BOP - Handbook

STANDARD OPERATING PROCEDURE
BLOWOUT PREVENTION
BOP Procedure/J.Keemink/2010 Page 1

TABLE OF CONTENT
1. GENERAL

SECTION I
GENERAL
1.1 HYDROSTATIC PRESSURE
Hydrostatic Pressure is the weight of the column of fluid at the bottom of the well and is normally referred
to in psi (pound per square inch). To calculate the hydrostatic pressure only use the vertical depth of the
well and not the measured depth since wells do not have to be, and rarely are, truly vertical.
A column of fluid one foot on each side exerts a downward force equal to the weight of the fluid in it.
If we would fill the cube with fresh water, for instance, the weight would be 62.36 pounds. To calculate
the pressure we would have to divide the weight by the area, in this case 62.36 / 12 x 12 = 0.433
psi/foot (pound per square inch per foot), also called the pressure gradient.
This would be the pressure of water standing still or the hydrostatic pressure.
If we wish to find the pressure exerted by a column of water 10 foot high we would have to multiply the
hydrostatic pressure of a 1 foot column by the height or: 0.433 x 10 = 4.33 psi. If the column of water
would be 100 feet high the pressure would be 43.3 psi. With a column (vertical well depth) of 1000 feet
the hydrostatic pressure would be 433 psi.
Notice here that the actual volume of water is not important, only the vertical depth of the well
determines the hydrostatic pressure at the bottom of the well. Please remember this when working with
deviated wells were using the measured well depth would result in large errors when calculating the
hydrostatic pressure at the bottom of the well.
It is not customary however to measure fluids in the oil and gas industry in psi/foot but in pounds/gallon.
To calculate the pressure gradient of fluids measured in pounds/gallon we can use the conversion factor
of 0.052, where psi/foot = 0.052 x ponds/gallon. For instance, fresh water weighs 8.33 pounds/gallon,
so 8.33 x 0.052 = 0.433 psi/ft.
Pressure can also be measured using different units such as kilograms/square centimeter,
Newton/square centimeter or kilopascals.
Density, or weight of fluid per unit volume can be measured in ponds per gallon (ppg), pounds/cubic
foot, kilogram/cubic meter and grams/liter.
Density can also be measured as specific gravity, a way of measuring without units. Specific gravity is
comparing the unit weight of a liquid compared to the density of fresh water where the density of fresh
water is set as 1. In case of gasses the density is compared to that of air where the density of air is set
as 1.
Conversion factors can be found in many engineering handbooks and tables. Some of the most common
ones are:
1 kg/sq. cm = 14.22 psi
1 Newton/sq. cm = 1.45 psi
1 kPa = 0.145 psi
Pound/gallon = 0.13368 pound/cu. Feet
Pound/gallon = 0.0238 pound/barrel
Pond/Gallon = 0.00834 kilogram/cu. meter
Pound/Gallon = 0.00834 grams/liter
Pound/Gallon = 8.336 s.g (water=1)

1.2 PRESSURE AND FLOW
Pressure on a gauge does not include the pressure exerted by the atmosphere, which extends upwards
from sea level to some ------- miles. Atmospheric pressure varies with the elevation, humidity and weather
conditions but 14.7 psi is often used as a standard.
Gauges as normally set to zero when only exposed to the atmosphere. The true, or absolute pressure
would be the gauge pressure plus 14.7 psi.
If we use the term psia (pressure per square inch absolute) it shows that the atmospheric pressure has
been added to the gauge pressure.
Since our main concern here will be differential pressures, and since atmospheric pressures acts on all
points in any system, we can in general ignore it.
In addition to static pressures there are dynamic pressures caused by the movement of fluid. This
dynamic pressure, also referred to as circulating pressure is actually the pressure required to overcome
friction, i.e. of fluid rubbing against a pipe surface, and the friction of fluid rubbing against itself
(turbulence).
Commonly the circulating pressure (CP) is the difference between the drill pipe pressure and the casing
pressure.
Circulating pressure decreases as it passes through a system. It is the highest at the point of fluid entry
and the lowest, often zero, at the point of fluid exit. In most drilling circulating systems the circulating
pressure at the bottom of the drill string is normally 10 percent (10%) of the circulating pressure at the
surface. If we assume that the circulating pressure is 250 psi than the circulating pressure at the bit will
be:
CP (bit) = 0.1 x CP
CP (bit) = 0.1 x 250
CP (bit) = 25 psi
If the well depth is 1000 feet and we use fresh water as drilling
fluid than the bottom hole pressure will be:
BHP = HP + CP
BHP = 433 + 25
BHP = 458 psi
One additional form of pressure is called the back pressure

(BP) caused by a restriction, such as a choke, in the system or
by pumping into a shut-in well. If we see pressure at the surface
after stopping pumping this is caused by the formation pressure
being higher than the hydrostatic pressure of the fluid in the
well bore.
If we refer to Fig. 1, with a CP of 435 psi and a BP of 185 psi

using fresh water in a 1000 ft well, than the bottom hole
pressure will be:
BHP = HP + Atm + CPbit + BP

BHP = (1000 x 0.052 x 8.336) + 14.7 + (0.1 x 435-185) + 185
BHP = 433 + 14.7 + 25 + 185
BHP = 657.7 psia

Pressure is required for flow and all equipment exposed to it must be able to withstand anticipated
pressures.
When we want to move mud, or other fluids, down the drill pipe and up the annulus we must apply a
certain amount of pressure to overcome friction before we can establish flow, The required pressures
depend on the size of the piping, characteristics of the fluid and velocity (speed).
If we are drilling there is a difference in mud weight between the annulus and the drill pipe. The drill pipe
will contain clean mud while the mud weight in the annulus will be higher due to suspended cuttings.
While the pump is running the mud will travel down the drill pipe and up the annulus, but when we stop
the pump the flow will be reversed due to the difference in hydrostatic pressure.
HPdp = 0.052 x 10.0 x 8,000 = 4160 psig

HPan = 0.052 x 10.2 x 8,000 = 4243 psig
P = HPannulus HP dp
= 4243 4160
= 83 psi
This reverse flow would be unsatisfactory since with a flow from the annulus to the DP solids and cuttings
in the mud would settle at the bottom of the well and could plug the nozzles in the drill bit.
To calculate how much the fluid level in the annulus would

drop, the HP in both the drill pipe and the annulus should
be the same so the annulus pressure has to be reduced to
4160 psi,
With a HP annulus of 4160 psi and a mud weight of 10.2

lb/gallon the column of fluid in the annulus would be:
HP / (0.052 x 10.2) = 7843
Meaning, the fluid level in the annulus would drop 8,000

7,843 = 157 foot.
If we would reverse Fig. 2, with 10.2 lb/gallon mud in the drill pipe and the mud in the annulus would be
cut by pore gas to 10.0 lb/gallon than the same 83 psi pressure difference would apply. However in this
case the annulus pressure would be lower than the DP pressure and the difference in HP would help or
accelerate the flow up the annulus.
Back Pressure is another form of resistance to flow, as the choke in Fig. 1. As the restriction gets bigger,
meaning the choke gets smaller, the resistance or back pressure increases until the circulating pressure
is overcome and the flow stops. Generally this would mean that a valve is closed.

SECTION II
FRACTURING AND LEAK-OFF TESTING
The pressure at which a formation can split or crack so that fluid can flow through these cracks is called
the fracture pressure. If a combination or hydrostatic pressure and surface pressure exceeds the fracture
pressure of the formation the formation will take fluid and returns to the surface will be reduced or lost
completely.
The fracture pressure, for any formation, depends on:

The compressive strength of the formation
Poissons ratio of the rock
Permeability
Bottom hole (pore) pressure
Characteristics of the fracturing fluid.
A clean fluid will penetrate the formation at a lower pressure than a fluid with a high solid content such as
drilling mud.
The fracture pressure gradient is the equivalent of the pressure gradient at which the formation will
fracture. The equivalent pressure gradient includes fluid density and circulating pressure.
The fracture gradient for the US Gulf Coast region, below 1,500 feet for clean fluid can be calculated as:
FG = 0.45 + ((0.55 x BHP) / Depth in Feet)
With a normal pressure gradient of 0.465 psi/ft, in the Gulf region, we would expect the BHP at 7,000 feet
to be 3255 psig. To fracture this reservoir we would calculate the required fracture gradient as follows:
FG = 0.35 + ((0.55 x 3255) / 7,000)

FG = 0.45 + 0.26
FG = 0.71 psi/ft (using clean fluid)
The fracture pressure would be:
FP = FG x Depth (ft)
FP = 0.71 x 7,000
FP = 4,970 psi
After many years of drilling in one area, such as the Gulf

Coast, data can be collected to establish empirical fracture
gradient graphs, such as in Fig. 3..
From this graph we can determine that at 7,000 feet the

required pressure gradient using drilling mud would be 0.79
psi/ft providing a fracture pressure of: 0.79 x 7,000 = 5.530
psi.
Please note the difference between the fracture pressure

using clean fluid and drilling mud of 560 psi. This is very
important when circulating out a kick using clean fluid.
Fig. 3 Pressure Gradient using Mud

The fracture gradient for clean fluids is derived from field experience and will be different from area to
area depending on the geology of the area. The pressure, or overburden, gradient can be as low as 0.25
psi/foot or as high as 0.7 psi/foot.
For wells shallower than 1,500 feet the equation is not valid because of shallower fractures with different
characteristics.
The pressure at which a formation will fracture controls the maximum allowable surface pressure. Using
the above case for a depth of 10,000 feet with a mud weight of 9.4 lb/gallon we find that:
HP (mud) = 0.052 x 9.4 x 10,000 = 4,888 psig
FP = 0.89 x 10,000 = 8,900 psig (gradient from Fig.3)
The maximum allowable surface shut in pressure, with mud in the hole, would be:
MASIP = 8,900 4,888 = 4,012 psig.
If the hole was filled with salt water, of the same weight, the maximum allowable surface pressure would
be reduced because the formation fractures more easily with a clean fluid.
FG = 0.45 + ((0.55 x 4,888) / 10,000) = 0.72 psi/ft.
FP = 0.72 x 10,000 = 7,200 psi.
In this case the maximum allowable surface pressure, with clean salt water in the hole, would be:
MASIP = 7,200 4,888 = 2,312 psig.
If this is not taken into account, the difference between using mud and clean fluid can result in serious lost
circulation problems.
Although many papers have been written regarding fracture gradients and how much pressure a well can
take before a formation breaks down and lost circulation occurs, the best way to determine the fracture
pressure is to conduct a so-called bleed-off or leak-off test. These tests are carried out after drilling
approximately one DP joint after drilling out of set casing. Many agencies require that such a test is
performed not more than 15 meters (49 feet) after drilling out of the surface casing and all subsequent
casing strings.
A successful leak-off test will provide invaluable data for control of kicks and design of casing string
setting depths. Leak-off tests should be properly supervised and correctly entered into the Drillers log and
included in daily drilling reports.
Leak-off test should be carried out with the DP pulled back into the casing to avoid sticking problems.
The pump(s) used for a leak-off test must be able to pump slowly at rates of 1/3 to barrel per minute
without surges. A mud pump might be used but normally a cementing unit pump, providing higher
pressures at lower volumes, is used.
Leak-off test procedures require that the stand-pipe pressure is recorded every minute or so along with
the cumulative strokes or volumes pumped.
The following is normally recommended:

1. Make a short trip into the casing
2. Close annular preventer on DP
3. Install a full opening safety valve in the drill pipe

4. Rig up lines to the drill pipe and fill the lines with drilling fluid.
5. Start pumping at 1/3 to pm
6. Record stand-pipe pressure and volumes pumped continuously.
7. Test to predetermined pressure (MACP) or till pressure drops and does not rise back again.
8. Stop pump, record stabilized pressure, bleed pressure of annulus.
9. Check that the well is dead.
10. Plot data on standard graph paper as pressure versus volume or strokes pumped.
The typical leak-off test curve will be almost a straight

line until leak-off starts. If pumping continues the
pressure will continue to increase until the rupture, or
fracture, pressure is reached. The pressure will then
decrease until the pressure to hold open and spread
the fracture (propagation pressure) is reached. When
the pump is shut down the pressure will bleed down
until the fracture closes and the formation heals.
Leak-off tests do not weaken the formation with respect to holding pressure. Repeated tests will result in
identical leak-off, propagation and bleed-off pressures as were reached during the first test.
As the well is drilled deeper, mud cake continues to age, the rotating DP will pack the cake and plaster
the wall, filtration will move deeper into the formation so that leak-off tests carried out later in the life of the
well show a higher leak-off, propagation and bleed-off pressures.
Rupture pressure is the true (surface) fracture pressure, however here we have no room for operator
error, faulty or un-calibrated gauges and therefore should not be used during drilling and kick killing
operations.
Bleed-off pressure, or the maximum pressure at which the reservoir will heal itself, is conservative and
would be a hindrance to efficient drilling operations.
Propagation pressure is just a little higher than the bleed off pressure and suffers from the same
problems.
The leak-off fracture pressure is reasonably conservative and realistic and is normally used when
calculating fracture gradients and pressures when selecting casing setting depths.
Surface pressures are normally the information required during drilling operation. The surface pressure
can be calculated by determining the reservoir fracture pressure and deducting the hydrostatic weight of
the fluid column. If the mud weight is changed we have to adjust the surface pressures allowable to
compensate for the changed hydrostatic pressure. At all times make sure that vertical depths are used
and not measured depths.
Example:
Rupture Pressure = 1310 psi

Leak-off Pressure = 1200 psi
Propagation = 1010 psi
Bleed-off = 970 psi
Old Mud Weight = 9.4 lb/gallon
New Mud weight = 9.7 lb/gallon
TVD = 10,000 feet
TVD casing seat = 8,200 feet.

Calculate:
New (adjusted) Leak Off Pressure = Leak-off Test [(0.052) x (Present Old Mud) x TVD casing seat]
= 1200 [(0.052 x (9.7 9.4) x 8400]
= 1200 128
= 1072 psi
In the above case we are drilling with 9.7 lb/gallon mud and the calculated fracture equivalent mud weight
is 11.7 lb/gallon. Such a well could take a 2.0 lb/gallon kick but a 2.1 lb/gallon kick would be pushing our
luck and a 2.2 lb/gallon kick would probably cause lost returns.
When drilling out of the surface conductor, and in general in formations shallower than 1,500 feet, and
sometimes deeper depending on the geology, the nature of fracturing is different. The fractures tend to
form horizontal lines, like pancakes, lifting the formation above them. If there is a lot of vertical movement
the earth is shifted relative to the casing and a channel can be created that allow fluids to travel to the
surface outside the casing. This is extremely dangerous and, especially in marine environments.
In shallow depths the fracture gradient of 0.71 psi/foot cannot be relied upon. After setting conductor pipe
the pressure at the casing seat must not be allowed to exceed 0.5 x casing depth (in feet). Surface
pressures allowed are further reduced by the weight of mud in the hole.
Fracturing a formation when the well is shut-in to control a kick causes loss of circulation and
may lead to total loss of control and extreme danger to personnel, equipment and the
environment.

SECTION III
BLOWOUT PREVENTER TESTING
The purpose of Blowout Preventers is to allow the annulus of the well to be closed during kicks to prevent
the well from unloading and causing a blowout.
Annular preventers are normally of the spherical

rubber seal type but can also be RAM type.
The annular preventer must be designed to

withstand the maximum shut-in pressure expected.
If the well is allowed to blow fluid from the hole and

we then shut in the well the maximum possible
pressure would be the reservoir pressure minus the
hydrostatic head of gas.
WP bop = Formation Pressure 0.1 x depth
Spherical BOPs are normally tested to 70% of their

working pressure.
RAM type preventers can be either single or double

type.
The single type is normally fitted with pipe rams

where a seal is created around the outside of the
drill pipe.
Double rams come with a (lower) pipe ram and a

(upper) blind ram. A blind ram is a set of shears
designed to be able to cut drill pipe cleanly and
create a seal at the same time.
Annular, or spherical rams, are normally only tested to 70% of their working pressure. Ram type
preventers are normally tested to 100% of their working pressure. However, in all cases blowout
preventers shall only be tested to a maximum of 70% of the burst strength of the casing, whichever is
higher.
The working pressure of BOPs, as for all other equipment, is the maximum pressure that the equipment
is expected to operate during its normal lifetime. The design test pressure is the maximum pressure that
the body of the preventer is capable of withstanding and is normally twice (2x) the maximum allowable
working pressure.
The term tested pressure might cause confusion. The tested pressure is the pressure to which a certain
stack has been tested to recently. Normally this is the pressure rating of the flange seals. If a stack is
tested to 3,000 psi, rated to 5,000 psi WP and has a 10,000 psi design test the maximum allowable
pressure on the stack is 3,000 psi.
If possible stacks should be tested to above the maximum SICP (Shut-in Casing Pressure) anticipated.

SECTION V
CASING SIZE AND STRENGTH LIMITATION
Seamless casing is fabricated by extrusion of a solid billed of steel into a tube using a mandrel and
outside rollers.
Seamless pipe, such as casing, is manufactured by

the extrusion of a solid billet of steel into a tube
using an internal mandrel and external rollers.
The grade, or type, of steel (metallurgy) and the

thickness and diameter determine the strength of
the casing pipe.
All casing has a failure or rupture pressure at which

the pipe will burst and an external pressure at
which it will collapse.
Steel grades, by the API system, start a low carbon steel F-25 (mild steel) to V-150 (high tensile steel).
Grades C-75 and lower are used in H2S service since higher grades of steel will become brittle and crack
in the presence of H2S.
The strengths listed in casing tables are design strengths for new casing and do not include any safety
margins. The casing pipe is designed to be able to reach the stated pressure once before failure.
Therefore, new casing pipe is only exposed to a maximum of 80% of the design strength to provide for a
margin of safety.
As the casing deteriorates from abrasion, corrosion and erosion its strength is reduces and failures may
occur at pressures as low as 10% of the original design pressure.
The burst strength of casing must be designed so that a kick can be controlled by shutting the well at
surface without failure of the casing.
Here we must keep in mind that the highest

pressures are encountered during a kick when a
gas bubble travels from the bottom of the well to
the surface without expanding. In such a case the
full reservoir pressure, minus the hydrostatic weight
of the gas column, is than placed on the surface
equipment..
The unexpanded, and therefore unreduced, gas

pressure is than exerted together with the
hydrostatic pressure of the mud on the formation. If
this would be allowed to happen than fracture
pressures would be exceeded resulting in loss of
mud into the formation. In reality this is not likely to
happen since the gas would be vented to
atmosphere through a choke.

The most likely event would be that all mud would be lost into the formation and that the well would be
filled with gas only. In such a case the surface pressure would be the formation pressure minus the
hydrostatic weight of the gas column (approx. o.1 psi/ft) giving:
CP = BHP 10,000 x 0.1 psi/ft = 4304 psi
In all cases, never allow the surface pressure to exceed the bursting pressure of the casing. If we allow
the surface pressure to approach the bursting strength of the casing the casing will probably burst
resulting in a uncontrollable blowout.
Maximum casing pressure for new casing should never be allowed to exceed 80% of the listed burst
strength of the casing. Old casing should be evaluated and more severe limitations should be set.
Collapse resistance is the external pressure, in psi, that is needed to collapse or crush the casing from
the outside without any pressure inside the casing.
Any internal pressure will assist in holding the casing open. However many combinations of external
pressures with only gas or light fluids inside the casing can lead to collapse and failed casing.

SECTION VII
MAXIMUM ALLOWABLE SHUT-IN CASING PRESSURE
MACP
When a kick is suspected, the first action to be taken is to shut-in the well and record shut-in casing
pressure (SICP) and shut-in drill pipe pressure (SIDPP).
If the SICP will exceed the burst strength of the casing the casing will fail resulting in uncontrollable flow
just below the wellhead. The surface casing pressure may never be allowed to exceed the actual
bursting strength of the casing.
The pressure that can be handle by the BOP stack further limits the maximum allowable SICP. If the BOP
stack is exposed to a pressure higher than previously tested the preventers or the seals may begin to leak
or burst altogether.
The BOP stack should always be tested to a pressure higher than the maximum SICP expected and
pressures may never exceed the latest pressure test of the BOP.
The leak-off test will provide the maximum allowable surface pressure that the open hole can take without
fracturing the formation resulting in lost returns.
The maximum pressure seen on the formation during kick-killing occurs just as the kick-kill fluid reaches
the zone and a still undiluted column of fluid exists between the formation and the surface.
The first permeable zone below the casing shoe is almost always the weakest fracture point. The surface
casing pressure must never exceed the (surface) leak-off test pressure adjusted for any changes
in mud weight.
EXAMPLE
From casing data tables we find that 7 N-80 casing with a weight of 29 ppf has a design burst pressure of
8160 psi. Using a safety factor of 20% we find a maximum allowable surface casing pressure of 6528
psi (with new casing) without fear of casing bursting.
The BOP stack has been tested to 3500 psi.
The formation at 3500 feet will fracture at 1200 psi surface pressure using 10 lb/gallon mud in the hole.
We can hold 1200 [(0.052 x (10.2-10) X 3500] = 1164 psi without losing circulation.
The maximum allowable casing pressure (MACP) is the maximum pressure that still ensures integrity of
the casing, BOPs and the open hole.
In Fig. 7, the casing is good for 6528 psi, the BOP stack is good for 3500 psi and the open hole is good
for 1164 psi. The maximum allowable MACP, to ensure the integrity of the casing, BOP and formation,
would be 1164 psi.
After the MACP has been determined it should be posted clearly at the drillers station and the choke
panel.
The MACP cannot be exceeded; pressures must be relieved rather than allow the SICP to exceed
the MACP.

Fig 7.
When only surface pipe has been set a pressure of no more than 0.5 x Depth (casing seat) HPmud
should be allowed on the casing. Drive pipe, conductor and surface casing require large diameter diverter
lines that allow the kick to flow safely rather than to shut-in.
Conductor MACP = (0.5 psi/ft x TVD Casing Shoe) HP Mud
If we drill through a fractured zone, gas might rise slightly in the well bore causing the BP to rise slightly
(see Fig. 8). Without causing any further problems.

SECTION X
KICK DETECTION
The first step to be able to handle a kick is early recognition that a kick is in progress.
Warning signs of a kick in progress may include any or all of the following symptoms:
1. Increase in fluid volume in the mud tanks (trip tank)

2. Increase in penetration rate.
3. Circulating pressure decreases and/or pump rate increases.
4. Flow from casing or DP with the pumps shut off.
5. Partial returns (lost circulation)
6. Hole takes less fluid than it should when pulling the DP out of the hole.
7. Hole gives up to much fluid when running the DP in the hole.
8. Return flow rate increases.
9. Mud weight changes.
10. Salinity changes.
11. Show of oil and/or gas in returns.
12. Presence of shale in the returns.
When drilling into a very permeable formation, that is under balanced, the kick will start immediately upon
penetration and will usually be concurrent (happening at the same time) with a drilling break.
A gas kick expands as it nears the surface and the rate of unloading mud will increase.
A salt water or oil kick will not expand and the increase in pressure at the surface will be steady (linear)
rather than sharply increasing (exponential) as is the case with a gas kick.
When a kick has gas associated with the kicking fluid, the shut n casing will continue to rise as the gas
migrates up the hole. In the case of a salt water or oil kick with no gas, there is no increase in shut-in
pressure with time.
KICK KILLING PROCEDURES

Response to a kick will depend on when and where the kick takes place, i.e. when close to bottom or
surface, onshore, offshore etc.
Drilling or circulating near bottom
1. Pick up the kelly to above rotary

Pipe rams and annular bop will not seal on kelly
2. Stop pumps.
Note: The pumps may continue to coast after being shut down and care should be taken that
circulating pressure is not trapped.
3. Open HCR valve to an open choke.
Prior to closing the BOP annular and/or rams, we must provide a circuit of flow from the annulus
or we could damage the seals in the BOP as we close against the flow. Monitor DP and annulus
Pressures.
4. Close annular BOP
To seal off the annulus, RAM type BOPs could be closed by a spherical annular BOP is
preferable. Monitor DP and Annulus pressures.
5. Close Choke
Close choke quickly but carefully monitoring DP and annular pressures. Do not close choke to
quickly to avoid hydraulic shock to the system.
Do not allow pressures to exceed maximum allowable limits. Relief excess pressure rather than
to exceed the allowable maximum pressure. If the well cannot be shut in without exceeding
maximum allowable limits immediately circulate heavier mud while holding the annular pressure
just below allowable limits.
6. Record Data
Record the volume of the kick, SICP and SIDPP. Calculate the required mud weight increase to
kill the well.
7. Circulate
Circulate kick out using the constant bottom hole pressure, technique. Use an adjustable choke
to maintain allowable annular pressure.
TRIPPING
1. Stab Safety Valve
Stab in fully opened drill pipe safety valve.
2. Open HCR Valve
Open HCR valve to choke.
3. Close annular BOP
If only drill collars are in the hole it might be required to chain these down to prevent them from
being blown out of the hole. Drill collar clamps, in good condition, and chains should be readily
available at all times.
If extreme flow is encountered it might be necessary to drop the string so that the rams can be
closed.
4. Close DP safety valve.
5. Close adjustable choke
Close choke with care, do not exceed maximum allowable pressures.
6. Record Data
7. Strip back pipe into the hole. Do not allow casing pressure to exceed allowable limits. (see
Chapter on Stripping and Snubbing)
8. Circulate kick out using constant bottom hole pressure method.
WHAT IS A KICK

A kick is an uncontrolled flow of formation fluids into the well bore.
If the kick flows uncontrolled from the formation to the surface it is called a blowout.
If a kick flows uncontrolled from a high pressure formation to a lower pressured formation it is called an
underground or sub-surface blowout.
A kick occurs when the formation pressure is higher

than the effective mud weight in the well bore and
the circulation pressure.
The pressure at the bottom of the hole is calculated

using the mud weight, the vertical depth of the well
plus any circulating pressure at surface.
As long as the formation pressure does not exceed

the HP (hydrostatic pressure) at the formation fluids
can enter the well bore.
When the well is being circulated the annular pressure drop is added to the static hydrostatic pressure
which gives a more accurate hydrostatic equivalent pressure then when we only consider static
pressures.
SPP = Pressure Loss Through DP, Collars and Bit Annular Pressure Drop = Zero (0)
Therefore, if we are circulating the Bottom Hole Pressure (BHP) is equal to the static hydrostatic
pressure, from the mud weight, plus the annular pressure drop.
If we are drilling balanced and the pumps are stopped the formation, if there is any permeability, will give
up some fluid into the well bore.
The pressure drop from bit to surface can be calculated using the power law equation or estimated using
any of the slide rule equations available. However, since the annular flow is almost always laminar we can
estimate the pressure drop in the annulus to be equal to 10% of the circulating pressure (SPP)
Kicks are cause by:

Insufficient mud weight.
Swabbing
Balled or plugged bit
Improper hole fill-up or failure to keep hole full
Lost circulation (Fractured formation)
Core gas or Drill Stem Test
Mechanical failure of tubular goods.
Insufficient Mud Weight

The drilling of a well through impermeable rock can be done with mud weights far below the equivalent
pore pressure gradient of the formation. In a impermeable formation fluids are trapped in their pore space
and cannot move freely into the well bore. Drilling in impermeable formations the only fluid that can enter
the well bore is the fluid actually trapped in the drilled volume. This volume is insufficient to cause a kick
by itself.
Drilling under-balanced can be done safely trough zones of no or very low permeability. By using a low
density, low-solids drilling fluid the rate of penetration can be increased and drilling cost reduced.
Under-balanced drilling in permeable rocks causes surprise kicks, heaving shale and increased drilling
cost.
Normally mud weight should be about 0.3 ppg heavier than the calculated bottom hole pressure
equivalent to allow for mud weight variations and swabbing while tripping pipe. The trip margin is a
management decision and equal concern shall be given for it being to large or to small.
A to large trip margin could cause fracture of a zone and lost circulation. A to small margin may allow the
well to kick.
Accidental mud weight reduction can be caused

by an inaccurate mud balance, excessive fresh
water at the shale shaker(s), switching to the
wrong tank or failure to communicate between
crew members.
While drilling, or circulating out, the mud will be

laden with cuttings and the returns will be heavier
than the conditioned (clean) mud pumped down
the hole. Therefore when the pumps are stopped
the well will be unbalanced and flow back through
the work string.
Good drilling practice calls for circulating clean

and to check carefully for flow, from either the DP
or the annulus, prior to pulling out of the hole.
Swabbing
The hydrostatic bottom hole pressure can be reduced by the movement of the pipe in the hole. When
pulling put the drill string acts like a long pump by the fluid in the hole dragging against the pipe. Thick,
high gel fluids and rapid acceleration and speed of the pipe cause the largest swabbing pressures.
The closer the tolerances (clearance between work string and wall) the greater the swabbing action will
be. Swabbing pressure is also increased if the bit is plugged.
Swabbing pressures for a 15,000 feet well pulling out of the hole at 270 feet/min with a plugged bit can be
as high as 1,080 psi while with an un-plugged (open) bit the swabbing pressure would only be 620 psi.
Regardless of the actual swabbing pressure the bottom-hole pressure will be reduced. In this case by 1.4
ppg for a plugged bit and 0.8 ppg with an open bit, in both cases much larger than the normal 0.3 ppg trip
margin.

While running into the hole the swab pressure becomes a surge pressure, or additional pressure to the
normal hydrostatic pressure and can cause fracture of the formation and lost circulation.
Note that there are also swab pressures induced when running into the hole. The swabbing action is
caused by lifting the string to pull the slips so it is important to pull the slips slowly with minimum
movement of the string.
When running in the hole it reaches a maximum speed when the brakes are applied but the drill collars
continue due to inertia, the string stretches downward and then re-bounces upwards. Swabbing can be
reduced by running in the hole smoothly with soft gradual braking action at the end of each stand.
Special consideration should be given to:

Pulling out of the hole with a plugged bit causes severe swabbing action.
Rapid acceleration and stopping causes high swab and surge pressures,
Deep, high temperature wells, may require high gel strengths and surge pressures are stored in
the mud, breaking circulation a few times when running in the hole and re-starting circulatin while
slowly pulling up the kelly will reduce pressure put n the formation.
Slow down when running in the hole with weak formations to avoid fracturing.
Balled or Plugged Bit
A special case of swabbing is pulling of a balled or

plugged bit. When a drill bit becomes balled with
shale and clay, the rate of penetration (ROP) drops
to near zero it will be necessary to pull the string to
replace the bit.
With a balled bit the clearance between the bit/drill

collars and the hole is reduced to almost zero, in
that case the string effectively will act like a pump
plunger with only the mud inside the string able to
fill the hole below the bit to fill the void when pulling
out of the hole.
As the mud level in the string drops the bottom hole

pressure is reduced and the well can kick on the
drill pipe side. If the drill string has mud and shale
produced into it is possible that it will plug up.
A plugged bit can occur in conjunction with balling or may happen due to solids dropping out of the mud
and plugging up the nozzles of the bit from the inside.
A special case of plugging can occur when a barite pill is allowed to settle inside the drill string when
attempting to plug a kicking zone.
When a plugged bit is pulled the hole cannot be filled through the drill pipe and swabbing action
increases. If, in such a case, he well must be circulated the drill string may have to be perforated.
The effect of a plugged and balled bit is that of a nearly perfect swab. It will become necessary to either
perforate the pipe to establish circulation or to pull very slowly while filling up the annulus. Pulling the pipe
slowly and rotating it may assist in removing or reducing the ball and allow slow, but safe, pulling of the
drill string.
Improper Hole Filling

When pulling the string out of the hole it is necessary to replace the volume of the steel pipe removed,
including any fluid therein, with the exact same volume by filling the annulus. For deeper wells the volume
per joint might increase as we pull out of the hole as reduced tensile loads (weight) will cause the hole to
take more fluid per joint.
As we pull out of the hole the fluid level in the annulus will drop causing a reduction in bottom hole
pressure. The annulus must be filled often enough, at least every ten stands or every stand of collars, to
avoid kicks. The fill-up volume should be carefully noted every time to determine if the well is coming in.
Avoid dropping the fluid level in the annulus to more than 100 feet bellow surface, as measured from the
bell nipple. The fill volume required should be calculated using displacement tables, as provided in
cement service handbooks, and then compared to the actual fill volume when coming out of the hole.
Knowing that the hole is taking too much or too little fluid is very important to identify lost circulation or
kicks.
When it is identified that a well is not taking enough fluid while pulling out of the hole, the drill string shall
be run to bottom and the hole shall be circulated clean under positive control (pressure and volume) until
the cause and type of formation fluid influx is determined and the hole is stabilized.
Lost Circulation
Lost circulation is the loss of drilling fluid (mud) into the formation. Control of the well is lost when the
density of the fluid in the drill string cannot be controlled. If part of the returns are lost to a formation the
reserve volume in the surface mud tanks will be depleted. If the returns are totally lost, the fluid level in
the annulus will drop and the BHP reduced resulting in a kick.

Lost circulation is caused by fracturing of a low pressured zone. Reduction of the pressure will allow it to
close and heal, if an underground blow out does not occur.
Lost circulation material may be circulated down to bridge the fracture to regain control of the well. If an
underground blowout is occurring the lost circulation material may not be effective because the BHP will
remain above the fracture pressure of the weak formation and the lost circulation material, and produced
reservoir fluids from the stronger formation, are lost to continuous opening new fractures.
It may be necessary to temporarily plug the flowing zone to regain control of an underground blowout.
The use of a pumpable plug made of barite and fresh water, bentonite and diesel, or cement and diesel,
may allow isolating the kicking zone from the thief zone.
The plug is made up of bentonite (fresh water gel) and diesel and will not swell or thicken until in contact
with water. The lost circulation plug is made by mixing 3 sacks of bentonite with one (1) barrel of diesel oil
at a rate of 2-4 sacks per minute. A 300 foot column is most often used. The plug is preceded and
followed by a 10 barrel diesel spacer.
Using cement mixed in diesel allows for pumping a plug that can develop compressive strength when
coming in contact with water. Class H or A, where H class cement will result in slower settling times and
lower compressive strength. Cement is mixed at the ration of 5 gallons of diesel per 98 lbs sack of cement
resulting in a slurry density of approximately 15 lbs/gallon.
Extreme caution must be exercised to ensure that no water is mixed with the cement until setting is
required. Mixing tanks, lines, pumps, the diesel fuel, etc. must be free of water.
A barite plug is one of the best ways to plug of the borehole against a kick. It requires no fresh water to
set and the high density and impermeable nature provide a plug that is tough and heavy but can be easily
drilled out.
A 15 lbs/gallon slurry of barite and clean fresh water will give the best performance. If the mud weight is
higher than 14 lbs/gallon adjust the barite slurry density to 1 lbs/gallon above that of the mud.
Mud thinner is added to the fresh water prior to starting mixing and the ph is adjusted with caustic soda
(Na OH0 to 9.0. Enough plug material should be mixed to cover a 300 foot interval.
The plugs are pumped down the drill string and allowed to set between the lost circulation zone and the
kicking zone. If the vertical cross flow channels though the plug the procedure might have to be repeated.
Lost circulation is a very serious matter and sufficient mud material must be on location to be able to fight
a kick with lost circulation. Minimum stockage levels should be established and maintained.
Core Gas, DST, Pore Volume Gas
When in interval of gas sand is cored the gas will remain in the core as it is cut. After coring, the core bit
and barrel are pulled out of the hole to recover the core. The gas that is present in the core will expand,
with reduced hydrostatic pressure, and is released from the core. This core gas can cause a kick in the
drill pipe, together with swabbing action this could reduce the bottom hole pressure enough to allow the
formation to flow and a more serious kick is initiated.
Kicks caused by core gas can be prevented by conditioning the mud prior to puling of bottom and by
pulling slowly while keeping the hole full on the annulus.

Fast drilling of permeable gas sands may cause a kick on the annulus side. As the formations are drilled
the gas in the pore space is liberated and is circulated back to surface. As this gas reaches the surface it
expands and reduces the effective density of the mud.
I we drill balanced this reduction cam be sufficient to start a movement of formation fluid into the well
bore.
Circulating the well clean before we make a bit trip is the best way to prevent pore gas from initiating a
kick.
Reduce drilling rates in gas sands may be required.
During DSTs (Drill Stem Tests) the well is produced using the drill pipe and retrievable packers to
determine the productivity of a particular formation.
In open hole DSTs the well is not cased and the DST tool must provide a seal against the formation..
In cased holes DSTs can be performed using hook wall packers and the casing is perforated using either
TCPs (Tubing Conveyed Perforating) or wire line perforating techniques. With TCP the hook wall packers
are set prior to perforating.
When perforating using TCPs, it is important to monitor the fluid level in the annulus to determine that the
packers or not leaking allowing the well to flow on the annulus. When using wire line logging the annulus
fluid level should be observed to ensure that the well is not taking any fluid or is kicking.
After completion of the production test the well is reversed out (down the annulus and up the work string)
to remove all oil and gas from the work string and to kill the well. After reverse circulation the well should
be circulated (down the work string and up the annulus) clean before pulling the string out of the hole.
Circulating and reversing pressures can be higher than normal due to gelling of the mud during the test
period, a dose of water and additives may be required to condition returns.
Mechanical Failure of Tubular Goods
The drill string, or working string, and casing string conduct the fluid movement from the surface to the
bottom and back to surface. They allow for positive knowledge of volumes and flow paths. If tubular
goods fail it is possible to lose control of the well.
The abrasion of tool joints on the protective casing can cause a hole. If the equivalent mud weight at that
depth exceeds the fracture pressure of the reservoir a fracture will occur resulting in lost circulation.
Drill pipe rubbers protect against casing wear but they also increase swabbing and surge pressures.
Tool joints can fail due to fluid cutting through the sealing surfaces of the joint, it is also possible that a
hole develops in the drill pipe or work string due to erosion.
When a washout occurs only part of the fluid will go to and through the bit, a portion of the fluid is able to
make a short cut through the hole, or washout, back to the surface.
If this is the case we should note an immediate drop I circulating pressure at the surface. However, in
many cases, the washout will start as a small leak and gradually develop progressively reducing the
surface circulating pressure. In severe cases it is possible that the washout will progress to the point
where the string will twist off and is lost in the hole.

In case of a washout the penetration rate will normally decrease because full jetting ans cleaning action is
not available at the bit.
If a higher pressure zone is penetrated, or if swabbing induces a kick, the killing of the kick will become
very difficult since we are not able to get full circulation at the bottom of the string.
Washouts of tool joints are best avoided by using proper stabbing and handling techniques and close
inspection of the tool joints and proper application of API grade tool compounds.
Pipe should be carefully inspected for wear and tear regularly and any damaged or suspected joints
replaced immediately.

MUD DENSITY INCREASE
When a kick is detected shut in the well by raising the kelly, shut down the pumps, open the HCR valve
against an open choke, close the annular (spherical) BOP and close the choke carefully to avoid hydraulic
shock and/or to exceed casing and formation pressure limitations.
After the well is shut-in, the shut0in drill pipe pressure (SIDPP) and the shut-in casing pressure (SICP) will
raise from zero to a stabilized pressure, the time required depending on the nature and strength of the
kick but normally anywhere from 0.5 to 5 minutes.
If there is the question if the well is actually kicking or if there is trapped pump pressure present, release a
small quantity of fluid (0.25 to 0.5 barrel) from the casing side. If the pressure decreases while
bleeding but builds back up to the original shut-in pressure after the kick, do not bleed off any
more pressure/fluid.
Do not bleed-off any pressure from the drill pipe, this may cause gas-cut mud to enter the drill pipe
causing problems when calculating the required kill weight mud. It could also lead to a plugged bit since
contaminated mud can enter the drill pipe and solids can settle out to bridge across the bit jets.
The static shut-in casing pressure (SICP) and shut-in drill pipe pressure (SIDPP) must be accurately
recorded. Pressure accuracy should be within +/- 25 psi to allow for accurate calculation of the required
kill mud weight.
The rigs standpipe pressure, pump pressure, casing pressure and choke panel gauges may never give
the same readings due to daily shocks in normal operations. The choke panel gauges are often the best
source and most accurate but provisions should be in place to install more accurate gauges, normally
stored in the company mans office.
The SIDPP will show the amount of additional pressure that is required to hold and control the
formation pressure causing the kick.
If an inside BOP or float (BPV) is installed in the drill string, the SIDPP must be determined by slowly
pumping into the DP until the BPV opens and allows a small amount of fluid to pass through the valve.
The pump in pressure will approximate the true SIDPP.
To calculate the required mud weight to control the well we add the required additional mud weight to the
mud weight in the DP.
Assume:
Mud Weight = 9.5 lbs/gallon
True vertical depth = 8,000 feet
SIDPP = 75 psi
BHP = 0.52 x Mud weight x depth

BHP = 0.52 x 9.5 x 8,000
BHP = 3,952 psi
Add. Mud weight = 75 / (0.52 x 8,000)

Add Mud Weight = 0.18
Kill Mud Weight = 9.5 + 0.18

Kill Mud Weight = 9.68 lbs/gallon
Kill Mud Weight = 9.7 lbs/gallon

The additional required additional mud weight should be round up to the nearest tenth of a lbs/gallon
meaning that in this case the required kill mud weight should be 9.7 lbs/gallon.
In this case the actual BHP (kick) = 0.52 x 9.18 x 8,000 = 4.027 psi. The actual hydrostatic mud weight
after the kill would be 0.52 x 9.7 x 8,000 = 4,035 psi.
The additional 8 psi provides no operating margin to allow for drill pipe movement, choke variations,
mud weight variations etc. that could cause the BHP to drop below the minimum value required to control
the formation.
To properly kill the kick and control the formation we should first circulate with the calculated required mud
weight without operating margin. If the kick is controlled we circulate again using 200-300 psi over
pressure to create a operating margin before we proceed with drilling.
The additional mud weight to provide for an operating margin would be: 300/ (0.52 x 8,000) = 0.57.
Rounding up the required additional mud weight to the nearest tenth of a pound per gallon we would have
to establish a mud weight of 9.7 + 0.6 = 10.3 lbs/gallon before we can safely proceed with drilling.

KICK CIRCULATION
Methods used to circulate kicks vary from constant pit volume technique, which violated basic gas
behavior laws, to elaborate constant bottom hole pressure methods that require many pre-recorded well
data and numerous calculations, graphs, and sometime broad assumptions.
The desire for a simple, field applicable, accurate method has provided many systems following the same
basic principle, namely if the BHP is held constant and slightly above the pore pressure of the kicking
formation no further kicks will be introduced by the formation.
The most common techniques using the constant bottom hole pressure technique are called the drillers
method, engineers method, wait and weight, simplex and Constant Bottom Hole Pressure method.
PT Kasadasa Perkasa uses the Wait and Weight method because it is safe, simple and proven.
The name comes from the basic waiting, while the mud is being weighted up to the mud weight to
balance the formation pressure.
The kill mud is circulated to the bit while maintaining a constant pump rate by allowing the circulating drill
pipe pressure to decline on a calculated schedule.
After the kill mud weight (KMW) clears the bit, the circulating drill pipe pressure is maintained constant
until the kick fluid is totally displaced from the well.
The Wait and Weight ,method required certain data to circulate out a kick successfully:
1. Drill String I.D and volume capacity from surface to bit.
2. True vertical depth of the bit, casing seats and formation.
3. Actual length of the drill pipe in the hole.
4. Density of the fluid pumped down the work string.
5. Kill rate circulating drill pipe pressure, if possible but not required.
If the above is not know, certain estimates can be made from hung string weight, rental tickets, surface
pipe counts and mud density in the pits, etc.
The first step after safely closing in the well is to record the time of the kick, the volume of the kick, the
SICP and the SIDPP to be able to calculate the required kill mud weight (KMW)
KMW = DMW + [SIDPP / (0.52 x TVD)]
After the well is shut in we normally will observe a continuing increase in drill pipe and casing pressures if
there is a gas bubble migrating up the annulus. In such a case it will be necessary to bleed of annulus
pressure to prevent the SICP from exceeding the maximum allowable casing pressure.
The SIDPP continues to be a pressure gauge for the BHP. The BHP must continue to be equal or greater
than the pore pressure of the formation, if not another kick will be introduced into the well bore.
It is possible to bring a kick to surface using only gravity segregation and casing bleeding techniques. Gas
will migrate (segregate) through 10 14 ppg mud at 7 to 15 feet per minute.
During kill operations we pick a reduced circulating rate in order to reduce the pressure drop in the
annulus. By reducing the friction pressure we reduce the risk of fracturing the formation. A kill rate of 1/3
the normal circulating rate is common but lower rates may be desirable.
When the kill mud starts down the drill pipe the initial CDPP (circulating drill pipe pressure) will be equal to
the sum of SIDPP (shut in drill pipe pressure) plus KRCDPP (kill rate circulating drill pipe pressure.
After the kill mud gets to bottom, the SIDPP should be zero if the kill mud weight was correctly calculated.

The KRCDPP (kill rate circulating drill pipe pressure) will increase because the kill mud is heavier than the
normal mud and will have a higher viscosity so higher pressures are required to move it through the drill
pipe, collars and bit.
The kill operation is started by holding the casing pressure at 25 50 psi higher than the SICP (shut in
casing pressure) while bringing the pumps up to the kill rate pumping the KM down the DP. Be careful not
to hold to much back pressure on the annulus with the choke since this could cause formation fracture
and lost circulation.
As soon as the kill rate has been achieved note the CDPP (circulating drill pipe pressure).
Initial CDPP = SIDPP + KRCDPP + 25 to 50 psi.
When the KM reaches the bit, the final DPP will equal the KRCDPP corrected for increased velocity.
Final CDPP = KRCDPP x (KMW/DMW)
To maintain constant bottom hole pressure, the back pressure on the casing must be regulated so that the
initial CDPP declines to the final CDPP as the kill mud clears the bit.
As the KMW is pumped down the DP, the CDPP will decline from the ICDPP to the FCDPP, this decline
can be graphed as a straight line.
Preparing a writing schedule or a plot of the circulating drill pipe pressure versus pump volume (strokes)
is helpful in obtaining a uniform decline of the CDPP to the FCDPP.
( ICDPP FCDPP) / Strokes (Pipe Volume to bit) = psi/stroke
Cum. Strokes CDPP

ICDPP
100 ---------
200 ---------
300 ---------
400 ---------
500 ---------
Etc.
DP Capacity FCDPP

While pumping certain conditions can cause additional changes in friction pressure such as a plugged bit,
lost nozzle(s) or a annular bridge. If anything happens that would cause a change in the basic KRCDPP
the casing pressure should be immediately noted and held constant while establishing a new CDPP. The
new CDPP can, again, be adjusted as required while the well is circulated with KMW.
Normally, during circulation of kill mud the casing pressure required to maintain a constant BHP increases
very little.
After the kill mud has reached the bit, the SIDPP should be zero if the KMW has been calculated
correctly. However, it is best not to stop circulating but to continue until the kill mud is back to the surface
and full circulation has been established.
When full circulation has been established, stop the pump and close the choke. If pressure remains on
the DP or the Casing either the KMW was incorrect (to low) or pressure is trapped. If there is any trapped
pressure this can be bled off.
If the pressure is not trapped the SIDPP and SICP will remain the same after bleed-off. If pressure
remains on the DP the correct KMW can be calculated again and circulation can be repeated.
The Wait and Weight method requires no complicated graphs or math or any unusual equipment. It does
require a cool head and practice in applying this method.
STRIPPING AND SNUBBING OPERATIONS

When a kick is suspected during tripping, in or out of the hole, the well must be immediately shut-in using
the soft closure method and pressure must be monitored.
Stripping is running the drill pipe, or work string, into or out of the hole through closed BOP preventers
while there is pressure on the well bore. Stripping is necessary to get back to bottom when wells kick
during tripping or when it is necessary to pull out the drill string under pressure.
When the spherical preventer, and/or the pipe ram preventer, is closed on the work string there will be
pressure under the preventer. If the work string is plugged or closed off with a DP safety valve, inside
BOP or float valve, there is an upward hydraulic force that will tend to try to push the work string out of the
hole.
The upward pressure caused by the well bore pressure is equal to the sectional area (in the preventer)
times the pressure in lbs.
Upward force in pounds = Sectional area (square inch) x pressure (psi)
The cross sectional area of the work string included the entire area not closed by the preventer.
If the preventer is closed on the DP, and we

assume the DP is 5.5 and the pressure is 1,000
psi then the upward force would be:
/4 x d x P
(3.14 / 4) x 5.5 x 1,000 = 23,746 pounds
If the preventer is closed on the tool joint, with a

diameter of 7-3/8 we find an upward force off:
(3.14/4 x 7-3/4 x 1,000 = 42,697 pounds
It is clear that the larger the area of the tool joint in

the preventer the larger the upward force will be.
The weight of the work string in the hole will create a downward force that is equivalent to the weight of
the string in the hole multiplied by a buoyancy factor. The buoyancy factor can be calculated as follows:
BF = (65.5 x MW ppg) / 65.5
If we assume that we have 800 feet of 21.9 lbs/ft DP in the hole, below the preventer, with a mud weight
of 10.2 ppg, than the weight of the pipe would be: 21.90 x 800 = 17,540 lbs.
The downward force would be the weight of the pipe x BF or: 17,540 x (65.5 x 10.2) / 65.5 = 14,792 lbs
If the downward force would be less than the upward force than the pipe would continue out of the hole
unless it is chained down or otherwise arrested.
To strip the pipe we must overcome the frictional force of sealing rubber of the preventer closed on the
pipe. The frictional force will depend on the preventer type, condition and fluid lubricity. To strip the pipe
into the hole the floated string weight should be at least 10,000 lbs heavier than the upward force.
If we use the above assumed data than we find:

a) Upward force, DP in the preventer = 23,746 lbs
b) Upward force, Tool joint in the preventer = 42,697 lbs
c) Downward force = 14,792 lbs
If we assume that there is no frictional force than we find:

d) Chain Down force DP in the preventer = 23,746 14,792 = 8,954 lbs
e) Chain Down force Tool joint in the preventer = 42,697 14,792 = 27,905 lbs
In this example we cannot get back into the hole unless we were to overcome the upward force and the
frictional force.
If additional force is needed to push the pipe back into the hole the act of stripping is called snubbing.
Originally blocks and tackles where used to snub the pipe in or out of the hole. Present day the power of
the draw works or hydraulic cylinders is used to provide the additional force downward when there is not
enough string weight to overcome the vertical force caused by the well bore pressure and the frictional
force.
Stripping and snubbing are operations that must be carefully planned and prepared and use the
correct equipment.
The simplest stripping operations are those where the string weight is sufficient to allow the running of
tool joints through the annular BOP. The more complicated RAM to RAM stripping operations require that
two sets of RAMs are used, allowing the tool joint to pass through one open set of RAMs while the pipe
body strips through the second set of closed RAMs.
Annular preventer stripping requires as a minimum the following equipment:
The annular preventer is closed with the minimum required force to stop the flow, the use of higher forces
will only increase the friction and reduce the life of the sealing element.
Ram to ram stripping requires that there will be sufficient space between the rams for the combined
length of tool joints and other oversized bodies, such as inside BOPs, DP safety valves, etc.

All dimensions of the BOP stack, drill string components etc. must be accurately known. The stripping
operation will only be successful with careful planning, a program carefully designed around the available
equipment and personnel and competent supervision.
Snubbing operations can be practiced safely after cementing casing while tripping into the hole before
drilling the cement plug, pressure can be artificially introduced and maintained while moving the pipe
through the preventers. Practice is expensive but the result of a botched (failed) snubbing job is often
fatal.
During stripping or snubbing operations, as with all other kill procedures, it is important not to exceed
maximum allowable surface pressures.
Some wells will take fluid during the trips and when stripping into a well. It may be required to pump
additional fluids into the well to prevent the SICP from dropping to much to avoid additional influx of
formation fluids into the well bore.
Stripping operations require accurate measurement of volumes pumped and displaced. A accurately
calibrated trip tank will allow the correct displaced volume to be bled-off from the casing. The volume to
be bled-off is equivalent to the length times the displacement volume of the pipe stripped into the hole.
Tool joint displacement in this case is normally ignored.
Volume (barrel) = (3.14 x radius in ft x length in feet) / 5.61 cu.ft/bbl
For example, the volume of 90 feet of 5-1/2 OD DP would be:
Area = 3.14 x (5.5/2 x 12) = 0.165 square feet
Volume (barrel) = (0.165 x 90) / 5.61 = 2.64 barrel.
The principle consideration for subbing and stripping operations is to maintain a BHP greater than the
formation pressure and to maintain a surface pressure which is less than the formation fracture pressure
or bursting pipe and/or equipment.
When running into the hole the exact displacement volume of the pipe must be removed from the well to
maintain constant pressures.
Please note that during normal snubbing and stripping operations that some leakage will take place past
the BOP elements, gas migration can occur and non-uniform fluid densities can occur plus a host of other
variable conditions which should all be taken into account.

STRIPPING / SNUBBING PROCEDURE
1. Shut well I using the soft closure procedure.
2. Install inside BOP above the drill pipe safety valve, open drill pipe safety valve to check the
functioning of the inside BOP.
3. Calculate the upward force on the drill string caused by the SICP, determine whether the
spherical (annual) preventer, stripping or snubbing is to be used.
4. Go In hole with pipe, allow casing pressure to build to within 150 psi of the Maximum Allowable
Shut-in Casing Pressure, do not allow the SICP to drop below the initial shut-in pressure plus 50
psi. Running speed should not exceed 15-20 feet per minute.
a) As casing pressure comes within 150 psi of the MASICP (Maximum Allowable Shut-
in Casing Pressure), bleed-off the exact volume of the total displacement of the pipe
being put into the hole (Note: NOT the volume of the pipe already in the hole) and
continue bleeding-off the exact volume of each joint of pipe being run into the hole.
b) If the SICP drops below the initial SICP plus 50 psi, than mud should be pumped into
the casing to maintain pressure in the well bore to prevent another kick.
c) Casing pressure should be maintained between 50 psi above SICP and 150 psi
below the Maximum Allowable Shut-in Casing Pressure until the gas flow has
migrated to the upper portion of the hole, or at least to above the casing shoe.
5. As the gas nears the surface, bleeding the exact volume of the joint displacement being run may
result in the casing pressure continuing to rise above Maximum Allowable Shut-in Casing
Pressure as determined by the leak-off test. If so, let the pressure increase to within 150 psi of
the Maximum Allowable Casing Burst Pressure or the BOP testing pressure (whichever is lower),
while continuing to bleed-off the volume of the pipe being run into the hole.
6. Note all volumes and times accurately. Some well will take large amounts of fluids during trips
and this fluid loss may result in a decline of the BHP which would allow another kick to enter the
well bore.
7. Continue going into the hole with pipe, check for trapped pressure to ensure that the mud weight
is only increased to kill the well.
a) Pressure up the drill pipe until the Inside BOP opens, shut-down the pump and record
pressure.
b) Bleed barrel from the annulus, if pressure drops on both the casing and the drill pipe, pump
slowly into the drill pipe until the Inside BOP opens, shut-down pump and record pressure. If
the new SIDPP is lower, continue to bleed-off. If the new SIDPP is stable calculate the mud
weight increase required based on the stable SIDPP.
8. Circulate the well with KWM. Ensure that the kill rate is low enough to prevent the annulus
pressure to increase due to wall cake that has been removed during the stripping operation.

KICK KILLING
KICK DATA:
Gain Unknown
SIDPP 350 psi
SICP 525 psi
Depth 13,500 feet
Original Mud 12.9 ppg
DP Volume 200 barrels
Annular Volume Unknown
Kill Rate 32 SPM (1.5 BPM at 700 psi
SOLUTION
1. Calculate the Kill Weight Mud (KMW)
KMW = OMW + MWI
MWI = SIDPP / (0.052 x Depth)
KMW = 12.9 + [350 / (0.052 x 13,500)]
KMW = 13.4 ppg
2. Calculate the initial DP pressure when starting to pump.
ICDPP = KRCDPP + SICP + 25 psi
ICDPP = 700 + 350 + 25
ICDPP = 1,075 psi
3. Check for trapped pressure after circulating.
With well shut-in, bleed up to 0.5 bbl from the casing. Close choke and wait for SICP to
stabilize. If SICP is lower, repeat the procedure. If not, no pressure was trapped.
4. Kill well procedure.
1. Shut-in the well.

a) Pick Up Kelly.
b) Shut-down the pump(s)
c) Open HCR valve to a small choke.
d) Close annular (spherical) BOP
e) Close choke slowly to avoid hydraulic shock.
2. Collect and record data required.

a) Check for trapped pressure.
b) Record SIDPP, SICP and pit gain.
c) Collect well data:
casing depth and ID,
DP ID and length,
DC ID and length
True vertical depth.

d) Collect safety data:
Leak-off test
BOP test
Adjusted Casing strength
c) Collect other required data:
Pump capacities
Mud Weight
3. Calculate
a) MWI = SIDPP / (0.052 x depth)

b) KWM = OMW + MWI
c) DP capacity to bit = DP cap + DC Cap
d) Strokes to Bit
e) MACP, last BOP test, Leak-off test and Casing Burst
4. Weigh up mud and circulate

a) Open choke and bring pump up to kill rate slowly and hold 25-50 psi over pressure
on casing.
b) Read ICDPP
c) KRCDPP = (ICDPP SIDPP) Safety Factor
d) FCDPP = KRCDPP / (KMW / OMW)
e) Pressure drop per stroke : psi/srk = (ICDPP FCDPP) / strokes to bit
f) Prepare scheduled pressure drop table and/or graph.
g) Circulate mud to bit adjusting the choke to maintain CDPP as scheduled.
h) Complete circulation holding FCDPP constant
i) Once well has been circulated check that the well is dead.
If well is dead, add trip margin and circulate.
If well is not dead, repeat procedure.

PORE PRESSURE
The weight of the overburden rock is partially supported by the trapped fluid in the pore space of the rock
or sand. The pressure in the pore space of the reservoir is called the Pore Pressure.
In many places the pore pressure gradient can be estimated at 0.465 psi/ft. However, it is best to use
historical data from the area where you are drilling.
Pressure = 0.052 x MW ppg x Depth in feet.
Gradient = 0.052 x MW ppg
A normal pore pressure gradient of 0.465 psi/ft is equal to a mud weight 0f 8.94 ppg.
So, if only normal gradients are encountered we would never need a mud weight of more than 9.3 ppg
(8.94 + 0.36 margin)
However, in most cases the gradient will be very different; it can be as low as 7 ppg, in depleted sands, to
16 ppg in over pressured zones. The pore pressure also depends on the elevation of the well and the
elevation of aquifer source.
CONDITION OF ABNORMAL LOW PRESSURE
As is shown in the above illustration, in that case the pore pressure could only be equivalent to a 200 foot
water column.
BHP = 0.052 x Water (ppg) x Depth (feet)
BHP = 0.052 x 8.33 x 200
BHP = 86.6 psi
The equivalent mud weight would be:

86.6 = 0.052 x MW x Depth
MW 1.19 ppg
Meaning this well could only be drilled with air.

CONDITION OF ABNORMAL HIGH PRESSURE
An example where we could encounter over pressure is a situation where the aquifer source has a much
higher elevation than the reservoir and the drilling elevation is much lower than the aquifer source.
If we assume the sand is filled with 8.33 ppg water again, the over pressure would be: Formation
Pressure = 0.052 x 8.33 x 1500 = 650 psi.
The expected BHP would be: Expected BHP = 0.052 x 8.33 x 1000 = 433 psi
If we would use mud with a weight of 9.3 ppg, the BHP, before entering the reservoir: BHP (drill) = 0.052
x 9,3 x 1000 = 484 psi
Meaning we would encounter a 650 484 = 166 psi kick.
CONDITION OF ABBORMAL PRESSURE COASTAL AREAS

In coastal areas we can find enclosed reservoirs with pressures higher than expected. These lenses are
often formed originally at a greater depth and have moved upwards due to tectonic movements or erosion
are now closer to the surface.
The pressures in these lenses can be far greater than can be expected from the existing overburden.
However, these zones can often be recognized when some intermediate zone will start to flow before we
reach the zone with the greatest pressures. The distance over which the pressure increases from normal
to abnormal is called the pore pressure transition zone.
In the illustrated case we would expect a BHP of 0.052 x .465 or 4650 psi, however actual reservoir
pressures could be much higher.
SHALLOW GAS SANDS
Abnormal pore pressures occur in thick gas sands.
When drilling into a shallow thick gas sand with normal mud weight kicks are often difficult to control since
the gas will reach the surface by the time a trip tank level increase is noted.

In shallow low pressure reservoirs the pressure at the top of the reservoir would be almost equal to the
pressure at the bottom, the BHP at 2,000 feet, using 9.3 ppg mud, can be estimated as : 0.465 x 2,000 =
930 psig which would be the pressure we encounter as we drill into the reservoir. However at 1,500 feet
we would expect a pressure of 0.465 x 1,500 = 698 psi resulting in a kick of 232 psi.
This means also that the KWM can be estimated at:

Pressure = 0.052 x MW (ppg) x Depth (feet)
KMW = 930 / (0.052 x 1500)
KMW = 11.3 ppg
This shows that drilling in areas with suspected gas sands should be done very, very carefully. If a
kick occurs the well should be shut in as quickly as possible and before gas can reach the
surface. If gas is allowed to reach surface, catastrophic destruction of the rig, and possible loss of
life, can occur easily.
BLOWOUT PREVENTER
The purpose of a blowout preventer is to allow us to close in the well, with the drill pipe in the hole, during
kicks to prevent the well from unloading and causing a blowout.
Types of blowout preventers are spherical, or annular, preventers, Pipe Ram Preventers and Blind or
shear RAM preventers.
The BOP stack must be designed to withstand the maximum shut-in pressure expected. During drilling
operations the maximum surface shut-in pressure will be limited by the lowest fracture pressure of a
formation below the casing shoe.
If we allow a well to blow out and unload all the fluid in the well before we shut the well in, than the
maximum surface pressure will be the formation pressure minus the hydrostatic pressure of gas, and the
BOP stack should be designed for this pressure.
ANNULAR PREVENTER
An annular, or spherical preventer can be closed around any round shape, such as DP, DC, HWDP, etc.
by forcing a rubber ring against and around the shape, or even close an open hole.

Spherical, or annular, preventers should have a design working pressure equal to the rest of the surface
stack, however, due to the stress placed on the rubber element, they are normally only tested to 70% of
their rated working pressure.
When drilling surface pipe, the next string after conductor pipe is set, only a annular preventer is installed,
with diverter lines, to allow the diversion of a kick away from the rig. When drilling shallow depths the hole
cannot be shut-in during kicks due to the low fracture pressure of the soil. The diverter system should
have two fully opening valves on two separate lines, normally 6 or larger.
After drilling through the surface pipe a full BOP stack is installed.
RAM PREVENTERS
RAM type preventers work by forcing two rams inward. Blind Rams are designed to close against
themselves and will not seal when there is pipe in the hole. Shear rams are designed to cut the pipe to
create a seal. Pipe rams will seal around a pipe, note however that special rams are required for every
different pipe size although variable rams are available which will seal against a limited range of
diameters.
RAM preventers are normally tested to 100% of their rated working pressure. RAM preventers should be
operated at least once every working shift and tested at least once every week..

Blind RAM Shear RAM Casing RAM Pipe RAM
ACCUMULATOR SYSTEMS
An accumulator is a device that, by means of accumulating, or storing, hydraulic energy, is used to open
and closed the components of the BOP stack, such as the annular preventer, RAM preventers, HCR
valves, etc.
The use of an accumulator is essential to be able to operate the BOP stack components if all power
sources on the rig fail.
An accumulator should be able to:

1. Close and open, or open and close, a minimum of three (3) preventer members without re-
charging.
2. Should have at least a 50% reserve volume after closing and opening, or opening and closing,
after Point 1.
3. Have a minimum of 1,200 psi remaining pressure after Point 1.

Conventional Panel Electronic Panel
All accumulator systems should be tested prior to use to ensure that the capacity, regardless of
manufacturers claims, is sufficient to operate the BOP components as required.
The hydraulic fluid from the accumulator is stored under high pressure and passes through a number of
pressure regulators before it reaches the BOP components. Each component has a minimum and
maximum allowable pressure for the hydraulic fluids and each component shall have its own regulator.

The hydraulic pump that recharges the accumulator bottles should be capable of re-charging the system
to full capacity within 10 minutes. The pumps should be located and powered so that they do not create
an explosive hazard. Hydraulic recharge should be possible during a kick, kick drilling and threatened
blowout.
EQUIPMENT

INSIDE BOP
A drill pipe inside blowout preventer is a one-way, or back pressure,

valve that is installed in the drill string to prevent the well from
flowing back through the drill pipe during kicks.
The Inside BOP is normally the same OD as the drill pipe tool joints
so it can be stripped in and out of the hole.
When the Inside BOP is installed the true DP pressure can only be
measured when the valve is in the open position and this requires
that a small volume of mud is pumped down the drill string.
To get a true pressure reading the pump rate should be very low or
frictional losses will add significant errors.
An Inside BOP should be kept ready for use on the drill floor at all
times, ready to be installed in the drill string.
A drill pipe safety valve should be stabbed before the Inside BOP is
installed to allow removal of the Inside BOP.
The use of an Inside BOP is required for stripping and snubbing

operations.
DRILL PIPE SAFETY VALVE
The Drill Pipe Safety Valve, or TIW valve, is a full opening ball valve,
or almost full opening, that is installed in the drill string. The outside
dimensions are equal to the tool joint dimensions so that the valve
can be stripped in and out of the hole.
The valve is designed to hold pressure from below and is opened

and closed using a large Allen-head wrench.
A DP safety valve, of the proper OD and type of connection, is kept,

in the open position, at all times near the drillers station. The valve
handle should be hung from the draw works and should be ringed,
often with a used ring gasket, to prevent it from falling down the hole
when dropped.
Unless specially designed, a DP safety valve will only hold pressure

from below and should never be pressured from above. If pressured
from above it will leak and the seals can be cut out.
LOWER AND UPPER KELLY COCK

LOWER KELLY COCK
Below the kelly and above the saver sub we normally
install a kelly cock
The Kelly Valve provides a closure to stop mud loss when
the kelly is disconnected from the drilling string. Just
close the valve before disconnecting and mud in the kelly
and hoses stays there. With the cost of oil mud,
biopolymers and other costly drilling fluids, the valve can
pay for itself quickly. The rig floor and substructure stays
much cleaner and safer as well. Its streamlined O.D.
allows it to pass through the blowout preventer smoothly.
UPPER KELLY COCK

The Kelly Valve is also available with left-hand threads for
use as an upper kelly cock. When used between the
kelly and swivel, it provides a positive means for shutting
off flow in the drill string at any time. The inline body
design will not hang up on the cat-line or interfere with
operations.
Both valves are operated by an Allen type wrench. The

Allen wrench has to be ringed to prevent it from falling
into the well bore when dropped.
MUD PIT LEVEL INDICATOR
The volume of mud at surface, in the mud tanks, must be

continuously monitored to determine if a well is kicking or
taking fluid.
A pit totalizer uses floats in the each of the active pits to

allow for calculation of the total mud volume and alarms will
sound for losses and gains.
A pit level indicator system is absolutely essential to the

early detection of kicks or fluid losses.
Pit volume totalizers can be set as sensitive to as little as 1

bbl variation in surface volume before alarms are sound.
FLOW INDICATORS
A flow indicator must be installed in the line from the bell nipple to the shale shaker(s) to provide a
warning when flow starts from the annulus and to provide an indication of increases in flow while drilling
or circulating. The flow meter is normally installed in conjunction with the stroke counters enabling the
driller to monitor and control the volumes required to fill up the hole while pulling out with the drill string.
TRIP TANK

A trip tank may be used to measure the actual volume displaced by the string while running In the hole.
The trip tank is often installed next to the bell nipple and the displacement caused by the string is caught
and measured. When pulling out of the hole mud from this calibrated tank is used to fill the hole.
Sudden rise of the fluid level in the trip tank is often the first indication of a kick, similarly, a sudden drop in
the fluid level is often the first indication that the formation is taking fluid.
CHOKE MANIFOLD
The choke manifold is used to provide for controlled and safe handling of drilling fluids and pressures.
The manifold should be tested every week to the same pressures as the BOP stack. During the test the
valves should be operated (opened and closed). After the test the system is to be flushed with clean water
to ensure that all lines and chokes are open.
Choke manifolds, during the circulation of kicks, are subject to severe pressure shocks and vibration
loads so the choke should be securely installed on a base. Also, the erosion forces of fluids and gas
through the bends of the manifold system are very high. Tees and crosses should be used instead of
elbows so that the erosion forces d not act on the wall of the elbow but rather on the void space of the Tee
or Cross.
ORGANIZING AND DIRECTION A WELL CONTROL OPERATION

The control of a kick or the fighting of a wild well requires a high degree of technical and management
skills.
The organization and financing of a well control operation is normally the responsibility of the operator of
the lease or block unless other more specific contractual obligations state otherwise. The operator must
act immediately to protect personnel, equipment, the environment and the formation.
Chain of Command is the most important factor to establish immediately because without responsibility
of action even the simplest event will turn into complete chaos. Only one person can give orders, normally
the company representative or his designated replacement. The company representative will issue orders
to the senior contractors representative on site. The companys representative will take orders from his
main office, but again only from one person. To often when a Chain of Command is not firmly
established a well meaning staff engineer or geologist will offer recommendation which are then taken
as firm orders by the driller or mud engineer.
Communications is the second most important factor in successful well control operations. The
individual in command must more than ever fully listen to and fully explain all orders. To assume that
orders are fully understood automatically can be fatal. If an individual is not competent in an area, do not
run over him or force him to perform at a level beyond his competence. Instead instruct him but if he does
not understand the actions to be taken it is better to replace him/her.
Record all data taken, orders issued, orders received, calculations, equipment measurements, materials
on site, materials used etc. etc. together with the exact time and date. A well control operation can take
weeks, even months in severe cases, and one cannot expect people to remember exactly or sort out
what happened without full and complete records.
Protect personnel by providing detailed briefings and re-training or refreshing as needed. Evacuate all
non-essential personnel from the location and alert stand-by boats, if it happened offshore, and all other
operations in the area. Protect equipment by not exceeding their design limitations.
Many people hesitate to open a valve to relieve a dangerous pressure especially when this could cause
environment pollution. However this could lead to equipment failure and uncontrolled pollution, together
with injuries or loss of life, equipment damage and damage to the reservoir. Some pollution may be
unavoidable to allow for safe operation and well control. It is better to pollute and to clean up than to
exceed operating limits of equipment and total loss of control.
Know your equipment, know your people, know your laws and protect everyone by taking command and
control of your area of responsibility.
ORGANIZING AND DIRECTING A DIVERTER OPERATION

Formations may be too weak to kill conventionally or equipment may fail, leak or prove otherwise to be
unsound, or operations may require that a kick cannot be shut-in.
When a kicking well cannot be shut-in the annular flow is diverted by closing the spherical diverter ad
allowing the well to flow through diverter lines while the rig pumps are pumping as fast as possible into
the work string.
Control of a diverted well is regained when sufficient mud has been pumped into the well to load the
annulus sufficiently to allow the well to be shut-in, or a plug is pumped that plugs back the kicking zone.
When the well cannot be shut-in on a kick the following actions should be taken:
1. Open the diverter valve, through a fully opened choke, to down-wind to allow flow to a flare,
burner, reserve pit or other facility.
2. Close the spherical diverter.
3. Start pumping immediately down the work string as fast as possible.
4. When the annular flow rate decreased sufficiently to allow the well to be shut-in, pump at the
determined kill rate and circulate clean.
BLOWOUT PREVENTION AND CONTROL

1. Bottom Hole Pressures
Hydrostatic pressure of fluids.
Can be more than one, especially on workovers.
Hole not full.
Internal pipe friction
Drop at pipe end, i.e. bit etc.
Annular friction
Circulation back pressure
Surges or swabbing due to pipe movement
Rate of fluid circulation
2. Frequent causes of kicks or blowouts.

Not keeping the hole full
Swabbing when pulling the pipe out of the hole
Lost circulation
Communication with a zone behind the casing
Insufficient fluid weight
3. Warning signs
Increase in volume in surface tanks
Flow back of completion fluid after stop pumping
Lost circulation
Hole takes less fluids than it should when POOH
Shows of oil or gas In returns
Hole repeatedly filling with shale or sands
Change in mud characteristics
4. Basic First Instruction to Rig Crew

Know that the most common first indication of a kick or blowout is the increase in surface
fluid volume.
Shut down the pump
IMMEDIATELY close the annular (spherical) BOP
Shut in casing and work string
Read and record annular and DP pressures
Measure the volume increase as volume of kick
5. Limits on Normal Decisions

Do not exceed casing burst pressure
After Stabbing the valve on a very big flow, close the valve slowly to avoid hydraulic
shock.
Volume and pressure of a large gas kick may make circulating difficult.
Gas containing H2S is extremely hazardous to health, and can cause death, so extreme
care must be taken when circulating gas containing H2S and proper procedures should
be followed at all times.
6. Bringing a Kick Under Control

With the string at or near the bottom of the well, constant bottom hole pressure is the only
safe way to go.

The Drillers Method of circulating out influx into the well followed by increasing mud
weight is the easiest on field personnel.
In workovers, increasing mud weight is seldom required.
Use reverse circulating if possible,
Advantages:
Gets kick fluid out in about 1/3 of the time.
Often have a tree and choke at surface to control flow.
Tubing or work string can handle high pressures.
Disadvantages:
May plug bit
Pressure on casing is higher, especially if the bit is at bottom.
Do not use reverse circulating if a bit, circulation ports, sliding sleeves or other limited
orifices restrict flow at the bottom of the string.
Always let the uncontaminated side of the U-tube call the play in keeping BHP constant.
Gas bubbles inside the drill string are revered out by holding the aanular pressure
constant.
Do not over control and dont let bad habits result in mistakes.
Delay between pitching the choke and pumping pressure will 0.5 to 1 second / 1000 feet
of circulating path (well depth x 2).
When pipe is off bottom the required mud weight will be higher if the fluid below the DP
cannot be bullheaded into the formation.
Shut-in pressures must be met with mud weight increases calculated to the depth of the
work string, and not the total well depth.
Remember that the mud weight must be reduced if we work the pipe back to bottom after
controlling the kick.
When pipe is out of the hole bullhead clean fluid into the hole at maximum allowable
pressures.
After displacing the well volume wait one hour (or longer if required) for pressures to
stabilize.
Bleed-off pressures slowly to ensure the well is dead.
When stripping into the hole install a back pressure valve in the work string and keep
the string full at all times.
Allow annular pressure to leak a little to keep the rubber element in the annular BOP
lubricated.
Dont forget to bleed-off annular volume equal to the volume of the pipe stripped into the
hole.
With workovers the producing formation is almost always open to the well bore, RAM
changes are frequent and mud is normally less over-balanced as during drilling

operations inviting more frequent kicks and more pressure build-up when the pipe is out
of the hole.
Common errors found on workover rigs:

Accumulator to small to close BOP more than once.
Rented adaptor spools with cracks, damaged faces, etc.
Re-use of ring gaskets.
Hand wheels not attached to valves, BOP tracks etc.
Only use dual rams without enough space between them to allow for
stripping.
Choke manifold inaccessible under the rig floor
No back pressure valve available for stripping
Sub structure to small to accommodate BOP stack
Cement/mud etc. set up in flow lines, valves and manifolds.
Only one (often manual) choke.
Ells instead of Tees
Lines and fittings too small to handle large volumes of flow.
Piping not anchored against vibration.
No support for flowlines with heavy valves installed.
Bad practices on workovers

- Operate rams manually without setting hydraulic lever to close
- Kelly cock wrench not readily available.
- No information on casing burst rating and/or condition.
- Failure to go to bottom when a kick is suspected.
- Trying to circulate a kick out with constant pit level.
- Failure to distinguish between TVD and actual well depth when calculating
fluid weight effects.
Special considerations when using clean fluids

- Clean fluids mean 0 overbalance.
- If weight exceeds formation pressure at all, fluid should drop.
- Tripping out of the hole will easily create under balance due to swabbing.
- Hole must be filled frequently.
- Gas migrates up through water very quickly, much quicker than through mud.
Special considerations when using concentric tubing (multiple strings)

- Concentric tubing means a close fit inside the well, meaning that internal fluid
volumes are relatively very small compared to normal completions.
- Small annular volumes mean and that swabbing actions are severe and a
quick response to changing bottom hole conditions.
- If macaroni (small bore) tubing is used it will not be able to handle large flows
and can be shot out of the hole.
Published formation fracture gradient can be misleading.

- Wells fracture at higher pressures with mud than when using clean fluid.
- Fracture gradients are based on empirical data, actual conditions can vary
greatly even in relative small areas.


BOP - Handbook

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STANDARD OPERATING PROCEDURE

BOP Procedure/J.Keemink/2010 Page 1

BOP Procedure/J.Keemink/2010 Page 2

1.1 HYDROSTATIC PRESSURE

BOP Procedure/J.Keemink/2010 Page 3

One additional form of pressure is called the back pressure

If we refer to Fig. 1, with a CP of 435 psi and a BP of 185 psi

BHP = HP + Atm + CPbit + BP

BOP Procedure/J.Keemink/2010 Page 4

HPdp = 0.052 x 10.0 x 8,000 = 4160 psig

To calculate how much the fluid level in the annulus would

With a HP annulus of 4160 psi and a mud weight of 10.2

Meaning, the fluid level in the annulus would drop 8,000

BOP Procedure/J.Keemink/2010 Page 5

The fracture pressure, for any formation, depends on:

FG = 0.45 + ((0.55 x BHP) / Depth in Feet)

FG = 0.35 + ((0.55 x 3255) / 7,000)

The fracture pressure would be:

After many years of drilling in one area, such as the Gulf

From this graph we can determine that at 7,000 feet the

Please note the difference between the fracture pressure

Fig. 3 Pressure Gradient using Mud

BOP Procedure/J.Keemink/2010 Page 6

HP (mud) = 0.052 x 9.4 x 10,000 = 4,888 psig

FP = 0.89 x 10,000 = 8,900 psig (gradient from Fig.3)

FG = 0.45 + ((0.55 x 4,888) / 10,000) = 0.72 psi/ft.

FP = 0.72 x 10,000 = 7,200 psi.

The following is normally recommended:

BOP Procedure/J.Keemink/2010 Page 7

The typical leak-off test curve will be almost a straight

Rupture Pressure = 1310 psi

BOP Procedure/J.Keemink/2010 Page 8

BOP Procedure/J.Keemink/2010 Page 9

Annular preventers are normally of the spherical

The annular preventer must be designed to

If the well is allowed to blow fluid from the hole and

WP bop = Formation Pressure 0.1 x depth

Spherical BOPs are normally tested to 70% of their

RAM type preventers can be either single or double

The single type is normally fitted with pipe rams

Double rams come with a (lower) pipe ram and a

BOP Procedure/J.Keemink/2010 Page 10

Seamless pipe, such as casing, is manufactured by

The grade, or type, of steel (metallurgy) and the

All casing has a failure or rupture pressure at which

Here we must keep in mind that the highest

The unexpanded, and therefore unreduced, gas

BOP Procedure/J.Keemink/2010 Page 11

CP = BHP 10,000 x 0.1 psi/ft = 4304 psi

BOP Procedure/J.Keemink/2010 Page 12

The BOP stack has been tested to 3500 psi.

BOP Procedure/J.Keemink/2010 Page 13

Conductor MACP = (0.5 psi/ft x TVD Casing Shoe) HP Mud

BOP Procedure/J.Keemink/2010 Page 14

1. Increase in fluid volume in the mud tanks (trip tank)

KICK KILLING PROCEDURES

BOP Procedure/J.Keemink/2010 Page 15

Drilling or circulating near bottom

1. Pick up the kelly to above rotary

BOP Procedure/J.Keemink/2010 Page 16

A kick occurs when the formation pressure is higher

The pressure at the bottom of the hole is calculated

As long as the formation pressure does not exceed