C HAPTER

C HAPTER

3
6
 6-1

W ELL C ONTROL
B ASICS
T
he basic mathematics of well control
requires straightforward calculations.
Addition, subtraction, multiplication,
division and squaring are commonly used. Pressure,
fluid density and volume calculations are also
A good understanding necessary. These calculations and principles will
provide answers to many well control problems.
of basic mathematics This section will introduce the mathematics of well
control and will illustrate sections of the worksheets
to simplify the calculations.
is required for
every well control CIRCULATING CONSTANT
BOTTOMHOLE PRESSURE METHODS
operation.
After wells are shut in, and formation fluid
flow stopped, the bottomhole pressure soon equals
the formation pressure. Additional pressure must
be held to prevent more formation fluid flow
 C HAPTER 6
6-2
WCS
exercise for Surface Line Volume 3.5 bbls
chapter PUMP

Pump #1: 6" X 16" Duplex, Output .157 bbls/stk

Pump #2: 5 1/2" X 16" Duplex, Output .126 bbls/stk

Maximum Pump Pressure 3,950 psi ANNULAR

BOP Stack Rating 10,000 psi

RAM
PIT
RAM
HCR

Volume in Active Pits 500 bbls

RAM

Surface Line Volume 3.5 bbls

Present Mud Weight 12.5 bbls CASING

Reserve Pit Mud Weight 14.7 bbls Outside Diameter 9 5/8", Inside Diameter 8.835"

Weight 40 lbs/ft, Grade N-80

Internal Yield (100%) 5,750 psi

Length TVD 5000 ft, MD 5000 ft

TVD 5000 ft, MD 5000 ft

DRILL PIPE

Outside Diameter 4.5", Inside Diameter 3.826"

Weight 16.6 lbs/ft

Integrity/Leak-off Test Mud Weight 9.1 ppg
Capacity .01422 bbls/ft
Integrity/Leak-off Test Pressure 1,570 psi
Total Length 9,000 ft
Depth of Test (Shoe or Weak Zone) TVD 5,030 ft

DRILL COLLARS

Outside Diameter 6 1/2", Inside Diameter 2.8125"

Capacity .00768 bbls/ft

Total Length 1,000 ft

Well Depth: TVD 10,000 ft
MD 10,000 ft Hole Size 8 1/2" bit

while circulating out the kick. At the same
time, excessive bottomhole pressure must be
avoided to prevent loss of circulation.
A record of
If an influx is to be circulated and removed
essential
from the well, it requires circulating the kick
information
should be kept
while maintaining the bottomhole pressure.
available for Procedures for doing this are called Constant
well control Bottomhole Pressure Methods.
situations. There are choices as to when to circulate
out the kick and when to weight up. Either may
be done first, or both may be done at the same
time, but bottomhole pressure must always be
kept at or slightly above the formation pressure.
Methods with either choice are the same.
Based on the order of kick circulation and
weight up, the following are the most common
Constant Bottomhole Pressure Methods.
w Driller’s Method – circulate kick out of the
well and then weight up pits and wellbore
w Wait And Weight Method – weight up pits
and then circulate kick, maintaining weight
w Concurrent Method – circulate kick and
build weight at the same time
These methods have relative advantages and
disadvantages which are discussed separately
in the following chapter. They must be fully
understood before the appropriate method is
selected.
W ELL C ONTROL B ASICS
6-3

NON-CIRCULATING PRE-RECORDED INFORMATION

CONSTANT BOTTOMHOLE
A record of essential information needs to
PRESSURE METHODS be kept to kill or maintain control of a
well. This record must be as accurate as
There are several techniques that relate possible. Calculations must be performed to
pressure to the fluid volume released from the find other information for pressure control Calculations
well. The Volumetric and Lubricate/Bleed are and kill operations. WCS killsheets are easy using the
two such techniques providing control without to follow and use. This may seem simplistic prerecorded
circulating on bottom. at times, but it is probably the most thorough data provide
the information
approach.
for pressure
control and kill
operations.

WELL DATA
WELL NAME COMPLETED BY:

DRILL PIPE

INCHES INCHES FT BBLS/FT LBS/FT MD FT

Outside Diameter Inside Diameter Length Capacity per Foot Weight Total Drill String
Length
(DP & DC)

DRILL COLLARS / HOLE SIZE

INCHES INCHES FT BBLS/FT INCHES TVD FT

Outside Diameter Inside Diameter Length Capacity per Foot Hole Size True Vertical Depth
(to Bit)

CASING

INCHES INCHES TVD FT MD FT PSI @ 100%

Outside Diameter Inside Diameter True Vertical Depth Measured Depth Weight & Grade Internal Yield

PUMPS / SURFACE LINES

X X
LINER X STROKE BBLS/STK LINER X STROKE BBLS/STK PSI BBLS
Pump #1 Output _____%EFF Pump #2 Output _____%EFF Maximum Pump Surface Line Volume
Pressure

MUD

PPG PPG PPG PSI TVD FT BBLS

Present Mud Weight Reserve Mud Weight Integrity/Leak-off Integrity/Leak-off Depth of Test Volume in Active Pits
Test Mud Weight Pressure (Shoe or Weak Zone)
 C HAPTER 6
6-4

*1029.4 is the conversion factor from

VOLUME CALCULATIONS cylindrical inches diameter to barrels/foot
([π × D² ÷ 4] × [12 inch/ft ÷ 231 in³/gal ÷
Most well control activities require circulating 42 gal/bbl]). In drilling applications, 1029.4 is
or, at a minimum, pumping a certain volume. often rounded to 1029. For smaller tubulars,
Once volume has been determined, the time 1029.4 should be used to obtain results that
or strokes to pump volume may be calculated require greater accuracy.
from pump rate. In the metric system to find m³/m, mm
diameters must be converted to m (divide mm
The smaller the
To calculate capacity per foot (m): by 1000) prior to using equation π × D² ÷ 4.
tubing size, the
**0.7854 is derived from π ÷ 4 = 0.7854
higher the
Capacitybbls/ft = ID² ÷ 1029.4* The bbls/ft (m³/m) is often carried out to five
degree
of decimal decimal places for accuracy. The smaller the
tubular sizes, the higher degree of accuracy
accuracy is Capacitym³/m = (IDmm ÷ 1000)² × 0.785**
warranted when that is warranted – especially when displacing
computing or pumping treating fluids.
volumes.

EXAMPLE 1
What is the capacity per foot (m) of 4.5" (114.3 mm) OD, 3.826" (97.18 mm) ID drillpipe?

Capacitybbls/ft = ID² ÷ 1029.4

= (3.826)² ÷ 1029.4

= 14.6383 ÷ 1029.4

= 0.01422 bbls/ft

Capacitym³/m = (IDmm ÷ 1000)² × 0.7854

= (97.18 ÷ 1000)² × 0.7854
= (0.0972)² × 0.7854
= 0.00945 × 0.7854
= 0.00742 m³/m

PROBLEM 1
What is the capacity per foot (m) of 2 7/8" (73 mm) OD, 2.441" (62 mm) ID production tubing?

To find out how much volume is between two points, multiply the capacity per foot (m) by the
length between the points:

Volume = Capacity × Length

Volumebbls = Capacitybbls/ft × Lengthft

Volumem³ = Capacitym³/m × Lengthm

W ELL C ONTROL B ASICS
6-5

EXAMPLE 2
How much volume is in 9,000' (2743.2 m) of pipe? (use pipe from Example 1)

Volumebbls = Capacitybbls/ft × Lengthft

= 0.01422 × 9,000

= 128 bbls

Volumem³ = Capacitym³/m × Lengthm

= 0.00742 × 2743.2
= 20.35 m³
PROBLEM 2
How much volume is in 6,000' (1828.8 m) of pipe? (use pipe from Problem 1)
For strings with different size inner diameters, the above calculations to determine capacity and
volume would be performed for each size and totaled. If a different fluid density will be pumped,
the surface line capacity (usually known or given) should be included in the total string volume.

String Volume = Volume in Drillpipe/Tubing + Volume in Collars + Surface Line Volume

TIME/STROKES TO BIT/END OF TUBING

In all well-killing methods involving weighting up the fluid, the amount of time or strokes
from the pump to the bit or the end of tubing (EOT) must be known. (Units that use small When using
pumps may measure volume pumped in barrels or cubic meters per minute rather than strokes methods which
per minute.) In reality, the use of strokes to bit is more accurate, since a mud pump is a positive require
weighting up,
displacement pump. Below is the equation and a sample problem.
the workstring
volume must be
Strokes to Bit/EOT = String Volume ÷ Pump Output
determined.

Strokes to Bit/EOT = String Volumebbls ÷ Pump Outputbbls/stk

Strokes to Bit/EOT = String Volumem³ ÷ Pump Outputm³/stk

Drill String Volume & Stroke Calculations

(9) Drill Pipe, Drill Collar Volumes

x = x =
FT BBLS/FT BBLS FT BBLS/FT BBLS

Drill Pipe Length Capacity per Foot in DP Volume in Drill Pipe Drill Collar Length Capacity per Foot in DC Volume In Drill Collars

(10) Strokes Surface to Bit

+ + = ÷ =
BBLS BBLS BBLS BBLS BBLS/STK STKS

Volume in Drill Pipe Volume in Drill Collars Surface Line Volume Drill String Volume Pump Output STKS Surface to Bit
 C HAPTER 6
6-6

Tubing Volume/Strokes (Surface to End of Tubing, E.O.T.)

x = ÷ =
MD FT BBLS/FT BBLS BBLS/STK STKS
Tubing Length Capacity per Foot Tubing Volume Pump Output Strokes Surface
Surface to EOT in Tubing Surface to EOT to EOT

EXAMPLE 3
How many strokes will it take from the pump to the bit using the following information?
Drillpipe Capacity = 0.01422 bbl/ft (0.00742 m³/m)
Drillpipe Length = 9,000 ft (2743.2 m)
Drill Collar Capacity = 0.00768 bbls/ft (0.004 m³/m)
Drill Collar Length = 1,000 ft (304.8 m)
Surface Line Volume = 3.5 bbls (0.557 m³)
Pump output = 0.157 bbls/stk (0.02496 m³/stk)
Pump rate = 30 stks/min

Strokes to Bit/EOT = String Volumebbls ÷ Pump Outputbbls/stk

Stks = (Drillpipe Volbbls + Drill Collars Volbbls + Surface Line Volbbls) ÷ Pump Outputbbls/stk

= ([0.01422 × 9,000] + [0.00768 × 1,000] + 3.5) ÷ 0.157

= (128 + 7.7 + 3.5) ÷ 0.157

= 139.2 ÷ 0.157

= 886 stks

Strokes to Bit/EOT = String Volumem³ ÷ Pump Outputm³/stk

Stks = (Drillpipe Volm³ + Drill Collars Volm³ + Surface Line Volumem³) ÷ Pump Outputm³/stk

Stks = ([0.00742 × 2743.2] + [0.004 × 304.8] + 0.557) ÷ 0.02496

EOT: the
accepted Stks = (20.353 + 1.219 + 0.557) ÷ 0.02496
abbreviation
for the term
Stks = 22.13 ÷ 0.02496
end of tubing. Stks = 886 stks

Time to displace the volume can be calculated by:

Time = Strokes ÷ Pump ratestks/min

= 886 ÷ 30

= 29.5 minutes
W ELL C ONTROL B ASICS
6-7

Time may also be calculated from volume and pump output. If the pump speed is 30 stk/min, and
it has an output of 0.157 bbls/stk (0.0249 m³/stk), then the rate per minute would be:

Pump Rate = Pump Speed × Pump Output

Pump Ratebbls/min = Pump Speedstkump Outputbbls/stk

= 30 × 0.157
= 4.71 bbls/minute
Annular
geometry:
Pump Ratem³/min = Pump Speedstks/min × Pump Outputm³/stk
describes
= 30 × 0.0249 various annular
= 0.7485 m³/minute volumes within
Then, volume to pump divided by rate per minute will give time: one well: e.g.,
casing, open
Time = Volume to Pump ÷ Rate per Minute
hole, open hole
with tubulars.
Timemin = Volume to Pumpbbls ÷ Rate per Minutestks/min
= 139.2 ÷ 4.71

= 29.5 minutes

Timemin = Volume to Pumpm³ ÷ Rate per Minutestks/min

= 22.13 ÷ 0.7485
= 29.5 minutes

PROBLEM 3
How many strokes and how much time will it take from the pump to the EOT using the following
information?
Production Tubing Capacity = 0.00579 bbl/ft (0.00302 m³/m)
Production Tubing Length = 6,000 ft (1828.8 m)
Surface Line Capacity = 1.5 bbls (0.24 m³)
Pump output = 0.049 bbls/stk (0.00779 m³/stk)
Pump rate = 40 stks/min

ANNULAR CAPACITIES, VOLUMES & STROKES

The following equations will show how to calculate annular capacities in barrels per foot
(m³/m), volumes in barrels (m³) and pump strokes necessary to displace that volume. Once
the total amount of barrels in the annulus is known, time/strokes to displace that volume
may be calculated.
Annular geometry is dependent on the sizes of drilled hole, casing and tubulars. It is possible
to have several different sizes or diameters between the pipe and casing or open hole. Each different
geometry has a different bbls/ft (m³/m) that should be calculated. Once each capacity per foot (m)
is known, multiplying each by the length of that section gives the volume that may be contained.
 C HAPTER 6
6-8

Annular Volume & Stroke Calculations

Annular Capacities and Volumes

A. Annular Volume Between Drill Pipe (DP) and Casing (CSG)

– ÷ 1029.4 = x =
CSG ID2 DP OD2 . __ __ __ __BBLS/FT FT A BBLS
ID of CSG Squared OD of DP Squared Capacity per Foot Length of DP in CSG Volume Between
Between DP & CSG (Measured Depth) DP & CSG

B. Annular Volume Between Drill Pipe (DP) and Open Hole (OH)

– ÷ 1029.4 = x =
OH2 DP OD2 . __ __ __ __BBLS/FT FT B BBLS
Hole Size Squared OD of DP Squared Capacity per Foot Length of DP in OH Volume Between
Between DP & OH DP & OH

C. Annular Volume Between Drill Collars (DC) and Open Hole (OH)

– ÷ 1029.4 = x =
OH2 DC OD2 . __ __ __ __BBLS/FT FT C BBLS
Hole Size Squared OD of DC Squared Capacity per Foot Length of DC in OH Volume Between
Between DC & OH DC & OH
Bottoms up:
D. Total Annular Volume
used to
describe the + + + =
time or pump A BBLS B BBLS C BBLS D BBLS E BBLS
Volume Between Volume Between Volume Between Volume in Choke Line Total Annular Volume
strokes required DP & CSG DP & OH DC & OH (Subsea Only)
(See back of Kill Sheet)
to move fluid Strokes Bit to Casing Shoe
from the well
bottom to the + ÷ =
B BBLS C BBLS BBLS/STK STKS
surface. Volume Between Volume Between Pump Output Strokes Bit
DP & OH DC & OH to Casing Shoe

Strokes Bit to Surface

÷ =
E BBLS BBLS/STK STKS
Annular Volume Pump Output Strokes Bit to Surface

Total Strokes Surface to Surface

+ =
STKS STKS STKS
Strokes Surface to Bit Strokes Bit to Surface Strokes Surface to Surface

Adding each section’s volume together will give the total annular volume.

EXAMPLE 4
Calculate the annular volume and required strokes to circulate bottoms up.
Casing ID = 8.835” (224.4 mm), length = 5,000’ (1523.93 m)
Drillpipe OD = 4.5” (144.3 mm), length = 9,000’ (2743.2 m)
Drill collar OD = 6.5” (165.1 mm), length = 1,000’ (304.8 m)
Hole size = 8.5” (215.9 mm)
MD = 10,000’ (3048 m)
Pump = 0.157 bbls/stk (0.02496 m³/stk)
Pump rate = 30 stks/min
W ELL C ONTROL B ASICS
6-9

In this example there are 3 different geometries: A. Drillpipe in Casing, B. Drillpipe in Open
Hole, and C. Drill Collars in Open Hole. The lengths to use for the calculations follow.
A. Drillpipe in Casing = MD Length of Casing
Drillpipe in Casing = 5,000’
Drillpipe in Casing = 1523.93 m

B. Drillpipe in Open Hole = MD of Hole – MD of Casing – Length of Drill Collars

Drillpipe in Open Hole = 10,000 – 5,000 – 1,000
= 4,000’
Drillpipe in Open Hole = 3047.85 – 1523.93 – 304.79
= 1219.13 m
C. Drill Collars in Open Hole = Length of Drill Collars
Drill Collars in Open Hole = 1,000’
Drill Collars in Open Hole = 304.79 m
To calculate the annular capacity the formula is similar to the one used to calculate internal
capacity, except that diameters are larger and you must subtract out the volume displaced by the
string and bottomhole assembly (BHA). In each section there is a larger diameter OD, which
is either the hole diameter or the inner diameter of the casing. Subtracting out the total cross
sectional inner diameter (ID) volume displaced by the pipe or BHA, use its outside diameter.
Once the bbls/ft (m³/m) capacity for each geometry has been calculated, multiply it by the length
of that section.

Annular Capacitybbls/ft = (OD² – ID²) ÷ 1029.4

Annular Capacitym³/m = ([OD ÷ 1000]² – [ID ÷ 1000]²) × 0.785

A. Annular Capacitybbls/ft Between Drillpipe & Casing = (OD² – ID²) ÷ 1029.4

= (8.835² – 4.5²) ÷ 1029.4
= (78.057 – 20.25) ÷ 1029.4
= 57.807 ÷ 1029.4
= 0.05616 bbls/ft
Capacity refers
Multiply this by the length to get volume:
to units of
Annular Volumebbls/ft Between Drillpipe & Casing = Annular Capacitybbls/ft × Lengthft
volume per
= 0.05616 × 5,000
length, e.g.,
= 280.8 bbls bbls/ft. Volume
refers to total
Annular Capacitym³/m Between Drillpipe & Casing = ([OD ÷ 1000]² – [ID ÷ 1000]²) × 0.785 contents, e.g.,
= ([224.4 ÷ 1000]² – [114.3 ÷ 1000]²) × 0.785 barrels.
= (0.05036 – 0.01306) × 0.785= 0.0373 × 0.785
= 0.02928 m³/m
Multiply this by the length to get volume:

Annular Volumem³/m Between Drillpipe & Casing = Annular Capacitym³/m × Lengthm

= 0.02928 × 1523.93
= 44.6 m³
 C HAPTER 6
6-10

B. Annular Capacitybbls/ft Between Drillpipe & Open Hole = (OD² – ID²) ÷ 1029.4
` = (8.5² – 4.5²) ÷ 1029.4
= (72.25 – 20.25) ÷ 1029.4
= 52 ÷ 1029.4

= 0.05051 bbls/ft
Multiply this by the length to get volume:
Annular Volumebbls/ft Between Drillpipe & Open Hole = Annular Capacitybbls/ft × Lengthft
= 0.05051 × 4,000

= 202 bbls

Ann. Cap.m³/m Between Drillpipe & Open Hole = ([OD ÷ 1000]² – [ID ÷ 1000]²) × 0.785
= ([215.9 ÷ 1000]² – [114.3 ÷ 1000]²) × 0.785
= (0.04661 – 0.01306) × 0.785
= 0.03355 × 0.785
= 0.02634 m³/m

Multiply this by the length to get volume:

Annular Volumemm³/m Between Drillpipe & Open Hole = Annular Capacitym³/m × Lengthm
= 0.02634 × 1291.13
= 32.1 m³

C. Annular Capacitybbls/ft Between Drill Collars & Open Hole = (OD² – ID²) ÷ 1029.4
= (8.5² – 6.5²) ÷ 1029.4
= (72.25 – 42.25) ÷ 1029.4
= 30 ÷ 1029.4
= 0.02914 bbls/ft
Multiply this by the length to get volume:
Annular Volumebbls/ft Between Drill Collars & Open Hole = Annular Capacitybbls/ft × Lengthft
= 0.02914 × 1,000
= 29.1 bbls
To divide by
1000, simply
Ann. Cap.m³/m Between Drill Collars & Open Hole = ([OD ÷ 1000]² – [ID ÷ 1000]²) × 0.785
move the
decimal point = ([215.9 ÷ 1000]2 – [165.1 ÷ 1000]²) × 0.785
three places = (0.04661 – 0.02726) × 0.785
to the left. = 0.01935 × 0.785
= 0.01519 m³/m

Multiply this by the length to get volume:

Annular Volumem³/m Between Drill Collars & Open Hole = Annular Capacitym³/m × Lengthm
= 0.01519 × 304.89
= 4.6 m³
W ELL C ONTROL B ASICS
6-11

Once the volume of each section is known, add them together to calculate the total annular
volume. The total annular volume is: A. bbls (m³) between drillpipe and casing plus B. bbls (m³)
between drillpipe and open hole plus C. bbls (m³) between drill collars and open hole, or:
Total Annular Volume = A + B + C

Total Annular Volumebbls = Abbls + Bbbls + Cbbls

= 280.8 + 202 + 29.1

Tip: when using
= 511.9 bbls
a calculator be
sure to check
Total Annular Volumem³ = Am³ + Bm³ + Cm³
the window
= 44.6 + 32.1 + 4.6 after your entry.
= 81.3 m³ Remember:
garbage in =
To calculate strokes for bottoms up, or in this case Bit to Surface, divide the annular volume garbage out,
by the pump output. every time.

Strokes Bit to Surface = Annular Volume ÷ Pump Output

Strokes Bit to Surfacestks = Annular Volumebbls ÷ Pump Outputbbls/stk

= 511.9 bbls ÷ 0.157 bbls/stk
= 3,260 stks

Strokes Bit to Surfacestks = Annular Volumem³ ÷ Pump Outputm³/stk

= 81.3 m³ ÷ 0.02496 m³/stk
= 3259 stks

The time required to displace the annulus would be:

Time = Annular Volume ÷ Rate per Minute

Time = Annular Volumebbls ÷ Rate per Minutebbls/min

= 511.9 ÷ 4.71

= 108.6 minutes

Time = Annular Volumem³ ÷ Rate per Minutem³/min

= 81.3 ÷ 0.7485
= 108.6 minutes

PROBLEM 4
Calculate the annular volume, required strokes and time to circulate bottoms up.
Casing ID = 5.920” (150.37 mm)
Production Tubing OD = 2.875” (73.03 mm)
Circulating Depth = 6,000’ (1828.7 m)
Pump Output = 0.049 bbls/stk (0.00078 m³/stk)
 C HAPTER 6
6-12

w If fluid density or flow properties change;

KILL RATES AND
KILL RATE PRESSURES
In many well control situations, you must
Kill Rate Pressure: be able to not only prevent the formation from
pressure required flowing, but also circulate kick fluid from
to overcome the
the well. Where possible, a predetermined kill
friction in the
rate and kill pressure (KRP) should be taken
circulating
with the pump. Determining this circulating
system at a given
pressure is critical and cannot be stressed
(slow) pump rate.
enough.
The circulating or kill rate pressures are
often called by various other names such as
slow circulating rates (SCR), slow pump rates
(SPR), reduced circulating rate, etc., but they
are all the same. This is the pressure required to
overcome the friction in the circulating system
at a given (slow) pump rate.
Because mud (fluid) properties and other
well parameters can affect kill rate pressures, it
is very important that kill rates and kill rate
pressures are taken on a regular basis.
Kill rate pressures should be taken:
w When changes are made to bit (e.g., jet
nozzle sizes) and BHA, and also drilling
assembly weight changes;
w When 500+ ft (152 m) of new hole drilled;
w Each tour; and
w After pump repair.
There are several different approaches to
taking a KRP. In typical scenarios they are
taken approximately one-sixth to one-half the
normal drilling or circulating rate. Another
method is to use the idle speed of the pump,
then a series progressing up from there. Many
drilling rigs simply use 20, 30 and 40 stks/min.
In addition, some operators require the driller
to find the circulating rate at specific pressure
(e.g., 200, 300, 400 psi, etc. [13.8, 20.68, 27.6
bar, etc.]).
Pump speed is critical. Pump pressure is
dependent on this speed, and a slight change in
speed may drastically affect circulating pressure.
Most drilling and workover rigs use pump
stroke counters, which also measure pump rate.
Pumps that do not use stroke counters should
record gear and rpm used to take KRP, and the
volume pumped per minute determined.

Kill Rates (Slow Pump Rate)

and Pump Pressures (3 Different Rates)
Measure at beginning of each tour, after drilling 500 feet and after each mud weight and viscosity change.

PUMP = PUMP =
#1 STKS/MIN PSI #2 STKS/MIN PSI
Kill Rate Speed Kill Rate Kill Rate Speed Kill Rate
Pump Pressure Pump Pressure

PUMP = PUMP =
#1 STKS/MIN PSI #2 STKS/MIN PSI
Kill Rate Speed Kill Rate Kill Rate Speed Kill Rate
Pump Pressure Pump Pressure

PUMP = PUMP =
#1 STKS/MIN PSI #2 STKS/MIN PSI
Kill Rate Speed Kill Rate Kill Rate Speed Kill Rate
Pump Pressure Pump Pressure
W ELL C ONTROL B ASICS
Generally, the circulating rate should be
chosen to minimize potential complications.
A slow kill rate is chosen for the following
reasons.
w It is easier to increase the mud weight
smoothly when pumping at slow rates.
w Choke reaction time is increased with
higher rate.
w It is less likely pump rating will be exceeded.
w High pressure surges are less likely to occur.
w Higher annular friction pressure (especially
in subsea, slim hole, and through tubing
applications) could result in formation
damage/failure and loss of returns.
w Higher annular friction could increase the
chances of differentially sticking the string.
w Complications may develop when gas
reaches surface.
Since kill rate pressures are needed in well
killing, ideally they should be taken through
the kill manifold and choke. When taking
them through the bell-nipple (open BOP), the
kill rate pressure will not reflect the actual
pressure required circulating from the BOPs
through the choke/kill line, manifold, through
the choke, separator system and back to pits.
Since the choke line friction is small on most
surface-stack rigs, crews typically take them
through the bell-nipple and ignore this friction.
However, on critical wells this pressure should
be known and taken into consideration.
Accurate gauges are necessary. If there is a
difference between the kill rate pressure on the
driller’s console and the pressure on the choke
panel, choke panel pressure should be used.
If the pressure variance is great enough, an
additional calibrated gauge should be used.
To calculate pump rate in bbls/min (m³/min):
Bbls/min = stks/min × Pump Output
Pump #1, 0.157 bbls/stk (0.02496 m³/stk),
30 stk/min = 1,000 psi (68.95 bar)
Pump #2, 0.126 bbls/stk (0.02003 m³/stk),
30 stk/min = 550 psi (37.9 bar).
Use Pump #1 to kill well.
6-13
PSI
Shut In Drillpipe Pressure
Shut In Tubing Pressure PSI
SHUT IN PRESSURES –
SIDPP, SITP, SICTP
When the well is shut in, the drillpipe or
tubing is simply a gauge stem that reaches to
the bottom of the hole. This pressure gauge is a
surface gauge that would read the bottomhole
pressure if the drillpipe were empty. But since
the drillpipe is not empty, the gauge shows the
difference between the bottomhole pressure
and the hydrostatic pressure exerted by the
column of mud in the drillpipe.
Mathematically, SIDPP is represented by:
SIDPP = Formation Pressure – Hydrostatic
Pressure of Mud in Drillstring
Since the shut in drillpipe pressure (SIDPP)
(shut in tubing pressure [SITP] in workover, or
shut in coiled tubing pressure [SICTP]) is used
to calculate formation pressure, kill weight mud
and initial circulating pressure, it is important Usually kill rate
that it is accurate. pressure is
A word of caution about shut in drillpipe recorded from
pressures: The assumption is made that the the gauge on
shut in drillpipe pressure is correct, and should the remote
generally be lower than the shut in casing choke panel.
pressure. It is possible to have a higher shut
in drillpipe pressure than casing pressure if the
overall density of the fluids in the annulus is
heavier than in the drillpipe.
 C HAPTER 6
6-14

If shut in drillpipe pressure seems unreasonably

high or low, it could be due to one of the following
SICP, SIWHP
reasons:
Shut in casing pressure (SICP) or shut in
w With a large kick, the pipe may U-tube
wellhead pressure (SIWHP) is also a crucial
and be partly empty;
pressure to determine. When a kick occurs,
w Pressures were trapped; formation fluids enter the wellbore. Since the
w Float in string; formation fluid is usually lighter than the mud
w May have read the pressure too soon, before or fluid in the annulus, it reduces the overall
formation pressure had time to stabilize; or pressure exerted in the annulus. The total
hydrostatic pressure in the annulus is typically
w May have read the pressure too late,
less than the hydrostatic pressure in the
showing the effect of gas migration.
drillstring because the mud in the annulus is
Some operators have a standard procedure either fluid cut or replaced by formation fluid.
of bleeding a small (1/4 bbl [approximately 0.04 This has the effect of reducing effective mud
m³] or less) amount of mud from the casing weight, reducing mud column length or both.
to check for trapped pressure. In the event of Since the formation pressure is pushing against
trapped pressure, the expected response would
both sides (drillstring and annulus) and the
be drillpipe pressure dropping below original
hydrostatic of the annulus is less, a higher SICP
(and incorrect) SIDPP. However, if the drillpipe
generally occurs. However, if the hydrostatic
pressure returns to the value, the original
of the annular fluid, cuttings and influx is
SIDPP was correct. SICP after an initial drop
greater than the string’s, then SICP will be less
could be slightly higher due to gas expansion,
than SIDPP.
or allowing more influx.
Mathematically, SICP is represented by:
Shut in pressure It is good practice, upon shut in, to begin
values should recording both shut in pressures. They should
SICP = Formation Pressure – Hydrostatic
be recorded be recorded at least once a minute until the
Pressure of Mud in Annulus –
about once pressure difference between readings slows and
Hydrostatic Pressure of Influx
every minute appears to stabilize. If the influx is gas, and the
until the viscosity of the fluid is low, pressure stabilization The weight of cuttings may increase the
pressures may not occur. If a pressure chart is available, hydrostatic pressure of mud in the annulus.
stabilize. it may be used to determine where pressures
stabilize versus the effect of kick migration.

KILL FLUID
The kill fluid, or kill weight mud is the
mud weight that is needed to balance the well’s
PSI
hydrostatic pressure with formation pressure.
Shut In Casing Pressure
Kill fluid must circulate throughout the hole
before drilling operations can be resumed.
Depending on the method used to kill the well
(Driller’s, Wait and Weight, or Concurrent)
will determine when the kill fluid is pumped.
Following is the equation and example problem
for determining kill weight mud. The answer is
Shut In Casing Pressure PSI
in ppg (m³/m), and carried one number to the
right of the decimal point. In most instances, it
is rounded up to the next higher tenth.
W ELL C ONTROL B ASICS
6-15

Kill Mud & Pressure Considerations

Required Kill Mud Weight

÷ 0.052 ÷ + =
PSI TVD FT PPG PPG
SIDPP True Vertical Depth Present Mud Weight Kill Mud Weight
(to Bit or Kick Zone)

Proper kill
Kill Fluid Density
mud weight is
dependent
÷ 0.052 ÷ upon an
PSI TVD FT PPG
accurate
Formation Pressure Depth to Perforations = Kill Fluid Density
Top/Middle/Bottom SIDPP value.

PROBLEM 5 INITIAL CIRCULATING PRESSURE

Calculate the kill fluid density.
The initial circulating pressure (ICP) is the
SIDPP = 300 psi (20.69 bar)
combination of the shut-in drillpipe pressure
TVD = 10,000’ (3048 m) plus the pressure necessary to circulate fluid at
Present Mud Weight = 12.5 ppg (1498 a given rate. It is the shut in drillpipe pressure,
m³/m) which is necessary to hold back the kicking
formation, and the kill rate pump pressure that
Kill Weight Mud = ______ ppg ( ______m³/m) is necessary to move fluid through the well.
If the kill weight mud calculates to 13.07 ppg
(1566 m³/m), the kill weight mud should be
13.1 ppg (1570 m³/m). PROBLEM 6
Calculate the initial circulating pressure.
ICP = SIDPP + KRP
CIRCULATING TO KILL THE WELL
Kill Rate Pressure = 1,000 psi (68.95 bar)
SIDPP = 300 psi (20.69 bar)
To prevent additional influx while killing
the well, bottomhole pressure (BHP) must
ICP = _______ psi ( _______ bar)
be kept at or slightly higher than formation
pressure. Additionally, it is more efficient to
circulate the influx out. The combination
of several pressures – hydrostatics, annular Initial Circulating Pressure (ICP)

circulating friction pressure and pressure held

on the choke – maintains well control during + =
this time. We must have an understanding of PSI PSI ICP PSI

what pressure to hold and the relationship of SIDPP

Kill Rate
Pump Pressure
Initial Circulating
Pressure
circulating different fluid densities.
 C HAPTER 6
6-16
as you pump a kill fluid in the well. However,
Final Circulating Pressure (FCP)
because of the slugging effect due to gain of
hydrostatic pressure from kill fluid, a decrease
x ÷ = in circulating pressures is generally seen once
PSI PPG PPG FCP PSI
kill fluid starts down the string.
Kill Rate Final Circulating
Kill Mud Weight Present Mud Weight
Pump Pressure Pressure

GRAPHING PRESSURE DROP

FINAL CIRCULATING PRESSURE
If the pump A certain amount of plotting and arithmetic
rate is constant The final circulating pressure (FCP) is the is required when circulating a kill fluid. The
we can expect circulating or kill rate pressure mathematically Circulating Pressure Graph shows what happens
circulating
corrected for heavier fluid. This pressure should to tubing or drillpipe pressure for the interval
pressure to
be held from the time kill fluid is at the bit until of time when new heavier mud weight is being
the annulus is filled with the kill fluid. pumped down the string. The graph shows
decrease as
the kill fluid that the Initial Circulating Pressure gradually
is pumped to
PROBLEM 7 changes to the Final Circulating Pressure over
the bit. Calculate the final circulating pressure. the period of time and/or strokes required to
Kill Rate Pressure = 1,000 psi (68.95 bar) displace the string.
TVD = 10,000’ (3048 m) 1. To prepare the graph, plot the Initial
Circulating Pressure at the point on the left
SIDPP = 300 psi (20.69 bar)
margin of the graph.
Present Mud Wt. = 12.5 ppg (1498 kg/m³)
2. Across the bottom of the graph fill in the
FCP = _______ psi ( _______ bar) number of pump strokes below each five-
minute interval of time, until you reach the
time or pump strokes required to displace
the string. Multiply stroke rate (spm) by
INTERMEDIATE PRESSURES minutes to get the total strokes.
What happens to pump pressure when 3. Draw a line vertically up the graph, based
you circulate fluid of a different density? on the time and/or pump strokes required
Heavier fluid generally requires more pressure to displace the string as shown on the
to circulate due to an increase in friction. You bottom line of the graph.
would expect circulating pressure to increase

DRILL PIPE PRESSURE SCHEDULE

2000

1000

ICP 1300 1257 1215 1172 1130 1087 1048 FCP

Strokes 0 150 300 450 600 750 886
Time 0 5 10 15 20 25 29.5
W ELL C ONTROL B ASICS
6-17

Pressure Chart
Theoretical Drill Pipe Pit Volume
Strokes or Volume Actual Drill Pipe Pressure Casing Pressure
Pressure Deviation

ICP
0

BIT FCP

A pressure/
volume
schedule
enables us to
maintain a
÷ 10 = – ÷ 10 = constant
Stks Surf to Bit Strokes per Step Initial Circ Pressure Final Circ Pressure PSI per Step bottomhole
pressure while
circulating out
a kick.

4. On the line that you have drawn, plot the

Final Circulating Pressure. PRESSURE CHART
5. Connect the points representing the Initial
and Final Circulating Pressure. Some operators prefer to keep a chart of
The completed graph shows the pressure the circulating pressures versus the time or
that must be held on the tubing or drillpipe pump strokes. To prepare a chart:
gauge, using the choke, at any time during the
first phase of the kill operation. 1. The top of the stroke section is 0, with the
bottom of the stroke section being strokes
PROBLEM 8 to bit. Divide strokes to bit by 10, this will
be the checkpoint while kill weight mud is
Fill in the pressure chart.
being pumped to the bit. So the box under
ICP = 1,300 psi (89.7 bar)
0 will be 1/10 of strokes to bit, the next
Time to Bit = 29.5 min.
one equals 2/10 of strokes to bit, etc. The
FCP =1,048 psi (72.3 bar)
result of the stroke column should be 10
Strokes to Bit = 886 stks
evenly spaced stroke checkpoints.
Kill Rate = 30 stks/min
 C HAPTER 6
6-18

2. The first block under pressure should be 3. Most of the additional friction pressure will
ICP and the final block, FCP. Subtract occur at one point: the jet nozzles of the
FCP from ICP and divide by 10. This will bit.
represent the pressure drop per checkpoint. 4. Annular friction loss due to kill and original
fluid is also treated as if it occurred in the
Strokes to Bit = 886 stks
string.
ICP = 1,300 psi (89.63 bar)
The two graphs below show a comparison
FCP = 1,048 psi (72.26 bar)
between actual drillpipe pressure distribution
and the results obtained by simple methods. As
Graphing or charting to determine the
you can see, at rates under 2.5 bbls/min (0.397
drillpipe or tubing pressure while pumping
m³/min) and required mud weight increases
kill fluid, i.e., ICP to FCP, follows standard
of less than 1.0 ppg (119.8 kg/m³), the excess
methods taught in all well control schools and
backpressure would be quite small, 50 psi (3.45
used in the field. This will result in holding
bar) or less. At pump rates of 5 bbl/min (0.795
some excess backpressure above what it takes
m³/min) and/or mud weight increases above
to balance formation pore pressure. The reason
1.0 ppg (119.8 kg/m³) the extra pressure could
Use lower kill for this excess backpressure is that the heavier
amount to as much as 200 psi (13.8 bar)
rate speeds to kill mud is treated as if it occurred uniformly
and would be a consideration in selecting
minimize throughout the total length of the string.
slower pump rates if lost circulation has been
excessive The actual distributions of friction pressure
experienced. Also, this could serve as another
pressure if due to kill mud are as follows:
reason for not intentionally holding too much
standard ICP to 1. Drillpipe will have the lowest psi/ft change. extra backpressure over what it is calculated, as
FCP pressure
chart is used.
2. Drill collars will be higher than drillpipe we already have some safety factor built into
due to smaller diameter and smaller bbls/ft. the system.

A-10 WELL A-10 WELL

5.0 BPM (.795 m³/min) 2.5 BPM (.397 m³/min)
1.0 Kick Intensity (119.6 g/l) 1.0 Kick Intensity (119.6 g/l)

ICP = 696psi ICP = 1589psi

psi 700 bar 48 psi 1600 bar 109.6
bar 48.3 bar 110.3

Sta
Ac Ac n da
psi 600 tu psi 1500 tu rd M
a St al eth
lD an bar 103.4 Di od
bar 41.4 ri l l da str
Pi rd ibu
pe tio
DP Pressure
DP Pressure

Me n
Pr tho of FCP = 1397psi
es Pr
su d es
re su bar 96.3
psi 500 Di psi 1400 r
str eD
bar 34.5 ibu bar 96.5 ro Annular Friction
tio p
n
Bit Jets
psi 400 FCP = 370psi psi 1300 Drill Pipe
Drill Pipe
bar 27.6 bar 25.5 bar 89.6
Bit Jets Annular Drill Collars
Drill Collars
psi 300 psi 1200
bar 20.7 bar 82.7
100 200 300 400 100 200 300 400

Pump Strokes Pump Strokes

W ELL C ONTROL B ASICS
6-19

Pressure Considerations
Estimated Formation Integrity/Leak-off/Fracture Fluid Density (Mud Weight)

÷ 0.052 ÷ + =
PSI TVD FT PPG PPG Each well
Integrity/Leak-off Depth of Test Integrity/Leak-off Estimated Integrity
Pressure (Shoe or Weak Zone) Test Mud Weight Fluid Density control effort
Estimated Formation Integrity Pressure (With Present Mud Weight) should be
based on
– x x 0.052 = conditions
PPG PPG TVD FT PSI
Estimated Integrity Present Mud Weight Depth of Test Estimated Integrity unique to that
Fluid Density (Shoe or Weak Zone) Pressure
well.
Casing Internal Yield

x =
PSI @ 100% PSI
Casing Internal Yield Safety Factor Adjusted Casing Yield
(.70 or less)

B.O.P. Test Pressure

=
PSI
BOP Test Pressure

During a well control procedure there

DRILLING ANNULAR is a possibility that formation damage, lost
PRESSURE CONSIDERATIONS circulation or an underground blowout may
result if the estimated integrity pressure is
Regulations often require that the exceeded. This is only a surface pressure
maximum pressure at surface beneath the estimate (a decision reference point, not an
absolute stopping point) and each well control
BOPs be posted near the driller’s station. It
effort should be based on the conditions
must be calculated for each subsequent casing
unique to that well.
string. This pressure consideration is generally
Casing depth, formation integrity, present
based on one of three different values.
and kill fluid density, kick position and imposed
w Casing Burst Pressure surface pressures are all factors that affect this
w BOP Stack Limits pressure consideration.

w Pressure that may cause formation damage. PROBLEM 9

If casing or BOP Stack limits the pressure Fill in the pressure considerations.
that can be put on the well, the crew must be
careful not to exceed that value. It is seldom Depth of Test = 5,030’ (1533 m)
that this limit occurs because well programs Present Mud Weight = 12.5 ppg (1497 kg/m³)
generally require that both the casing string and Leak Off Test Mud = 9.1 ppg (1092 kg/m³)
the BOPs handle any pressure encountered.
Leak Off Test Pressure = 1,570 psi (108.25 bar)
However, in field use, casing and equipment
are subject to wear, fatigue and corrosion Casing Internal Yield (100%) = 5,750 psi
damages that may lead to less than optimum (396.46 bar)
performance and pressure ratings. BOP Stack Test = 10,000 psi (689.5 bar)
 C HAPTER 6
6-20

TUBULAR PRESSURE Tubular Pressure Considerations

CONSIDERATIONS Casing Internal Yield

Many operations performed within existing x =

PSI PSI
Internal yield: tubulars must consider burst and collapse
Casing Internal Yield Safety Factor Adjusted Casing
the pressure limitations. A safety factor is decided upon (.70 Or Less) Yield

value which, if (based on age, wear, corrosion and other Tubing Collapse
applied inside damage) and the tubing derated or adjusted
the tubular, will from its original specifications. Examples of
cause the pipe
x =
this follow. PSI PSI
to burst. Tubing Collapse Safety Factor Adjusted Tubing
(.70 Or Less) Collapse
Adjusted Casing Internal Yield =
Casing Internal Yield × Safety Factor Tubing Yield

Adjusted Tubing Internal Yield =

x =
Tubing Yield × Safety Factor PSI PSI

Tubing Yield Safety Factor Adjusted Tubing

Adjusted Tubing Collapse = (.70 Or Less) Internal Yield

Tubing Collapse × Safety Factor

Bullhead Pressure Chart

Volume in Estimated Max. Actual Tubing Casing
Strokes Volume in BBLS Pump Rate Notes
GALS Static Pressure Pressure Pressure
Initial
0 0 0

Kill Point Final

Overdisplace
W ELL C ONTROL B ASICS
6-21
Average Hydrostatic Pressure in Tubing
FORMATION PRESSURE = Formation Pressure – Initial Shut in
CONSIDERATIONS Pressure
Then, the maximum pressure that may be
If an existing well is to be killed prior applied (based on existing data) is:
to subsequent operations, pressure imposed
against the formation may increase the time Initial Estimated Maximum Pressure on
and costs to bring it back to production. Field Tubing = Estimated Formation Integrity
calculations may be performed to determine Pressure (Fracture Pressure) – Average
allowed static pressures to minimize the risk Hydrostatic Pressure in Tubing
of overpressuring the well while attempting a As kill fluid is pumped down the production
kill. string, the amount of static surface pressure
The approximate average hydrostatic of the that may be imposed prior to incurring damage
produced fluids in the production string can decreases. Once kill fluid is to the formation, a
be determined by: final static pressure may be calculated:

Formation Pressure Considerations

Estimated Formation Integrity Pressure (Fracture)

x 0.052 x =
PPG TVD FT PSI
Estimated Integrity Depth to Perforations Estimated Formation
Fluid Density Top/Middle/Bottom Integrity Pressure

Average Hydrostatic Pressure in Tubing

– =
PSI PSI PSI
Formation Pressure Initial Shut In Average Hydrostatic
Tubing Pressure Pressure in Tubing

Initial Estimated Maximum Pressure on Tubing (Static)

– =
PSI PSI PSI
Estimated Formation Average Hydrostatic Initial Estimated Max.
Integrity Pressure Pressure in Tubing Pressure on Tubing
If formation
Kill Fluid Hydrostatic Pressure pressure is
known, average
x 0.052 x = hydrostatic
PPG TVD FT PSI
Kill Fluid Density Depth to Perforations Kill Fluid Hydrostatic pressure can
Top/Middle/Bottom Pressure
be estimated,
Final Estimated Maximum Pressure on Tubing (Static) once the
producing well
– = is shut in.
PSI PSI PSI
Estimated Formation Kill Fluid Hydrostatic Final Estimated Max.
Integrity Pressure Pressure Pressure On Tubing

Pressure Consideration PSI per “Step”

– ÷ 10 =
PSI PSI PSI/STEP
Initial Max. Pressure Final Max. Pressure Number of “Steps” PSI per “Step”
on Tubing on Tubing
(Lesser of #3 or #6) (Lesser of #3 or #8)

6-22
Final Estimated Max Pressure On Tubing
= Estimated Formation Integrity Pressure
(Fracture Pressure) – Kill Fluid Hydrostatic
A chart may be prepared to document
volume vs. pressure. This chart (p. 116) is
simple to complete like the drilling pressure
chart.
Volume calculations to the kill point must
also be completed prior to operations. The
volume calculations and an over displacement
(if required) are prepared.
C HAPTER 6
Circulating friction increases as the kill
fluid is pumped down the string. This increases
surface pressure and pressure within the tubing.
Sudden pressure increases may burst the tubing,
or be an indication of complications developing.
Keep good notes. Be prepared to shut down if
a problem occurs.
More complex calculations may be required
on a critical well, including the effects of
circulating friction.

Estimated Barite Requirements

Total Volume In Active System

+ + + =
BBLS BBLS BBLS BBLS BBLS
Volume in Active Pits Drill String Volume Total Annular Volume Volume Between DP & Total Volume
Riser (Subsea Only) in Active System
Sacks Per 100 Barrels

35 – =
PPG
Kill Mud Weight

– x 14.7 ÷ =
PPG PPG SXS/BBL
Kill Mud Weight Present Mud Weight Sacks per
Barrel
Total Barite Required

x =
BBLS SXS/BBL SXS
Total Volume in Sacks per Total Barite Required
Active System Barrel
Volume Increase Due To Barite Addition

÷ 14.7 =
SXS BBLS
Total Barite Required Volume Increase
1,500 lbs of
barite added Required Mixing Rate
to the system
will increase x =
SXS/BBL BBLS/MIN SXS/MIN
the volume by Sacks per Circulating Rate Required Mixing Rate
Barrel
about 1 barrel.
Dilution of Reserve Mud With Water

– 8.33 =
PPG
Kill Mud Weight

– x ÷ =
PPG PPG BBLS BBLS
Mud Weight in Kill Mud Weight Volume in Volume of Water
Reserve Pit Reserve Pit to Add
W ELL C ONTROL B ASICS
BARITE REQUIREMENTS
If kill fluid is used, consider the total barite
required, amount on location and the required
mixing rate. These calculations follow:
1. Bbls in Active Pits = 600 bbls (95.4 m³)
2. Bbls in Annulus = 509 bbls (80.9 m³)
3. Bbls in Drillstring = 139 bbls (22.1 m³)
4. Present Mud Wt = 12.5 ppg (1498 kg/m³)
5. Kill Weight Mud = 13.1 ppg (1569 kg/m³)
6. Mud Weight, Reserve Pit =14.7 ppg (1761
kg/m³)
7. Reserve Pit Volume = 150 bbls (23.8 m³)
8. Kill Rate = 4.71 bbls/min (0.748 m³/min)
9. Strokes to Bit = 886 stks
10. Kill Rate = 30 stks/min
6-23
SUMMARY
Well killing basics are not difficult, but
they are vital. If we didn’t know how to apply
the basics, well killing would have to rely on the
SWAG (or scientific wild-ass guess) method.
Prerecorded information – such as kill rates,
Accurate
kill rate pressures and maximum allowables
information
– must be gathered. The more information is vital to
that you know about the kick, the shut-in performing a
conditions and your equipment, the better successful kill
your chances are of performing a successful kill in the shortest
in the shortest time. time.
And remember: station bills and job
responsibilities are vital to any rig operation.
All organizing and directing activities should
be completed well in advance of a kick. t