,575 1,100

138
Medium 1,146 800 1,719 1200
Soft 1,289 900 1,862 1,300
Very hard 1,432 1,000 2,292 1,600
142 to
Hard 1,575 1,100 2,578 1,800
147 Medium 1,719 1,200 2864 2,000
Soft 1,862 1,300 3,008 2,100
Very hard 2,292 1,600 2,864 2,000
187 to Hard 2,578 1,800 3,150 2,200
189 Medium 2,864 2000 3,437 2,400
Soft 3,008 2,100 3,724 2,600
Note:
1. The Conversion from deca Newton to Tonne Force is as follows:
1*103daN=1.02 T
2. For subsequent cut-offs, total work given in the table must be
reduced by 143*103 daN.km (146 T-kms or 100 Ton-miles) for 1-1/8
inch & smaller wire ropes and by 286*103daN.km (292 T-kms or 200
Ton-miles)for other wire rope diameters
Table-4 gives work done by Improved Plow Steel drilling line before
257
first cut off using a factor of safety of 5. If a different factor of safety is

selected, curve below gives the correction factor to apply to the work
given in the Table-4 above.
Fig. 1 : Correction Factor vs Factor of Safety

Example:
Mast height = 138 ft; Wire rope diameter = 1-1/4";Drum diameter = 28 in
Drilling difficulties = hard; Factor of safety = 3
Value of work done 1,575*103daN.km is obtained from Table-4:
Cumulative Work Done before First Cut off for factor of safety 5.
Above curve at Fig. 1 gives a corrective ton mile factor of 0.58 for factor of
safety of 3.
So work done with factor of safety 3 for slip & cut is
= 1,575*103* 0.58 = 914*103daN.km before the first cutoff
Table-3 : Cut Off Length and Wraps gives cut-off length as a function of
drum diameter and it is 25.70 m (11-1/2 wraps) for 28 inch diameter
drum.
h) Attachment of U-clamps on wire rope

1. Always use the U-clamp of the same size as wire rope.
2. Ensure U-bolt clamps are attached correctly and in required numbers
as shown in picture below.
3. Turn back the recommended length of rope.
258
Wire Rope
4. Recommended procedures for attaching U-bolt clamps are as

follows:
a) Apply first clamp one base width from the dead end of the wire
rope.
b) Tighten nuts evenly to the recommended torque.
c) Apply the next clamp as near the loop as possible. Turn on nuts
firmly but do not tighten.
d) Space additional clamps if required equally between the first
two. Turn on nuts, take up rope slack, and tighten all nuts evenly
on all clamps to the recommended torque.
4 (a)
4 (c)
Proper procedure
to fit U-Clamps
4 (d)
e) Apply the initial load and retighten nuts to the

recommended torque. Rope will stretch and be reduced in
diameter. Inspect periodically and retighten nuts to the
recommended torque.
5. The number of clamps shown in Table-5 below is based upon
using Right Lay Regular Lay (RLRL), or Right Lay Lang Lay (RLLL)
wire rope, 6 x 19 class or 6 x 36 class, fibre core or IWRC, IPS or
EIPS. If Seale construction or similar large outer wire type
construction in 6 x 19 class is used, then add one additional
clamp for wired rope of 1 inch and larger size.
6. For other classes of wire rope not in Table No-5, it may be
necessary to add additional clamps to the number shown.
259
Table-5 : Wire Rope U-Clamps

Wire rope No of Length of rope Torque, N -m
diameter, Inch clamps turn back, Inch
1/8 2 3¼ 6
3/16 2 3¾ 10
¼ 2 4¾ 20
5/16 2 5¼ 41
3/8 2 6½ 61
7/16 2 7 88
½ 3 11 ½ 88
9/16 3 12 129
5/8 3 12 129
¾ 4 18 176
7/8 4 19 305
1 5 26 305
1-1/8 6 34 305
1¼ 7 44 488
1-3/8 7 44 488
1½ 8 54 488
260
Safety in Drilling Operations
13 Safety in
Drilling Operations
Safety is of vital importance in all drilling and well operations at rig.

Adhering to safe working practices is the responsibility of each individual
who is involved in drilling of a well. It enhances company’s image as ‘Safe&
Responsible’organization.
Drilling of a well involves various hazardous operations and requires a
proactive Safety Management System (SMS). Safety does not mean safety
of the human beings only, but it is redefined as ‘Loss Control’. Loss Control
encompasses safety, occupational health, property damage, process loss
and consequential environmental impact. Commitment to safety is vital
at all organizational levels as it fulfills statutory / regulatory requirements,
manages costs, improves overall management of operations .
This chapter covers the safety aspects of following :
(a) Rotary slips
(b) Power tongs
(c) Rotary Table
(d) Cat Heads
(e) Air hoists/winches
(f) Rig Floor Area
(g) Hot Job (Gas Welding/Cutting)
(h) Hot Job (Electric Arc Welding)
(i) High Pressure Testing & Pumping Job
(j) Important Safety Points
(a) Rotary slips

1. Hold the slips with the palms facing upward.
2. Persons working on rotary should use proper posture to remove slips
to avoid injury to the back.
3. Never use slips to stop downward motion of the pipe. Use draw work
brakes instead.
4. Never kick the slips in rotary bowl while RIH.
261
5. Do not let the slips ride the pipe while POOH.

6. Always use safety goggles while changing dies.
7. Never use damaged/ worn-out slips.
8. Always use proper size of slips.
9. Ensure that welding is not done on any part of the slips.
10. Always change complete set of dies.
11. Dope should be applied regularly on outer load bearing surface of
slips to facilitate easy removal of slips.
12. Ensure hinge pins are free and segments move freely.
13. Slips should be inspected regularly using a steel scale to detect any
uneven wear on back of segments.
14. Always keep slips’ dies free from mud and dirt.
(b) Power tongs

1. Tongs should always be used with safety line of proper size and
length.
2. Ensure the strength of safety line is more than break out line
strength of the tongs.
3. The ends of tongs safety line should be spliced/ secured with
recommended number of wire line U-clamps.
4. No jerk should be applied to any pull line or safety line. As these
are not designed for shock loading.
262
5. During crack opening/ final tightening, all rig floor personnel

should be in safe position. No person should stand behind
tongs in tong swing zone.
6. Do not use tongs on any mouse hole operation when Kelly is
rotating as it may lead to serious accidents.
7. Line-pull gauge should be used to ensure recommended
torquing.
8. Inspect pull lines, safety lines, tongs hang-off lines and all pulleys
periodically and replace as and when required.
9. Monkey tongs should never be used for cracking open and final
tightening of tubular joints during tripping as it is meant only for
initial tightening and opening of tubing joints. If broken it may
cause serious injury to crew.
10. Never use damaged tongs.
11. Ensure that welding is not done on any part of the tong
12. Use both the tongs for making and breaking out tubulars.
13. Recommended line sizes are:
o 16 mm: Tong hang off line
o 19 mm line: Pull-line of Make-up tong
o 22 mm line: Break out line
o 25 mm line: Ezy-Torq line/ Back-up line for tongs
14. The tong dies should be kept clean and checked for wear. If worn
out, replace immediately.
15. Adjust tong counter balance for easy up and down movement of
tongs.
16. Hang tongs properly by adjusting balancing screw.
17. When tongs are not in use, secure properly in the derrick.
18. Grease hinge pins regularly.
19. Never use smaller size pin in a bigger size hole in a hinge as it may
lead to serious accident. Use only proper size of tong jaw pin.
20. Tongs should be at 90 degree to pull/ safety line when final
tightening is carried out.
21. Do not apply tongs on pipe body as it may crush or damage the
pipe
22. Hydraulic cathead (Ezy-Torq) should be used for making up/
breaking out joints requiring torque more than make-up cathead
capacity, normally for 8" or bigger size drill collar.
263
(c ) Rotary Table
1. Rotary table gear, driving chains and sprockets should be secured
with proper guards.
2. Driller should start the rotary only after ensuring rotary table is clear
of all material/ personnel.
3. Check both mechanical locks are working. Never use mechanical lock
of the rotary table to stop rotary motion which may lead to accident.
4. Rotary table should not be used for crack opening or tightening of
tubular joints.
5. Set rotary torque limit based on drill string in use.
(d) Cat Heads

1. Crew members should be watchful and careful while operating
cathead.
2. Ensure that separator is in place with the cat head to avoid
overlapping of manila ropes which may cause an accident.
3. The driller must be vigilant to stop rotation of the cat head, in the
event of any emergency.
4. Three safety rules to keep in mind when using a cat line on cathead
are :
(i) Never add more than necessary wraps on the cathead.
264
(ii) Driller should always be on the controls to stop power to cathead

in case of emergency.
(iii) Crew member should never stand on coil of surplus cat line on
the floor.
5. Never use damaged cat lines or jerk lines on cathead.
e) Air hoists/winches
1. Ensure rig air supply pressure of 120-125 psi for safe and efficient
working of air winch.
2. When hoisting line is unspooled from the drum, at least six wraps
should be left on the drum to avoid excessive loading and slipping of
wire line from anchor clamp.
3. Use man rider winch only for lifting rig personnel.
4. The winch operator should always be vigilant while operating winch.
5. Winch line should be secured with a tag line while lifting light load to
avoid winch line flying off in derrick. The same can also happen while
handling loads higher up in the derrick.
6. Operate winch smoothly and without jerks. Make sure that winch
line and loads are moving with same speed.
265
7. Do not lower winch further if load is stuck in derrick/ mast to avoid

falling down of load in case of sudden release.
8. Ensure rig personnel operating winch are not wearing any loose
clothing.
9. Never operate winch without drum guard.
10. Periodically check winch brake shoe to ensure safe operation.
11. Load being lifted should always be visible to the winch operator.
12. Winch should not be used to lift more than recommended load
capacity.
13. Check winch foundation bolts regularly.
14. Check wire rope regularly and replace if required.
15. Check wire rope pulley mounted on crown block and greased
regularly.
16. Operator should never leave the winch even in locked condition
unattended when load is on the winch.
17. Use only certified shackles of proper load capacity.
18. Make sure winch line is not entangled anywhere in the derrick/ mast.
f) Rig Floor Area

1. Ensure proper house keeping;
§Rig floor should be kept clean and non-slippery.
§All un-wanted material should be off loaded from the rig floor.
§All drilling handling tools including power tongs, elevators, slips
etc. should be properly arranged.
§Ladders and the railings and steps of stairs should be in order.
2. Wear PPE at all times
3. Ensure Top man safety belts are in proper condition.
4. Ensure Top man escape device is tested at new location and is
working properly. Also it should be provided with proper landing
platform.
5. All guy ropes are properly anchored.
6. Ensure fall arresting device is working.
7. Ensure Toe Board around Derrick Floor is available.
8. Check BOP Accumulator unit is charged to required pressure:
266
§Accumulator pressure: 3,000 psi;

§Manifold pressure: 1,500 psi
§Annular pressure: 600-1,500 (As required).
9. Ensure proper illumination of derrick floor and mast.
10. Ensure aviation light is in working order.
11. Ensure IBOP and FOSV are available on the rig floor in open position
and with required cross overs and operating wrench.
12. Avoid swinging of travelling block.
13. Do not lift any tubular to derrick floor when rotary is in motion to
avoid accident.
14. During casing operation, crane should be visible from rig floor and
only designated person should give signal.
15. Use balancing rubber strap on elevator for easy operation of elevator.
16. Never use mobile phone at Derrick Floor.
17. Ensure Crown-O-Matic/ Twin Stop is functioning properly.
18. Avoid water wastage as it may lead to water logging in the site.
19. Escape routes from the rig floor should remain obstacle free at all
times.
20. Ensure that mouse hole and rotary table opening are covered when
not in use.
21. In case of gas well, gas detector should be available at derrick floor.
g) Hot Job (Gas Welding/Cutting)

1. Always obtain Hot Work Permit prior to any Hot Job.
2. Use goggles, hand gloves, face shield/helmet with dark glasses and
cotton overalls with full sleeves.
3. All oxygen lines and fittings should be free of oil or grease.
4. Ensure pressure gauges are functioning properly.
5. Operate cylinder valves slowly to avoid sudden release/ pressure
surging.
6. When welding in vicinity of flammable material, beware of flying
sparks and hot slug. Keep fire extinguishers ready close by.
7. Ensure Spark Arrestor (Non return safety valve-NRV) is installed to
avoid back fire.
267
8. Never carry out hot job in an enclosed area/tank unless it is properly

ventilated and all necessary safety measures are in place.
9. Never use gas cylinders as work supports.
10. Store acetylene and oxygen cylinders separately with proper cap.
11. Never keep cylinders near source of heat.
12. Never weld galvanized or coated metals without taking due
precautions.
13. Use trolleys to transport cylinders to avoid crushing or damaging
hoses.
14. Only authorized and qualified welder should be allowed to carry out
any gas welding job.
(h) Hot Job (Electric Arc Welding)

1. Before carrying out any electric welding job, hot work permit should
be issued and ensure all the safety measures and precautions are in
place.
2. Designate and display “Welding Area”properly.
3. Use certified electrode holder and welding cables.
4. Ensure that shield of helmet has the correct filter glass.
5. Wear adequate personal protective gears like full-sleeve overall,
leather gloves & shock proof shoes etc.
6. Ensure that cables and connections are in good condition.
7. Make sure that the welding equipment; bench or work piece is
properly earthed.
8. Weld inside enclosed vessels only after ensuring that the area is free
from any toxic gas and necessary safety measures are in place.
9. Protect welding transformer from rain/ water. Do not carry out
welding in rain/ wet conditions.
10. Only authorized and qualified welder should be allowed to carry out
any electric arc welding job.
(i) High pressure pumping & testing Job
1. Safety meeting should be conducted prior to carry out any high

pressure pumping and testing jobs.
2. Individual job responsibility should be assigned to personnel
involved in operation.
268
3. Area of pressure testing should be clearly demarcated.

4. Flammable or combustible fluids are not to be stored in open tanks.
5. When pumping and carrying out pressure testing, ensure that:
i. High pressure lines are secured and anchored properly.
ii. Pressure gauges are of proper range and calibrated.
iii. Safety valves are set at the recommended pressure and tested.
iv. All pumping and pressure testing jobs should be recorded on
pressure-charts.
v. Only authorized personnel to be allowed in the operational area.
6. Surface pumping pressure should be limited to working pressure
rating of line and assembly parts viz union/chicksans/valves/cross-
over etc.
7. After testing is over, ensure that pressure is completely bled off from
test lines before disconnecting lines.
8. Do not tighten any leaking joint without releasing pressure.
(j) Important Safety Points

1. Always conduct a safety meeting before starting a job on the rig floor
to discuss hazards involved and safety precautions to prevent
untoward incidents and accidents.
2. All work platforms that are 1.80 meters or more above ground level
shall be guarded by a standard railing at least 1.00 m high with toe
board of 0.15 m height.
3. Safety valve should be set at 10 % higher than the normal working
pressure. It must be calibrated and tested every year or as and when
required.
4. Air pressure vessels should be tested as per statutory guidelines.
5. All moving parts should have guards.
6. Portable Gas Detector must be calibrated every year.
7. Availability of Electrical Safety gadgets like Earth Leakage Relay (ELR)/
Earth Leakage Circuit Breaker (ELCB), use of flame proof equipment
in classified zones, proper angle earthing of equipment, use of
proper PPE, rubber mats etc. should be ensured.
8. Pump discharge line and rotary hoses must be fitted with safety lines.
9. While working on any machinery/ equipment, ensure power is
switched off and lock-out permit is to be issued. Ensure ‘Man at
269
Work’ signage is displayed properly at necessary places like work

place, control room and rig floor.
10. In case BOP is closed, it should be clearly displayed at rig floor, driller’s
console and Accumulator Unit.
11. Portable Fire Extinguisher must be tested as per guidelines.
12. Never allow any rig personnel under moving load at drill site.
13. Work Permit System like lock out permit, Hot and Cold work permit
should be adhered to.
14. All engines to be provided with discharge muffler, acoustic enclosure
and spark arrestor.
15. Engines are to be equipped with safety devices like over speed
tripping, low lube oil alarm and hot engine shut down etc.
16. Ensure dykes (bundh) around diesel tank and waste pit.
17. Fencing: around Drill site, Fire Water Tank, Oil Pit–Not less than 1.80
M in height.
18. Use certified mast pins/studs with proper lock pins/check nuts.
19. Material Safety Data Sheet (MSDS) should be made available at
operation site.
20. Ensure:
o Proper Rig Illumination.
o Good housekeeping.
o Safety Sign Boards and Hazardous Zones are displayed.
o Availability of round-the-clock emergency vehicle/ambulance.
o Availability of breathing Apparatus.
o Availability of safety torch.
o Availability of eye wash facility at hopper
o Availability of first aid kits.
o Wind socks are installed on the site to check wind direction.
o Disaster and contingency plan is displayed on site.
o Availability of round-the-clock communication at rig site with
alternate means of communication.
270
ABOUT THE AUTHORS
•Dr ASHOK KUMAR PANDEY, Ex-GGM (Chem.) A Drilling Fluid

Expert in Designing and implementation of remedial measures for
specific Bore hole problems. Successfully used High Performance
water based Mud systems and SOBM in HTHP wells More than 30
years experience in Conformance Control Viz. Water shut off &
Profile Modification, Well Stimulation, Work overs and Hydrofrac
Campaign in Gandhar field of ONGC.
•A. JAVED, GM (Drilling), B.Sc. (Mechanical Engg.) from National
Institute of Technology, Jamshedpur joined ONGC in March 1982
and worked in Sibsagar, Assam as a shift in charge till 1986 and as
DIC till 1990.He worked in Mumbai Offshore from 1990 in various
capacities in technical section, as a tool pusher on a drilling rig, in
charge of BOP cell and Rig Manager of Ed-Holt and SagarSamrat till
2002. From 2002 to 2005 he was posted at Cachar Forward Base,
Silchar as Operations manager and Location manager, drilling and
was associated with the successful drilling of a number of deep
wells. Presently is Head of R&D(drilling),Operations Monitoring
Group,PC&CGgroup,OABG group and Support Manager at IDT,
Dehradun and is also a senior faculty for advanced, basic and door
step drilling training courses.
•V K GUPTA, GM(D) Incharge OMG, is M TECH from NIT, Bhopal and
has 32 years experience in ONGC. He has wide field experience in
drilling operation in Offshore and on the Land Rigs. He is a regular
faculty for Drilling Technology courses. Presented Papers in;
Petrotech'12 & Workshop by OISD in Nov'13. Awarded Best Paper
in International Conference on Drilling Tech. at IIT Madras in
Dec.'12
•RAJEEV DHUPAR,GM (D) Head Training, is a Mechanical Engineer
from Jiwaji University, Gwalior and has more than 32 years'
experience in ONGC. He has 18 yrs of field experience in drilling
operations in Bombay Offshore mainly on drill ships and Assam
asset. He is also a member of National Gas Hydrate Programme. He
is a regular faculty for Drilling Technology courses and specializes in
the latest advancements.
271
•SANJAY DOBHAL,GM(D)Incharge Drilling Technology School,is BE

(Mechanical Engineering) from BITS, Pilani and has 30 years
experience in ONGC. He has wide field experience in drilling
operation in Mumbai Offshore and on the Land Rigs. He is a regular
faculty for Drilling Technology courses.
•CHANDAN PAUL He is BE (Mechanical Engineering) from Assam
Engineering College, Gauhati and has 32 years experience in
ONGC. He has wide field experience in cementing operation in
Offshore and on the Land Rigs. He is a regular faculty for Drilling
Technology courses.
•A.K. GOYAL DGM (D) is a mechanical Engineer from Punjab
University & joined ONGC in 1984.He has vast experience of
offshore floater rigs & specializes in Subsea BOPs and was I/C BOP
Yard, Sibsagar .He is a faculty on Well Control for IWCF/IADC &
IAWC.
•V.N.RAI, Ex-DGM (Chem.) A Drilling Fluid expert with more than 36
years of experience in Onshore and Offshore oil fields of ONGC in
Tripura, Assam, Mumbai Offshore and Ahmedabad. Have drilled
approx.. 250 wells using different types of Mud Systems like CL-CLS,
KCl-PHPA-Polymer, Polyamine – Polymer Mud, Non damaging
Drilling Fluids, Oil based Mud System etc.
•SANJEEV SINGHAL Presently working as In-Charge , Well control
school, IDT, ONGC Dehradun and is Centre Manager for Well
control courses under IWCF & IADC at IDT. He is BE (Mechanical) ,
MBA ( Project Management) and has been associated with the
Oil Industry for last 27 years.He has worked in different positions
like as Driller, Tool Pusher, Drilling Engineer and Rig Manager on
land rigs in ONGC.
272
Notes
273
Notes
274
Notes
275
Notes
276

Standard Drilling Procedures for Efficient Operations

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Standard Drilling Procedures for Efficient Operations

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STANDARD OPERATING PROCEDURES

Oil and Natural Gas Corporation Limited

Designed & Printed by

S.No. Chapter Page

1. Drilling Operations 1-28

2. Bottom Hole Assemblies 29-38

3. Drilling Bits 39-48

4. Drilling Hydraulics 49-61

5. Drilling Fluid Management 63-117

6. Casing Operations 119-132

7. Cementing Operations 133-172

8. Installation of Well Head 173-181

9. Directional Drilling 183-194

10. Fishing 195-208

11. Well Control 209-246

12. Wire Rope 247-260

13. Safety in Drilling Operations 261-270

Drilling operations need to be carried out in a safe, efficient, and

a) Preparation for spudding the well

6. False conductor may be pre-installed to a depth of approximately 20-

Checklist prior to spudding

b) Common drilling practices for all phases

9. Gauge all stabilizers and check connections of all BHA components

31. Equivalent thread connections:

c) Drilling 26" hole section

S.N. Items Qty required

S.N. Items Qty required

d) Drilling 17-1/2” hole section

S.N. Items Qty required

Sequence of Drilling Operations

5. Test casing to 500 psi or as per specific requirement of well maximum

e) Drilling 12-1/4” holesection

S.N. Items Qty required

S.N. Items Qty required

Sequence of Drilling Operations

c. Monitor shakers for change in shape and volume of cuttings and

f) Drilling 8-1/2” hole section

S.N. Items Qty required

Sequence of Drilling Operations

20. During logging, monitor well on trip tank.

g) Drilling 6” Hole Section

9. Ensure activation balls/darts (e.g. for PBL circulating subs) are of

Sequence of Drilling Operations

8. Wash down to bottom and drill 3 m fresh hole.

- Circulate and condition mud

- Release the pressure and measure the volume of fluid recovered in

i) Leak-off Test (LOT)

Ps=Surface pressure in kg/cm2at the point after which formation

j) Recommended practices for tripping out

5. Hole conditions will determine when to pump slug. It is advisable to

k) Recommended practices for tripping In

6. If not then ream down as explained below.

I) Recommended practices for reaming

m) Recommended practices for back-reaming

4. In the event of a pack-off, which can be identify by pressure shoot up.

n) Recommended practices for wiper trips in deviated hole

o) Recommended practices to clear pack-off

2. Stop pump as soon as pack-off is suspected. Continuous pumping will

p) Recommended practices for surface seepages

In case mud loss is not controllable by system drilling fluid,

10. Confirm seating of ball in core barrel with rise in pressure.

28. Place core in boxes as per proper sequence

r) Casing Rat Hole Clearing/Reaming