SPE 157220

Identify Safe Drilling Margin, Detect and Distinguish Kicks from Ballooning
and Better Well Control for Deepwater,Through Independent Downhole
Measurements
Daan Veeningen, NOV IntelliServ

Copyright 2012, SPE/APPEA International Conferenceon Health, Safety, and Environment in Oil and Gas Exploration and Production

This paper was prepared for presentation at the SPE/APPEA International Conference on Health, Safety, and Environment in Oil and Gas Exploration and Production held in Perth, Australia,
11–13September 2012.

This paper was selected for presentation by an SPE/APPEA program committee following review of information contained in an abstract submitted by the author(s). Contents of the paper have
not been reviewed by the Society of Petroleum Engineers or the Australian Petroleum Production & Exploration Association Limited and are subject to correction by the author(s). The material
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Abstract
Well control events are predominantly detected through surface measurements. Measuring an increase in the ‘closed loop’
mud circulation system, a standpipe pressure decrease or changes in a variety of drilling parameters provide identification of
a kick. Especially in deepwater, where the riser comprises a substantial section of the wellbore, early kick detection is
paramount to limiting the severity of a wellbore influx and improving the ability to regain well control.

While downhole data is presently available from downhole tools near the bit, available data rates are sparse as mud pulse
telemetry bandwidth is limited and wellbore measurements compete with transmission of other subsurface data. Further, data
transfer is only in one-direction, latency is significant and conditions along the string are unknown.

This paper describes the use of a high-bandwidth downhole data transmission system via a wired or networked drillstring
system that is uniquely equipped with real-time pressure and temperature measurement capability at many locations all along
the drillstring. This system provides high-resolution downhole data available at a very high speed, eliminating latency and
restrictions that typically limit the availability of downhole data.

The along-string data acquisition and broadband communication via the networked drillstring provides real-time downhole
data independently from surface measurements which aid to identify, analyze, and control a wellbore influx. First, the system
aids in identifyingpore pressure, fracture gradient and safe drilling margin. Second, the independent measurement capability
provides early kick detection with distinction from ballooning and improves the ability to analyze and control an influx –
even with heterogeneous mud column – through the ‘direct measurement method’. Third, during tripping operations that are
associated with approximately 25% of all well control events, downhole data is now available to provide early kick detection.
Introduction
Prompt kick detection is critical in deepwater operations with a subsea blowout preventer (BOP), as it is imperative that the
rig crew detect the influx since reaction times are shorter than with a stack at surface. Kick detection is crucial before the
hydrocarbons rise above the BOP stackibecausewell control response options are severely limited and the risk of a blowout
increase significantly.Especially in deepwater wells, it is paramount to detect a kick early to limitthe severity of wellbore
influx andto improve the ability to regain well control. This is because in deepwater wells the marine riser comprises a
substantial section ofthe wellbore and productive hydrocarbon zones can be found relatively shallow below the mud line and
often the margin between pore pressure and fracture gradient is narrow.

While response times for early kick detection are crucial, traditionally, wellsite and operational personnel rely on surface
measurements such as flow in and out, pumping pressures, and a number of mechanical measures to identify a wellbore
influx. An increase in the ‘closed loop’ mud circulation system, a standpipe pressure decrease or changes in a variety of
drilling parameters provide identification of a kick.
2 SPE 157220

Unsurprisingly, correct interpretation of developing downhole events using surface measurements is impacted by many
circumstances, listing a few below:
- Equipment issues, for example proper functioning of surface equipment as flow meters and pedal position meters,
- Execution factors, such as correct lining up of (trip) tanks and surface lines,
- Mechanical factors,for instance plugged lines or hydrate formation,
- Environmental conditions,like heave, roll, and pitch,
- Procedural problems, as volume transfers, solid equipment operations etc.,
- Physics behaviors, like gas remaining soluble in oil-based mud and thereby avoiding detection until the point where
it breaks out of solution at shallower depths near or even above the BOPs,
- Downhole conditions, such as ballooning or wellbore breathing and lost circulation.

Training and experience deficiencies may also impact speedy recognition of well control events that are unfolding including
the corrective measures to arrest the event. Standard well control training assumes homogenous kill mud weight instead of
heterogeneous columns in the annulus and drillstring as methods rely predominantly on surface measurements.

Technical challenges are posed by long choke lines in deepwater subsea systems that generate substantial friction effects.
Unpredictable pressure swings result for instance when gas breaks out of solution, enters and displaces the liquid mud inside
the choke line, followed by its displacement by liquid kill mud.These pressure swings result in substantial fluctuations in
bottomhole pressure as personnel and systems currently rely on modeling and surface measurements. This is due to not
having the means to quickly adjust the choke to prevent formation breakdown, associated fluid losses, and other
complications.

Although drilling operations have a long history of benefitting from measurement while drilling (MWD) and logging while
drilling data (LWD) measurements, real-time downhole data has largely been absent while tripping, running casing,
cementing, and a number of completion operations. One studyii suggests that tripping operations were ongoing in 24% of the
drilling phase operations that resulted in a well control event (and actual drilling was ongoing in 29% of the
instances).During the completion phase tripping is the leading cause (28%) of the well control occurrences.

Telemetry Options to Obtain Downhole Data

MWD technology transmits subsets of downhole acquired data to surface using a wireless protocol such as mud pulse or
electromagnetic systems. However, these wireless systems do not offer the bandwidth required to transmit all acquired data
in realtime. Further, data rates degrade to a dozen bits per second (bps) as the distances increase between the transmitter near
the measurement tools and the receiver at surface. This effectively results in one-way communication. Finally, data
acquisition is limited to a single section near the bit while conditions along the string are unknown due to the absence of
measurements along the string.

A high-bandwidth downhole data transmission system via a wired or networked drill string systemnowadays provides an
alternative to the standard wireless telemetry protocols to obtain data from downhole tools. This wired system provides a data
transmission rate three magnitudes higher than typically experienced with a wireless system. Further, the data transmission is
two-way. Besides data transmission from the end of the pipe, real-time pressure and temperature measurements are available
from discreet positionsiiialong the drill string.

At a data transmission rate of 57,600 bpsiv,v, the current bi-directional data transfer system impacts well construction safety
by providing faster updates of subsurface information which reducesgeological uncertainty. In addition, formation pressure
testsare effectively conducted by commanding downhole tools through two-way communication, which further reduces
uncertainty in the pressure regimes. Table 1summarizes distinctions between the wired and the wireless telemetry
specifically to identify, analyze, and control a wellbore influx.
SPE 157220 3

Table 1. Differences between wired and wireless data transmission specifically to identify, analyze, and control a wellbore influx.
WELL Wireless transmission of downhole data Wired transmission of downhole data
CONTROL through mud pulse telemetry through networked drillstring telemetry
Identify - Insufficient data from downhole during - Wired-pipe or networked drillstring transfer
subsurface operations, degrade by depth data from downhole tools three magnitudes
faster (57,600bps)

- Annular pressure measurement updates - High resolution annular pressure

transmitted only a few times per minute measurement update frequency ≈5sec
Analyze - Limited by data that is only acquired near - Along string annular pressure evaluation at
the bit discrete network nodes provide dynamic
insights beyond just near the bit

- Reliance on surface data as downhole
annular pressure measurements require a
minimum flow rate for transmission to
surface, and downhole data is therefore
absent during shut-in and well kill
operations
Control - Reliance on surface data
- Multiple annular pressure and bore pressure
measurements along the drillstring providing
downhole information even during periods
without flow during all well construction
phases involving networked drillstrings
- Direct measurement of bottomhole pressure,
independent of surface measurements

- Constrained by one-way data due to - Two-way communication provided efficient

receiver-transmitter arrangement commanding and quality control of downhole
tools

- Downhole tools actuate through mechanical - Direct actuation through wire of battery-
actions only, as ‘downlinking’ to electronic powered downhole tools (flow bypass valves,
tools that require flow etc.)

Workflows Enabled by Networked Drillstrings that Improve Safety in Deepwater Operations

The real-time downhole information through the networked drillstring complements the surface measurements. Significant to
well control, the system provides both dynamic and static bottomhole pressure readings at discrete measurement or network
nodes allowing for conditions to be measured along the entire hydrostatic column around the drillstring.There are four steps
that are carried out when utilizing these capabilities. First, the safe drilling margin is identified. Second, an influx in the
annulus is analyzed and is distinguished from the wellbore ballooning. Third, a well control methodology is proposed based
on direct measurement circulation. Lastly, a measurement while tripping methodology is offered to identify kicks early while
tripping.

Identify: Pore Pressure, Fracture Gradient and Safe Drilling Margin

The safe drilling margin encompasses the pore pressure, fracture gradient, and true mud weight. The networked drillstrings
enable the three elements comprising the safe drilling margin to be established independently from surface measurements.

IdentifyPore Pressure
Identifying the pore pressure, the first element of the safe drilling margin, is routinely accomplished with a
formation pressure testing tool. The operation of formation pressure testers is about 50% more efficient compared to
downlinking through the two-way communication capability in high-permeable formations such as in deepwater
Gulf of Mexicovi. This not only significantly reduces the chance of getting stuck through reduced stationary time,
but also quality control in real time is obtainable during drawdown – even with pumps off –instead of relying on
communication via downlinking and mud pulse that require mud flow.

In a recent deepwater wellvi, 54 formation pressure tests were taken. Nine tests were tight while 39 tests were taken,
exploiting the ability for real-time quality control similar to the feedback when testing on wireline. The 12 ¼in.
testing tool with a 14in. extension pad tested successful in five tests in the 14 ½in. hole at 18° inclination. A seal
could not be established in the six tests that were conducted in a large hole with a well inclination below 8°, which
were quickly aborted.The series of 54 formation pressure tests (FPTs) were conducted in seven minutes per test on
average. This equates to a time savings of approximately eight minutes per test in deepwater Gulf of Mexico and the
4 SPE 157220

improved quality control eliminated the time for a wireline run and associated check trip following the log-run.
Three good tests were achieved in 17 minutes in a 14 ½in. x 16 ½in. hole at approximately 15,000 ft.

IdentifyFracture Gradient
The fracture gradient, the second element that comprises the safe drilling margin, is routinely measured by
conducting a leak off or formation integrity test. While tools provided by service companiesrecord annular pressure,
the networked drillstrings transmit the formation breakdown, the fracture propagation, and the shut-in pressure for
real-time interpretation as the test is ongoing. Further, the compounding annular pressure and temperature
measurements at various network nodes reveal information about compressibility and fluid densities difference
throughout the annulus. Circulation time for obtaining a homogenous fluid column – a prerequisite for inference
through surface measurements – is eliminated through the direct bottomhole measurement.See Figure 1.

Figure 1.Annular pressure measurements at four positions along the drillstring during a leak off test.

IdentifyMud Weight
The downhole hydrostatic measurements displayed in Figure 1 above provide easy identification of the third element
of the safe drilling margin; the true mud weight and its distributions throughout the annulus. The fluid column may
or may not have a heterogeneous density and undergo compressibility under the influence of pressure and
temperature. This downhole measurement ability takes out interpretation and estimation of the position for slugs or
weighted sweeps that may cause U-tubing or other flow effects that may distort surface observations.

Analyze Influx in the Annulus

The location of the influx and the type of influx can be determined through independent pressure measurements from surface
measurementsvii. Once the influx is identified, maintaining and controlling bottomhole pressure is made possible based on
direct downhole measurements as opposed to a complex computation performed under stress.

The network’s ability to take multiple distributed pressure measurements along the entire length of the drillstring allows
developing well control issues to be accurately analyzed and characterized. The downhole data, independent from surface
data, is available both at stationary conditions with the pumps off as well as with the pumps on.It also improves safety as
corrective actions can be taken while the event is limited in size and more easily managed.

Figure 2below shows an example of a fluid traveling up the annulus. In this instance, a pressure increase is recorded at the
bottom two pressure sensors. The sensors up-hole will identify the pressure increase as time advances.
SPE 157220 5

Figure 2. Changes in the hydrostatic column may be identified earlierby analysis of along-string annular pressure through downhole
sensors located at the nodes along the network drillstring

DistinguishingBallooning from a Kick

Ballooning or wellbore breathing occurs while drilling (naturally) fractured formations and is often mistakenly interpreted as
a formation influx. The ballooning mechanism originates from fracture deformation, producing drilling fluid loss and gain as
fractures open and close. The fracture opening is caused by an increase of equivalent circulating density (ECD) during
periods of flow, resulting from the fluid flow friction in the annulus. With pumps off, the ECD is reduced to static mud
weight, closing the fracture and drilling fluid gains are observed. See Figure 3.

Wellsite personnel are trained to monitor for fluid gains as these are indicators of a wellbore influx. There are however
distinctive differences between a kick and ballooning. First, in case of a kick, the fluid gain rate will increase over timewhile
the rate decreases for ballooning. Second, the shut-in pressurecannot exceed the ECD value in the case of a ballooning effect,
while the shut in pressure is limitless in case of a kick. In order to distinguish a kick from ballooning, one typically relies on
surface measurements as there is currently no reliable downhole fluid flow measurement available.Establishing the shut in
pressure is not operationally feasible as it would unreasonably wear-out subsurface BOP elements.

Logging while drilling (LWD) downhole resistivity propagation logs can identify fluids invaded into fractures or micro
fractures. Figure 4 displays high-resolution resistivity propagation logs while drilling and a log acquired without pumping
fluid to identify the zone that caused ballooning. This methodology to acquire and compare the resistivity propagation logs
(See flow diagram in Figure 3) aids in identifying the zone responsible from ballooning and uniquely utilizes the network
drillstring’s ability to acquire high-definition log data in the absence of flow. An algorithm (patent pending) is utilized to
quantify the likelihood that wellbore sections are causing the ballooning.
6 SPE 157220

Figure 3. Fracture deformation through ECD effects and methodology to identify the wellbore section where ballooning occurs.

Identif
Propagation resistivity log revealing Propagation resistivity log of the ication of ballooning zones with low,
mud invasion during pumps-on same wellbore section during medium and high likelihood to contribute to
pumps-on ballooning

Figure 4.Analyzing and quantifying the likelihood that ballooning occurs in wellbore sections through the analysis of propagation
resistivity logs with pumps on and off, courtesy, Li viii, 2005.

Controlling the Well throughDirect Measurement Circulating Method

To regain well control, wellsite personnel must circulate out the wellbore influx and replace the fluid column with denser
mud. During this process constant bottomhole pressure must be maintained to prevent additional wellbore influx. Constant
bottomhole pressure is achieved by carefully operating the choke to keep adequate backpressure and is historically achieved
based on surface measurements.

Two widely used constant bottomhole pressure circulating methods are the Driller’s Method and the Wait and Weight
Method. The latter is frequently referred to as the Engineer’s Method as more calculations are required. The focus here is not
to discuss the relative advantages and disadvantages of the two methods, but rather to introduce a third method, the Direct
Measurement Method.This method benefits uniquely from the networked drillstring’s ability to acquire and transmit real-
SPE 157220 7

time annular and bore pressure data under both static and dynamic conditions all along the wellbore.

Once the influx is identified and BOPs have been closed the Direct Measurement Method presents a direct measurement of
the bottomhole pressure. Directly following, the circulate-out of hole of the influx can commence, maintaining the
established constant bottomhole pressure and operations of the (auto) choke. Table 3 compares the two popular methods with
the Direct Measurement Method.

Table 3.Comparison between the driller’s method, engineer’s method, and direct measurement method.
Driller’s Method Engineer’s Method (Wait & Direct Measurement
Weight) Method
Concept Circulate out influx, One circulation with heavier Direct start of well kill,
maintaining constant drill mud, applying the choke based on direct bottomhole
pipe pressure, followed by according to a calculated drill pressure measurement to
displacement to heavier mud pipe pressure schedule while circulate out the influx and
if required, and maintaining displacing lighter mud inside the introducing heavy mud
constant casing pressure. (tapered) drillstring, taking when available
trajectory into account. (heterogeneous density).
Constraints Constant pump rate Networked drillstring
Homogenous kill mud weight
Ease/difficulty No calculations required, Computation of pressure Direct, downhole pressure
using surface measurements response, using surface measurement to ensure
measurements constant bottomhole
pressure is maintained even
as gas travels up the choke
line
Impact - In some instances more - In some instances more time - Time efficient
time consuming efficient - Best ability to maintain
- Lower pressure at the shoe - Could increase risk for stuck constant bottomhole
than Engineer’s method pipe pressure without model or
calculation
Enhancements - Direct control of auto-
choke and automated
startup/shutdown of mud
pumps

The downhole pressure responses during a Direct Measurement Method well kill is presented in Figure 5 for three annular
pressure sensors and for one bore pressure sensor (or standpipe pressure) as a function of time. At point (1), the formation
pressure increases as drilling continues. At (2), the annular pressure decreases as hydrocarbons continue to enter the annulus,
the BOPs are closed at (3)and the BHP is established. Directly (4), original mud is circulated maintaining constant
bottomhole pressure. The weighted kill mud is circulated as it becomes available (5) at the available density as mixing
continues. The bore pressure sensors convey the pressure gradients inside the drillstring in real time for confirmation that the
kill mud passed the deepest drillstring sensor (and is entering into the annulus). At (6) kill mud is circulated to the surface
and the pressure gradients convey that heavy mud is in the annulus. Finally, at (7) the BOPs are opened for operations to
continue as before.

The Direct Measurement Method complements, or replaces, conventional well kill methods that depend on manually
following a kill-sheet that originated from complex calculations. These calculations were performed under time constraints
and stress by personnel who may have limited exposure or experience with well control events. The additional high-
frequency downhole information not only improves the safety and accuracy, but also allows for dynamically killing the well,
improving the efficiency, and saving rig time.Finally, wellsite personnel will appreciate the additional available downhole
data regardless of flow, providing accurate hydrostatic pressure even at typical kill-rates of 10-20 strokes per minute.
8 SPE 157220

Figure 5. Pressure responses of downhole pressure sensors during the Direct Measurement Method

Kicks while tripping

Tripping is a leading operation resulting in well control events (See Table 2). Swabbing is caused by friction effects and
volumetric changes as the drillstring is hoisted (see Figure 6).Detection of an influxhistorically relies on surface
measurements.To prevent swabbing, drillers rely on conservative rules of thumb or empiricalmodels to determine the safe
operating ranges for the trip speed. Excessive surge pressure could result in time-consuming lost circulation events, while
excessive swab pressure could lead to hazardous and costly well-control events.

Table 2. Ongoing operations when well control event occurs during drilling and during completionsii
Top 3 operations encountering kicks during “Drilling Top 4 operations encountering kicks during “Completions
Phase”: Phase”:

o Actual drilling (29%) 1. Tripping (28%)

o Tripping (24%) 2. Perforating (14%)
o Casing running (20%) 3. Gravel-pack (14%)
4. Killing (14%)

Through the networked drillstring, wellsite personnel could obtain insight in dynamic downhole hydrostatic pressures with
real-time measurements while tripping by either connecting to the networked drillstring while suspended in the rotary table
during connections, or while being hoisted in the elevators (See Figure 7).

Measurements while tripping (MWT) can accurately reveal the dynamic surge and swap pressures, which have not been
available in realtime without connecting the topdrive. Because the broadband network integrates the downhole measurements
with the surface equipment, the industry now has in reach a truly closed loop feedback system. The real-time downhole
pressure measurements allow the drawworks system to set the optimum tripping speed.
SPE 157220 9

Figure 6. ECD analysis, providing the equivalent static density as the drillstring moves. At (1) the drillstring moves down and ECD
increases by nearly 0.1ppg, and travels downwards (2) at approximately 1,300ft/hr. (about half the speed when tripping at 2min/stand). At
(3) and (4) ECDfluctuates by 0.1 ppg while driller carefully relogs a wellbore section, courtesy, Muñozix 2009.

MWT Static MWT Dynamic

Figure 6.Measurement while tripping devices that connect to the networked drillstring in static conditions (during connections) and in
dynamic conditions (while hoisting the string).

Summary and Conclusions

Deepwater operations call for new processes and technologies to ensure the safety of workers, environment, and assets.
Wired or networked drillstring technology offers acquisition of downhole measurements in real time for identification,
analysis, and control of subsurface processes independently from surface measurements. This redundancy promotes well
construction safetyin the following ways:

1. Compared to wireless telemetry of downhole data, the wired or networked drillstring offer high-resolution and high-
frequency downhole data– even during static conditions – from several discrete locations along the wellbore,
providing much more extensive pressure evaluation capabilities.
2. Networked drill string affords downhole data independent from surface measurements to identify pore pressure,
fracture gradient, and effective mud weight that comprise the safe drilling margin.
10 SPE 157220

3. Along-string pressure evaluation provides early kick detection and improved ability to analyze and control an influx
even with heterogeneous mud column.
4. Ballooning or wellbore breathing effects can be distinguished from an influx through the comparison of resistivity
propagation logs that were acquired with pumps on and pumps off. The latter measurement relies on the networked
drillstrings to uniquely convey high-definition log data in absence of flow.
5. The direct measurement circulation method is introduced with benefits of quicker and easier regainingof well
control through constant bottomhole pressure, and in some instances will result in a lower maximum casing
pressure.
6. Tripping operations – a leading cause for well control events – benefits from downhole pressure measurements both
during static conditions as well as dynamic conditions. ECD fluctuation below the bit by drillstring movements are
substantial and can cause swabbing an influx. The MWT Static and MWT Dynamic help earlier identify a kick
during tripping operations.

Recommendations and future work

While this proven networked drillstring system has deployed more than 1,000,000 ft on over one hundred wells, including
two deepwater wells in the pre-salt region of Brazil, and was mobilized as back-up for a relief well application in deepwater
Gulf of Mexico, new applications are still being developed. Offshore managed pressure drilling from floating rigs, dual
gradient drilling, and automated drilling based on closed-loop downhole measurements are a few of these applications.
 
Future work is ongoing in four categories. First, the network upgrade to 2.0Mbps from 57,600 bps will deliver time
synchronization capability, which is very useful for seismic measurements and for providing a look-ahead as opposed to just
the side-view of many logging measurements. Second, a number of “active” tools are under development. Examples are flow
bypass valves, packers, and reamers that are activated from surface through the network. Activation of wall-contact pads
offers opportunities for improved cement bond logging with spell out (LWD). These “active” tools not only increase the
functionality, but also create opportunities without the limitations by mechanical tools that are frequently activated with balls
or time – consuming handling routines. Third, developments are ongoing to determine flow rate at distributed measurement
stations along the networked drill string. These flow rate sensors, as well as fluid identification sensors, would provide
additional means for kick detection and lead to better well control. Fourth, safetyand efficiency are improved by downhole
tools that can be commanded through two-way communication. Flow bypass valves are conceived that can be operated from
surface with instantaneous confirmation that the command was executed.

Acknowledgements
The author wishes to thank management, operations teams, wellsite crews of National Oilwell Varco IntelliServ, and our
service partners for their contribution and support in publishing this paper.Courtesy to Schlumberger for figure 6.

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