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    Well Control BOP

    Uploaded by

    Aman Deshmukh
    This document discusses well control methods used during drilling operations. It covers primary, secondary, and tertiary well control. Primary control uses mud weight to maintain wellbore pressure above formation pressure. Secondary control activates blowout preventers if a kick occurs. Tertiary methods are needed if primary and secondary fail, like drilling relief wells. The document also describes blowout preventers and their components like annular valves, ram valves, seal rings, and insert plates. Design features are discussed to reduce stress concentrations in insert plates. Green sand molding is mentioned for casting the plates.

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    © All Rights Reserved
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    Well Control BOP

    Uploaded by

    Aman Deshmukh
    103 views54 pages
    This document discusses well control methods used during drilling operations. It covers primary, secondary, and tertiary well control. Primary control uses mud weight to maintain wellbore pressure above formation pressure. Secondary control activates blowout preventers if a kick occurs. Tertiary methods are needed if primary and secondary fail, like drilling relief wells. The document also describes blowout preventers and their components like annular valves, ram valves, seal rings, and insert plates. Design features are discussed to reduce stress concentrations in insert plates. Green sand molding is mentioned for casting the plates.

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    This document discusses well control methods used during drilling operations. It covers primary, secondary, and tertiary well control. Primary control uses mud weight to maintain wellbore pressure above formation pressure. Secondary control activates blowout preventers if a kick occurs. Tertiary methods are needed if primary and secondary fail, like drilling relief wells. The document also describes blowout preventers and their components like annular valves, ram valves, seal rings, and insert plates. Design features are discussed to reduce stress concentrations in insert plates. Green sand molding is mentioned for casting the plates.

    Copyright:

    © All Rights Reserved
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    103 views54 pages

    Well Control BOP

    Uploaded by

    Aman Deshmukh
    This document discusses well control methods used during drilling operations. It covers primary, secondary, and tertiary well control. Primary control uses mud weight to maintain wellbore pressure above formation pressure. Secondary control activates blowout preventers if a kick occurs. Tertiary methods are needed if primary and secondary fail, like drilling relief wells. The document also describes blowout preventers and their components like annular valves, ram valves, seal rings, and insert plates. Design features are discussed to reduce stress concentrations in insert plates. Green sand molding is mentioned for casting the plates.

    Copyright:

    © All Rights Reserved
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    of 54

    Well Control

    BOP
    MIT-WPU
    2021
    • Well-control means methods used to minimize the potential for the well to
    flow or kick and to maintain control of the well in the event of flow or a
    kick.
    • Well-control applies to drilling, well-completion, well-workover,
    abandonment, and well-servicing operations.
    • It includes measures, practices, procedures and equipment, such as fluid
    flow monitoring, to ensure safe and environmentally protective drilling,
    completion, abandonment, and workover operations as well as the
    installation, repair, maintenance, and operation of surface and subsea well-
    control equipment.
    Causes of kick

    A kick will occur when the bottom hole pressure(BHP) of a well falls below the formation pressure and the
    formation fluid flows into the wellbore.
    There are usually causes for kicks some of which are:
    • Failure to keep the hole full during a trip
    • Swabbing while tripping
    • Lost circulation
    • Insufficient density of fluid
    • Abnormal pressure
    • Drilling into an adjacent well
    • Lost control during drill stem test
    Failure to keep the hole full during a trip

    • Tripping is the complete operation of removing the drillstring from the wellbore and


    running it back in the hole.
    • Tripping out of the hole means that the entire volume of steel (of drillstring)
    is being removed, or has been removed, from the well.
    • This displacement of the drill string (the steel) will leave out a volume of
    space that must be replaced with an equal volume of mud.
    • If the replacement is not done, the fluid level in the wellbore will drop,
    resulting in a loss of hydrostatic pressure (HSP) and bottom hole pressure
    (BHP).
    • If this bottom hole pressure reduction goes below the formation pressure,
    a kick will definitely occur.
    Swabbing while tripping
    • Swabbing occurs when bottom hole pressure is reduced due to the
    effects of pulling the drill string upward in the bored hole.
    • During the tripping out of the hole, the space formed by
    the drillpipe, drill collar, or tubing (which are being removed) must be
    replaced by something, usually mud.
    • If the rate of tripping out is greater than the rate the mud is being
    pumped into the void space (created by the removal of the drill
    string), then swab will occur.
    • If the reduction in bottom hole pressure caused by swabbing is
    below formation pressure, then a kick will occur.
    Lost circulation

    • Lost circulation usually occurs when the hydrostatic pressure fractures an open formation.
    • When this occurs, there is loss in circulation, and the height of the fluid column decreases,
    leading to lower HSP in the wellbore.
    A kick can occur if steps are not taken to keep the hole full. Lost circulation can be caused
    by:
    • excessive mud weights
    • excessive annular friction loss
    • excessive surge pressure during trips
    • excessive shut-in pressures.
    Insufficient density of fluid

    • If the density of the drilling fluid or mud in the well bore is not sufficient to keep the
    formation pressure in check, then a kick can occur.
    Abnormal pressure

    • Another cause of kicks is drilling accidentally into abnormally-pressured permeable zones.


    • The increased formation pressure may be greater than the bottom hole pressure, resulting
    in a kick.
    Drilling into an adjacent well

    • Drilling into an adjacent well is a potential problem, particularly in offshore drilling where


    a large number of directional wells are drilled from the same platform.
    • If the drilling well penetrates the production string of a previously completed well, the
    formation fluid from the completed well will enter the wellbore of the drilling well,
    causing a kick.
    • If this occurs at a shallow depth, it is an extremely dangerous situation and could easily
    result in an uncontrolled blowout with little to no warning of the event.
    Lost control during drill stem test

    • A drill-stem test is performed by setting a packer above the formation to be tested, and
    allowing the formation to flow.
    • During the course of the test, the bore hole or casing below the packer, and at least a
    portion of the drill pipe or tubing, is filled with formation fluid.
    • At the conclusion of the test, this fluid must be removed by proper well control techniques
    to return the well to a safe condition.
    • Failure to follow the correct procedures to kill the well could lead to a blowout
    Kick warning signs

    • Sudden increase in drilling rate


    • Increase in annulus flow rate
    • Gain in pit volume
    • Change in pump speed/pressure
    • Improper fill on trips
    Primary Oil Well Control

    • Primary oil well control is the process which maintains a hydrostatic pressure in the
    wellbore greater than the pressure of the fluids in the formation being drilled, but less
    than formation fracture pressure.
    • It uses the mud weight to provide sufficient pressure to prevent an influx of formation
    fluid into the wellbore. 
    • If hydrostatic pressure is less than formation pressure, then formation fluids will enter the
    wellbore.
    • If the hydrostatic pressure of the fluid in the wellbore exceeds the fracture pressure of the
    formation, then the fluid in the well could be lost.
    • In an extreme case of lost circulation, the formation pressure may exceed hydrostatic
    pressure, allowing formation fluids to enter into the well.
    Secondary Oil Well Control

    • Secondary oil well control is done after the Primary oil well control has failed to prevent
    formation fluids entering the wellbore.
    • This process is stopped using a “blow out preventer”, a BOP, to prevent the escape of
    wellbore fluids from the well.
    • As the rams and choke of the BOP remain closed, a pressure built up test is carried out
    and a kill mud weight calculated and pumped inside the well to kill the kick and circulate
    it out.
    Tertiary well control operational procedures
    • Tertiary oil well control describes the third line of defense, where the formation cannot be
    controlled by primary or secondary well control (hydrostatic and equipment). This
    happens in underground blowout situations.
    The following are examples of tertiary well control:
    • Drill a relief well to hit an adjacent well that is flowing and kill the well with heavy mud
    • Rapid pumping of heavy mud to control the well with equivalent circulating density
    • Pump barite or heavy weighting agents to plug the wellbore in order to stop flowing
    • Pump cement to plug the wellbore
    Blow-out Preventer (BOP)
    A blow-out preventer (BOP) is a high pressure safety
    valve system at the top of the well head which stops
    uncontrolled fluid/gas flow in the well bore.
    There are two types of BOP valves: annular and ram.
    -- One advantage the annular blow-out preventer
    has over ram-type blow-out preventers is the ability
    to seal on a variety of pipe sizes.
    BOP Seal Ring Function
    • In the annular type of BOP valve, the sealing
    element is an elastomeric packing ring which forms
    the conforming seal.
    • --The packing is mechanically squeezed inward to
    seal on either pipe (drill collars, drill pipe, casing, or
    tubing) or the open hole.
    BOP Seal Ring Function
    Insert Plates -- Description
    • A critical component in the packing ring are the
    multiple steel insert plates which reinforce the
    elastomeric ring.

    • --The plates mechanically strengthen and stiffen the


    elastomeric seal ring and transfer the forces from
    the forcing piston to the face of the seal ring.
    • --The number, dimensions, and weight of the steel
    plates in a given valve depend on the size and
    configuration of the BOP, which are produced in a
    wide range of sizes and capacities.
    Insert Plates -- Description
    Insert Plates -- Requirements
    • The nominal performance requirements for the insert
    plates are:
    • -- Yield strength of 85 ksi
    • -- Brinell Hardness of 235HB
    • -- 0.03" tolerance on machined surfaces
    • -- 500-900 RMS surface finish on as-cast surfaces.
    Alloy Selection
    • Based on the performance requirements, a Nickel-Chrome-Moly low alloy steel (AISI-
    SAE 8627) was chosen, based on the mechanical requirements at the best alloy cost.
    • The 8627 alloy has a nominal composition of:
    • 0.24- 0.31 Carbon
    • 0.55- 0.70 Nickel
    • 0.35- 0.60 Chromium
    • 0.15- 0.25 Molybdenum
    • The 8627 alloy has the following typical mechanical properties, depending on heat
    treatment:
    • -- Yield strength = 60-160 ksi
    • -- Hardness = 175-360 Brinnell
    Reducing Stress Concentrations

    • -- One of the benefits of casting is the design flexibility


    in shaping features in the casting.
    • -- Two important design principles in casting are:
    • -- Round corners and edges generously to reduce
    stress concentrations.
    • -- Reduce the size of isolated thick sections or
    provide gradual transitions between sections of
    different thickness.
    Reducing Stress Concentrations
    Feature A - Nose of the Header
    • A generous radius on the nose of
    the header will eliminate two
    sharp corners, reduce stress and
    avoid corner defects in the
    casting, which are produced by
    sharp, weak corners in the sand
    mould.
    Feature B - Interior Edge of the Bar
    • A generous radius on the edges of
    the bar will eliminate two sharp
    corners, reduce stress and
    produce better fill in this section
    that is tensile stressed.
    Feature C - Base of the Foot
    • -- The base of the foot is not
    highly stressed and will fill
    without problem.
    • -- Radiusing is not necessary
    Moulding Methods
    • GREEN SAND MOLD
    • Moist, clay-bonded sand is tightly packed around a wood or
    • metal pattern in mould boxes. The pattern halves are removed,
    • and the mould is assembled with or without cores.
    • AIR-SET SAND MOLD
    • Chemically bonded sand is packed around a wood or metal
    • pattern in mould boxes. At room temperature, the sand moulds
    • become rigid. Pattern halves are removed and the mould is
    • assembled with or without cores.
    • SHELL MOLD
    • Resin-coated sand is applied to heated metal patterns forming
    • shell-like mould halves. The shell halves are bonded together
    • with or without cores.
    Moulding Methods
    Shell Moulding
    • Shell moulding significantly exceeds the
    baseline requirements for tolerance,
    surface finish, and detail level for the
    insert plate.
    • But the high costs and long lead time
    for the metal tool for shell moulding are
    not justified in this case, where the
    tolerance and finish requirements are
    generous.
    Air Set Sand Moulding
    • Air-set sand moulding has a moderately
    tighter tolerance and smoother surface
    finish capability, compared to the green
    sand.
    • But the extra cost for the chemically
    bonded sand in the air-set mould is not
    justified in this case, where the
    tolerance and finish requirements are
    generous.
    Green Sand Moulding
    • Green sand moulding can meet the
    baseline requirements for the insert
    plate for tolerance, surface finish, and
    detail level.
    • Green sand moulding has lower costs
    for mould material compared to air-set
    sand and lower pattern and material
    cost compared to shell moulding.
    Orientation in the Mould

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