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SPE/IADC 39258 Soxaty of Petleun Enger ASSESSMENT OF APPLICATION OF DYNAMIC KILL FOR THE CONTROL OF MIDDLE-EAST SURFACE BLOWOUTS Dhafer A. Al-Shehri, SPE, Saudi Aramco ony 187, SPEAADC Mi Ea Oi Tesrey Coren ‘Th ge na puedo grsrian hw 1897 SPEAADC Mid Eat Ding Tec Caine hls Bar 25°25 Noe ‘he ae etn SPER Pg Gren ag ‘pr harass ri Se pe See rt SSee cee ae ee Bae ce ceaentrmeria mesan Cation SSH iy ete secre ace ‘Sreavutde an abaet ovat mare hon eraion may nt be capos he Roe Brana Sas Abstract This paper presents some results from research work!, The purpose of this work was to investigate and assess the potential of dynamic kill as a method for controlling blowouts from producing gas and oil wells. Only scattered and little previous work was done on dynamic kill, particularly in the areas of gas kicks and blowouts during drilling. Blowouts of oil and gas wells after completion and starting production have received much less investigation. In this work, a new dynamic kill model was developed for controlling surface induced blowouts of oil and {gas wells, The model simulates multiphase flow in a blowout and relief wells. Dynamic simulation is performed for both Kill through a relief well and through in-well surface injection. The simulator makes use of proven multiphase flow ‘models. Several assumptions and improvements are added or included in these models to account for flow geometry, temperature variation in the flow conduits and the effect'of sonic flow closer to the The simulator predicts and links the expected reservoir performance with wellbore hydraulics, The effects Of introducing the kill fluid into the well stream are also simulated, Relief well dynamic kill simulations can predict the minimum injection flow rate into the relief and blowout wells, initial and final kill fluid densities, size and type of drilling string requirement for achieving the required kill 125 rate(s) in the relief well(s),_ and horse power requirements. ‘Simulations can also check for ability to inject at the desired rate through the formation. In the case of in-well kill, the ‘model can be used to determine the optimum location of the point of kill fui injection. ‘The model results were in agreement with data presented in the literature and from Kuwait field measurements ‘The simulator leads to a much better level of understanding of blowout behavior and the potential of dynamic kill to bring gas and oil blowouts under contro. Background and Introduction A blowout can have catastrophic consequences including loss of lives, environmental pollution, loss of irreplaceable petroleum reserves, combat costs and other direct and indirect costs to fight the fires and bring the blowout wells under control. Such costs could measure in billions of dollars. Events of the year 1991 in The Middle East and the huge magnitude of the blowouts in Kuwait have focused attention on the seriousness ofthis problem. ‘The dynamic kill method has been used in many cases as a successful way to control a blowing well Different aspects of dynamic kill and field cases are found in the literature.20-45 ‘The method involves injecting a fluid, such as water, whose density is less than that required to control the downhole pressure hydrostatically. The fluid flow rate must be high enough so that the frictional head of the dynamic kill fluid and blowout fluids, plus hydrostatic pressure of the ‘mixture, exceed the static formation pressure. Thus, the well is dead as long as a sufficiently high injection flow rate is maintained. ‘fer the formation stops flowing and the blowout wellbore is swept of blowout fluids «fluid of suficent density to statically control formation pressure is pumped into the wellbore. Dynamic coniol is maintained unl the final Kil Mid statically controls the well There are two main options available for injecting 2 hater A. Al-Sheh \ADCISPE 39258 kill fluid into the blowing well (see Fig. 1). The kill fluid can either be introduced from the surface directly into the blowing well or by injecting the kill fluid through one or ‘more relief wells when the in-well kill is impractical ‘The dynamic kill as a method of controlling blow= out wells is a promising one. It can have a wide range of application. Assessing the technique and investigating the range of application are primary motivations for this research. ‘The Mathematical Approach and Methodology For any successful kill operation, the bottomhole pressure must be greater than the sandface pressure for any reservoir fluid rate. In graphical terms, the system intake (wellbore hydraulics) curve must lie above or tangent to the Inflow Performance Relationship (IPR) curve (see Fig. 2). For a kill fluid of any selected density, a stable flow condition would result if the wellbore hydraulics performance curve intersects the reservoir performance curve. That is, the reservoir would continue to produce at the rate corresponding to the point of intersection, and the well would not be killed. If the wellbore hydraulics performance curve lies entirely above the reservoir performance curve, then a stable oil or gas-lift flow condition would not be possible and the well would be killed. In the example shown in Fig. 2, a fluid injection rate between 20 and 30 barrels per minute will kill the wel ‘The basic approach to dynamic kill modeling will be based on treating the relief well and the blowout well as one system. The producing system is the blowing well and the relief well (if a relief well is used). If in-well injection is used, the producing system is the blowing well and the in- well injection sting. The inflow performance relationship and production string’s flow rates will interact to determine the conditions at which dynamic killing willbe achieved A dynamic kil will involve multiphase flow inthe wellbore “he distibution of gas and liqud phases can be very complex in multiphase flows making, computations based on ist principles simost nonexistent Two different approaches are commonly used to develop predictive tools for describing complex fluid mechanics problems. The empirical approach involves developing Simplified models containing parameters that must be evaluated with experimental data. Correlating variables are dimensionless groups determined by performing dimensional analysis of the phenomena involved. A classic example of this for a single phase fuid flow is the Moody diagram, in which fiction factors are correlated as a function of Reynolds number and relative roughness for turbulent flows.” The empirical approach does not address why or how things happen, but can yield excellent results quickly depending on the proper selection of variables and the quakity of data used for the correlation. The second approach involves developing physically based mechanistic models that describe all important phenomena. ‘This requires much tore in depth understanding and long term research, In this research, I modeled the multiphase flow with the aid of the best available correlation which is credited to 126 Beggs and Brill 46 Improvements to this correlation were suggested and ‘implemented. Analysis Method ‘The calculation procedure is based on a steady-state system analysis. In applying this analysis, the following steps are followed: 1. Determine the inflow performance of the reservoir (flowing bottom-hole pressure as a function of reservoir fluids production rate). 2. Determine the wellbore intake flow performance for various liquid injection rates taking into account pressure changes due to elevation, friction, acceleration, and the possibility of critical (sonic) flow. Hydraulic pressure drops are related to measured depths, but fluid heads are related to true vertical depths. 3. Determine the kill injection rate from the plot as the line of constant injection rate which is just above and does not touch the inflow performance line of the reservoir. 4, Plot the lowing annular pressure as a function of depth for various liquid injection rates up to the known kill injection rate, 5. Determine the frictional pressure losses in the injection string with and without friction reducers being present, The friction reducers are assumed t0 affect the pressure losses in the injection string only, 6 Determine surface injection pressure and hydraulic power requirements with and without friction reducers being present. In this research, the blowout dynamic kill mode! will take into consideration and investigate the effect of bottom- hole static pressure, subsurface formations fracture pressures, deliverability of the well and hydraulic constrains, ‘The simulator determines the following ‘The density of the initial kill fluids. ‘The dynamic flow rate needed inthe blowout ‘The injection flow rate needed in the relief well Pumping power requirements. ‘Tubular sizes needed in the relief well. ‘The maximum allowable bottom-hole pressure in the blow out well ‘The ability to inject at desired rate through the formation. In the case of in-well kill , determine the optimum location of the point of kill fluid injection in order to 1e. most benefit of available surface pumping equipment, available 2 pee pe TADOISPE 39088 MIDDLE-EAST SURFACE BLOWOUTS ASSESSMENT OF APPLICATION OF DYNAMIC KILL FOR THE CONTROL OF injection fluids, and the strengths of available tubing 9, Evaluate the mode! and compare results with available data in literature and elsewhere. Relief Well Dynamic Kill Application Regaining control over a blown out well might necessitate the directional drilling of one or more relief wells to attempt a kill from within the formation. If the surface equipment are not intact or if the produced fluids contain poisonous gases and the fire cannot be safely put out, then relief well kill approach may become the only solution, ‘The basic approach to dynamic kill is based on treating the relief well and the blowout well as one system. Fig. 3 depicts the dynamic kill system and the conditions of ‘Arun blowout 20 ‘An ideal dynamic kill procedure through a relief well would follow this sequence:203 1. Establishing communication between the relief well and the blowout well by acid worm-hole or fracturing, Testing the communication between the two wells to determine its adequacy for dynamic kil 3. Injecting the initial kill fluid at the determined dynamic kill rate or the rate that will give a bottomhole pressure less than the formation fracture pressure. If the pressure at which the tubing of drill string will be ejected is less than formation fracture pressure but greater than static formation pressure, then the ejection pressure will be the limiting pressure, 4. Once dynamic kill is achieved, converting to intermediate weight mud should start. Injection of the intermediate weight mud will be at the same rate as the initial kill mud until the intermediate mud passes the relief well shoe and starts up the blowout well. 5. Injection rate is reduced as needed to keep the relief well bottomhole pressure below the fracture pressure. The rate, however, should not be reduced to the extent that the bottomhole pressure of the blowout well will drop below the static formation pressure. 6 When the blowout well becomes full of the intermediate weight fluid, injection of final heavy kill fluid is started. Injection at the intermediate weight fluid rate continues until the final kill mud enters the wellbore of the blowout well 7. Injection rate is reduced as required to keep the bottombole pressure in the relief well below the 127 formation fracture pressure and the bottomhole pressure in the blowout well above the formation static pressure 8. As the blowout well becomes full with the final Kail fluid, injection is continued at a low rate for a few hours while observing the well, 9. When there are no indications of gas or oil influx , the injection is discontinued while the blowout well is observed, The kill fluid will probably flow out the surface slowly for some {ime because of thermal expansion. Afier the well is dead, the capping operations are stated. Blowout Flow Rate Determination As explained earlier, it is possible to calculate and plot both inflow and tubing performance relations. When at a specific rate these two pressures are equal, the flow system is, ‘equilibrium and flow is stable. ‘The intersection of the IPR id tubing intake curves determines the rate of stable flow from a particular well. The equilibrium rate and pressure constitute the natural flow point. If the two relations do not intersect, then production is impossible from the well exhibiting these relations. Mathematically, the stable point of natural flow exists when the two performance relations intersect with slopes (i.c., derivatives) of opposite signs. If the two curves hhave slopes of similar signs when they intersect, at a lower rate, then only a small change in the rate will cause the system to change its state of equilibrium, either killing the ‘well or moving it toward the stable point of natural flow. Fig. 4 is a flow chart of the algorithm used to determine the dynamic kill rate in this work. Relief Well Dynamic Kill Rate Variables Simulation Derivations and details of relief well dynamic kill rate variables used in this model are given in reference |. ‘These parameters include the minimum injection flow rate into the relief and blowout wells, the intial and final kill luid densities, the size and type of drilling string requirement for achieving the required kill ratc(s) in the relicf well(s), and horse power requirements. Simulations can also check for ability to inject at the desired rate through the formation. Surface Momentum and Off-Bottom Dynamic Kill ‘Applications A surface dynamic Kill ( top kill ) to control a blowout by pumping or circulating fluid into the well is often attempted. This approach accounts for a majority of all successful well control operations * The surface momentum kill is possible only if the a Dhater A. AlShehri IADCISPE 39258 lifting capacity of the blowout can be overcome without exceeding the strength of the tubular being pumped through. Itis sometimes possible to kill the well with a heavy brine or mud. Brines have lower viscosity allowing for higher pumping rates.> again, derivations and details of relief well dynamic kill rate variables used in this model are given in reference | ‘There are some applications when the Kill fluids may have to be injected some distance from the bottom of the blowout well. In this case, the volume fraction of kill fluid below the point of injection (POL) needs toe estimated Injection of the kill luid at the POI does not insure that the kill fluid will displace the reservoir fluids below the POL Special Features of Model Fluid physical properties correlations are used to predict fluid properties in this work. ‘These properties are ‘evaluated at the pressures and temperatures of interest in the wellbore. ‘The Swamee-Jain’® equation is used in this work to predict the friction factor for Newtonian fluids: [ 1 eae + as) i NRe Drilling muds and other drag reducing fluids may be used as kill fluids.232* These fluids will exhibit non- ‘Newtonian behavior A simple volumetric weighting rule for, two-phase liquid-liquid viscosity has been found inadequate.*667 To predict the frictional pressure losses, the power law model is used in this work to characterize the theological behavior of non-Newtonian fluids For the case of flow in the annulus, Kouba‘? pointed cout that an equivalent arca diameter, dye, defined below, is a more meaningful alternative as the fully eccentric tubing diameter gets smaller relative to the casing diameter dae = VR - A Calculating he friction factor using dag gave excellent agreement with Cactano’s”! friction factor data for single phase flow in a fully eccentric annulus. In this dynamic kill model, heat transfer is assumed to be at steady state, hence the heat transfer across each clement in the wellbore must be constant, This assumption allows us to write the rate of heat transfer across each element in terms of. the temperature difference across the element and the resistance offered by the element Evaluation of the overall heat transfer coefficient,U, is a difficult and critical step in finding an accurate solution, Also accounting for both the Joule-Thompson and the kinetic 128 energy effects is important, We made several assumptions in order tg simplify the expression for U and make use of Sagar et al. ” correlation for the Joule-Thompson and the kinetic nergy effects ‘The model also took in consideration the critical flow conditions and in these cases gas flow can be estimated using an equation for an adiabatic frictionless flow of an ideal gas through an orifice, Results and Discussion In this section, I will summarize the different aspects of the dynamic kill simulator "DK". The results from two dynamic simulated kills for a gas and an oil well blowout are presented. The model results will be tested by comparing them to available field and literature data. Finally, I will show how the model results can be used to improve the design and the practical application of a dynamic kill ‘operation, ‘The most important parameter in evaluating the potential of a dynamic kill for a blowout control is the kill fluid rate needed. A gas well blowout as well as an oil well blowout are discussed Laswell case: (Arun Blowout). ‘The Arun blowout was a huge gas well blowout in Indonesia.!292 "It is considered the Targest gas blowout ever. Well no, C-II-2 blew out while drilling June 4, 1978, ‘The well caught fire, destroyed the drilling rig and burned for 89 days at an approximate rate of 400 MMscfd, A tubing was used in the relief (killer) well for Pressure measurement and acid injection was employed to establish communication. The acid enlarged the ‘communication channel. Then mud was injected to form a filter cake on the channel walls to reduce loss of kill fluid to the formation. The kill fluid was then injected through the annulus of the killer well Data is extracted from references 20 and 43. Table 1 summarizes these data, 1. Blowout flow rate: ‘The intersection of the IPR and tubing intake curves determines the rate of stable flow from a particular well. The equilibrium rate and pressure constitute the natural flow point. If the two relations do not intersect, then production is. Impossible from the well exhibiting these relations, Mathematically, the stable point of natural flow exists when the two performance relations intersect with slopes (ie., derivatives) of opposite signs. The intersection of the inflow performance relationship (IPR) and the wellbore tubing performance relationship (TPR) determines the blowout flow rate, Fig. 5 indicates that this blowout is producing 447 MMscfd. This value agrees with data presented in the literature 2049 IADOISPE 29058, ASSESSMENT OF API MIDDLE-EAST SURFACE BLOWOUTS TION OF DYNAMIC KILL FOR THE CONTROL OF 5 2. Blowout kill rate: For a kill fluid of any selected density, a stable flow condition would result if the wellbore hydraulics performance ‘curve intersects the reservoir performance curve. That is, the reservoir would continue to produce at the rate corresponding to the point of intersection, and the well would not be killed If the wellbore hydraulics performance curve lies entirely, above the reservoir performance curve, then a stable oil or {gas-lif flow condition would not be possible, and the well ‘would be killed. Fig. 6 shows that as the injection rate of kill fluid increases the gas natural flow decreases and finally flow will stop at an injection rate of 82 barrels/min. This value agrees ‘very well with the value reported in Reference 29. Fig. 7 presents the dynamic kill rates needed for controlling the blowout for various densities of the kill fluid. Required kill rates are 64, 44 and 16 barrels per minute for Kill uid densities of 10, 12, and 14 ppg respectively Fig. 8 shows how the bottomhole pressure varies with the dynamic kill rate, For a specific kill lid density, the reservoir pressure of 7100 psia will be overcome when enough kill fluid rate is achieved Fig. 9 shows the bottomhole pressure versus ‘dynamic kill rate when the equivalent area diameter, dae, oF the hydraulic diameter are used. Area based equivalent diameter, which is defined previously. yields more realistic and conservative dynamic kill rates. When an initial kill fluid with a density of 10 ppg is used, a kill rate of 64 bbis/min is required. However, if a simulation is performed ‘with the hydraulic diameter defined above a far less realistic and misleading flow rate of only 45 bbls/min, will be roquired. ‘The use of an equivalent area diameter, dae, was found to be a more conservative and meaningful alternative for the prediction of friction factor for flow in a fully ‘eccentric annulus . The use of the hydraulic diameter results in overprediction of friction factor and underprediction of kill rate requirement. Calculating the friction factor using dag gave excellent agreement with Cactano’s”! friction factor data for single phase flow in a fully eccentric annulus. 3. In-Well dynamic control: Fig. 10 indicates clearly that the in-well dynamic kill rate required to control Arun gas blowout is practically impossible. Even for kill fluid densities as high as 30 ppg and epths of several hundreds of feet , kill rates exceeding 110 bbbls/min would have been needed, Oil well case: (Burgan Blowout). Figs 11-13 present similar simulation results of a blowout in an oil well from the Burgan oil field in Saud: Arabia-Kuwait neutral zone. Data of a typical well is given in table 2 129 Itis clear that a kill from the surface is the method of choice to killa blowout in this case. Fig. 11 indicate that a relief well kill rate of only 5.25 bbls/min. 1s enough to control the well. However, as Fig. 12 shows, a surface kill rate of only 4.0 bbls/min, will kill the well and save the cost of drilling a relief well Figure 13 presents the kill rates needed when cquivalent aca diameter, dae, or the hydraulic diameter are CONCLUSIONS ‘The following conclusions can be made based on the analysis and the model developed: 1. A dynamic kill model was developed for controlling surface induced blowouts of oil and gas wells. Dynamic kill simulation is performed for both kill through a relief well or through In-Well surface injection, 2. Relief well dynamic kill simulations can predict the minimum injection flow rate into the relief and blowout wells, initial and final kill fuid densities, size and type of drilling string requirement for achieving ‘the required kill rate(s) in the relief well(s), horse power requirements and check for ability to inject at desired rate through the formation, 3, In the case of in-well kill, the model determines the optimum locaton of the pointof kil fluid inetion 1m order to gain the most benefit of available surface pumping equipment, available injection fluids, and the strengths of available tubing. 4 The model results were in agreement with data presented in literature and acquired data from Kuwait 5. Emulsions formation is not significant in affecting wellbore fluids viscosities during dynamic killing. Only oil in brine emulsions are formed whose viscosities may be approximated using brine’s viscosity, 6 Athigh flow rates, the distribution of gas and oil in ‘a dynamic kill is found to be homogencous with no slippage between the phases. However, neglecting slippage of the gas relative (o the liquid at moderate rates will cause underprediction of pressure loss resulting in overprediction of the kill rate 7. ‘The use of an equivalent arca diameter, dye, was found to be a more conservative and meaningful alternative for the prediction of friction factor for flow in a fully eccentric annulus . The use of the hydraulic diarncter results in the over prediction of friction factor and underpredicion of kill rate requirments. 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Re Wa Blowing We Ir ih /j ig. - Sctemati of blowout well showing the ro posible options of yam kag be vel well an eet wel injecon Pigg = BHP- Wate + Py Pag = BHP Phys +P 5 2 we a 2 e A z OH om go> a wt £ 24 ot 3 zy E ° rr (GAS PLOW RATE, Qe, sc) Fig.2, Prete nfo perfomance and system imake curves fr $svelinecon ts for daniel af well Dawes Ne Cont Orbea) “hye Fig 3 -tnasclet wel blowout well sytem se (Gv he aps oe eet wel et Ra tao ‘Slowout wernt 7100 | L__] or eyamie il id nected eommunzatcn and pte fa 133, TRIGA Row (<—| es T t t Fig. $ Flow cant of yams il ate determination. ‘Table {- Daa for Ana blowout cara Blowou Wer | CIS Reet Wes Resear pres i 700 = Resevoir temperate, dg. F x0 _— Spec ravi of seri gas 06 _ Casing 1.0 ass i Dlg 0D, | 500 150 pg Die ans 2992 Pipe roghnest 0 os — Meas ep, ro2I0 10500 Tra veal ep “0 eal 134, Fig. 5 Ineriecon of te IPR unt TPR indices ta hs lowout i pedcing {46 MiMi. Tis vale ares with dt presented he tere. 12 ob ye bo mm |NMECTION FLD KL RATE. BP Fig. 6 As the jection te oil id ness, he a mature dete ad Faulyow wisp at inte rate 82 bel Fig. 7 -Ntua fw rae versus dy il rie, At the Sensi ofthe il i increases ‘be recuved djame ila decease, 135 Fig 8 Bouombl ress vero dynam ll re At the density of the il id ‘neces te requred yi kl ate decreases. fig. 2 Am towout bam pa ee yi te Aredia ad oN, i: Reser Fig 10-I.wel dma irae eid 0 cont he Anu 3s blowout 136 Garo Rao HS) Procter Reser Pressure (Pa) “ea Depa Formation Rermeiy (2) Fest Tacks (7) ‘Welbre mt 1) Blow ou Wel latiston (Det) On Spesie Gre) Rae Specie Gri Gs Specie Gavi WatreadTenpentiet ‘Botoole Temperate () Production Sing Da Depa nerement Used Prous Tubing LD) Prete Taba O.D da) Producten Casing a) Posts Cane te) Poehie m n) a = in Sel) baw Ee A 5 g Fig, Ashe ection ao kil iinet he i and gs at fw dress ad ily fw wil'stop tan nj ae of 353 be 137 Fig. 1 -lnwel yam il ae guid cota he Horan ol well oweut 4 : J oo Af ole Sue \ \ 13 - Buran Nowoalbouombole ese ves dyzanic il te. Ave sed ‘Siva dee pide ore ec ad conervatve dynamic kl es 138

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