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BG GDP SSA 11 Workover Well Kill

Kes Evoy (kes.evoy@bg-group.com)


Where noted in square brackets, sources are as follows:
[1] Bellay, Jonathon 2009, Well Completion Design, Elsevier.
[2] Chevron 1994, Workover Well Control and Blowout Prevention Guide, USA.
Where sources are not noted, the information comes from the authors experience or
conversations with personnel.

Workover Well Kill 1


1

API 41 crude = 6.83ppg [2 p12-1]


1.10SG brine x 8.33 = 9.163ppg.
Inside tubing @ 6500ft,
P = CITHP + Crude hydrostatic
P = 620psi + (6500ft)(6.83ppg)(0.052)
P = 2930psi.
In annulus @ 6500ft,
P = brine hydrostatic
P = (6500ft)(9.163ppg)(0.052)
P = 3097psi.
P 6500ft = 167psi (greater on annulus side)

If no losses to occur to the formation once we open the side pocket, the CITHP
will be the sum of the original pressure plus the differential, = 787psi.
If, however, any pressure above the 620psi CITHP produces losses:
Currently, the 203ft of oil between the side pocket (6500ft) and the reservoir
(6703ft) comprises (203ft x 6.83ppg x 0.052) = 73psi.
As the differential pressure at the side pocket is greater than this, when the side
pocket opens, the brine will force the oil back into the formation and occupy the
space it contained in the tubing.
At that point the CITHP will be the reservoir pressure less the oil and brine
hydrostatic columns.
At the formation, 6703ft,
P0 = CITHP + Oil column to 6703ft
P0 = 620psi + (6703ft)(6.83ppg)(0.052)
P0 = 3001psi.
Once the side pocket is opened,
CITHP = P0 (6500ft)(6.83ppg)(0.052) (203ft)(9.163ppg)(0.052)
CITHP = 3001 2309 97
CITHP = 595psi.

What will the overbalance bedo you mean once Ive circulated the 1.15SG
brine around the system? Im assuming so, otherwise the overbalance is the
same as our pressure differential in q1, 167psi.
1.15SG brine x 8.33 = 9.58ppg.
After circulating,
Phydrostatic = 6500ft of 1.15SG brine + 203ft of 6.83ppg oil (assuming no mixing)
Phydrostatic = (6500ft)(9.58)(0.052) + (203ft)(6.83ppg)(0.052)
Phydrostatic = 3238psi + 72psi
Phydrostatic = 3310psi.
We know P0 = 3001psi.
So the overbalance after kill is 309psi.

Some volumes here first:


Annulus capacity = 0.0263bbls/ft (assuming 7 ID = 6.276)
Tubing capacity = 0.0083bbls/ft (assuming 3 ID = 2.922)
Annulus volume = (0.023)(6500) = 149.5bbls.
Tubing volume = (0.0083)(6500) = 54bbls.
ICP = 463psi @ 4bpm (given in question), thats with 1.1SG brine through the
system
FCP = ICP (1.15SG/1.1SG) = 509psi @ 4bpm; after 149.5bbls pumped.
CITHP = 787psi until the new mud is at the side pocket (149.5bbls), then it
declines linearly to 0psi.
Heres a graph:

Workover Well Kill 2


1

In question 3 here we find that we need a kill weight mud of 11.6ppg to kill the
well.
We currently have a 10.2ppg (0.53psi/ft) brine.
So, my plan is to kill the well with a reverse circulation drillers method. That
will be two stages, with the first to circulate 10.2ppg brine from the SSD to the
tubing head, and the second to circulate 11.6ppg kill weight brine down the
annulus and up the tubing.
Assuming we are rigged up and ready to pump down the annulus to the SSD and
up the tubing, the following procedure should be followed [from 2, pG-5 and G6]:
First Circulation:
1. Bring the pump up to speed holding tubing pressure constant at 5240psi
(this is the shut in CITHP plus a reasonable safety factor 200psi).

2. Once pumps are up to speed, monitor pressure on the annulus side and
keep it constant.
3. Once 10.2ppg brine is at surface, shut down the pump holding pressure
on both tubing and annulus side (should be the same).
Second Circulation:
1. Bring the pump up to speed holding tubing pressure constant at the shutin pressure (this shut in pressure will include the 200psi safety factor
already added in the first circulation).
2. Maintain constant tubing pressure until kill weight fluid fills annulus.
3. Maintain constant annulus pressure until kill weight fluid is at surface.
4. Shutdown the pumps.
5. Confirm tubing pressure = annulus pressure = 0 (bleed off pressure if
there is any: if no increase, continue bleeding until zero).
2

Formation pressure P0 = CITHP + gas column


P0 = 5040psi + (0.13psi/ft)(11900ft)
P0 = 6587psi.

Kill fluid.
Assume we need a kill mud that kills the well from the SSD up.
So, we need a hydrostatic column amounting to 6587psi at 10950ft.
= (6587) / (10950 x 0.052)
KW = 11.6ppg

Im going to draw the kill graph/tubing head graph for the second circulation
detailed in question 1.
Well need some volumes for this graph:
Annulus capacity = 0.0613bbls/ft (assuming casing ID = 8.681)
Tubing capacity = 0.0083bbls/ft (assuming 3 ID = 2.922)
Annulus volume over 10950ft = 672bbls.
Tubing volume over 10950ft = 91bbls.
ICP = unknown, lets call it ICP.
FCP = also unknown, lets call it 1.14ICP (= 11.6/10.2 x ICP)
CITHP after first circulation = P0 950ft of gas 10950ft of 10.2ppg brine
= 6587psi (950ft)(0.13psi/ft) (10950ft)(0.53psi/ft)
starting CITHP = 660psi, + 200psi safety = 860psi.
Heres the graph:

Workover Well Kill 3


1

(my words, but with assistance from [2] )


A workover is performed after an initial well completion has been set in place in
order to boost production; repair or replace tubing; or plug and abandon a well.
In most cases a workover will be performed on a well that is live and has been
producing. As a result the well being worked over will likely have hydrocarbons
to surface at least inside the tubing, and possibly inside the annulus. In order to
perform any of the remedial work already noted, a well kill is required.
(i) The workover will be performed by a Production Technologist Engineer,
Petroleum Engineer, or Well Engineer with the assistance of a rig contractor and
service companies to provide the equipment and personnel required to perform
work on the well.
To kill the well, the necessary well control equipment must first be rigged up on
site and over the well. This will include at the very least some kind of choke
manifold for fluid returns; a BOP; and a lubricator.
Once well control equipment is rigged up over the wellhead and pressure tested,
it is possible to re-enter the well and perform the workover well kill. The well
can be killed by the same methods that are used in drilling (Drillers method,

Wait & Weight, Bullhead), with the advantage that there is no exposed shoe
present that can be broken (and there is already a hydrocarbon to surface, so the
maximum surface pressures are already being seen). In many cases, a workover
well kill will involve reverse circulating, which we nearly never do in drilling:
circulating kill fluid down the annulus and up the tubing.
Still, one must know what the MAASP is that cannot be exceededthis will not
be derived from an FIT but rather from the tubing and casing burst and collapse
ratings. There may also be restrictions on the amount of pressure that can be put
on the well on account of open formation (this may be the case in (iv), where a
depleted reservoir needs a workover).
The three well types noted in the question (ii) are different in both the equipment
they require and the space available for it. The land rig workover will likely
have (except in protected or urban locations) no restrictions on space, so
equipment can be spread out around the site. The surface tree offshore will
require detailed logistical planning regarding the transport of equipment and
placement of equipment, particularly on a small, unmanned platform. The
subsea tree will require a vessel of some kind, at the very least a workover
vessel, if not a floating MODU.
Both oil and gas wells (iii) can be killed with the same methods noted already
(bullheading, drillers method, wait & weight, all in forward or reverse
circulation mode). Gas expansion must be accounted for in gas wells.
(iv) A drawn down gas reservoir will not need to be killedin this example we
are entering the well to get it flowing. Here the challenge will be ensuring that
the well control equipment is prepared to receive gas at surface once it is lifted.
By contrast, the HPHT well in the question will have condensate to surface. This
will require high pressure rated equipmentthis will mean larger BOPs with
more rams than the drawn down gas reservoir example, and a larger choke
manifold that can handle the high pressures.
2

Large volumes of trip gas can be detected by reductions in stand pipe pressure:
as trip gas enters the annulus, it reduces the density of the fluid in use, making it
easier to pump around the hole, thereby reducing the stand pipe pressure.
i. Large volumes of trip gas can be a problem if it is enough to expand at
surface, overload your returns equipment (shakers or whatever we have for this
workover), end up being released at surface in an uncontrolled manner and
ignited.
ii. Excessive trip gas (Im assuming trip, not strip as noted in the question)
is circulated out over the choke as one would an influx. i.e., treat it like a
swabbed influx (which it it!). However, assuming it is small (was not noticed on
active tanks), one can circulate normally until the gas is close to surface, and then
switch over to circulating over the choke at that point.

Maximum fluid densities:


1. Sodium Chloride NaCl = 9.9ppg.

2. Potassium Chloride KCl = 9.6ppg.


3. Potassium Bromide KBr = 11.5ppg.
4. Ceasium Formate = 19.2ppg.
5. Calcium Bromide CaBr = 14.9ppg.
[1 p606]
4

Heavy to ensure an overbalance, clear to ensure with the naked eye that the fluid
is uncontaminated.

Workover Well Kill 4


1

a. The formation pressure P0 is:


P0 = CITHP + gas column + oil column
P0 = 1773psi + (2900ft)(0.15psi/ft) + (9370ft-2900ft)(0.38psi/ft)
P0 = 1773 + 435 + 2459
P0 = 4667psi.
b. At the SSD depth, 9230ft:
Pannulus = brine column
Pannulus = (9230ft)(10ppg)(0.052)
Pannulus = 4800psi.
Ptubing = CITHP + gas column + oil column to 9230ft
Ptubing = 1773psi + (2900ft)(0.15psi/ft) + (9230ft-2900ft)(0.38psi/ft)
Ptubing = 1773 + 435 + 2406
Ptubing = 4614psi.
P @ 9230ft = 186psi (greater on annulus side)

2
3

[no question]
[no question]

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