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Updated for 2017: This article and associated study guide work book ( ) detail the exact techniques I used this April (2017) to pass the IWCF Level 4 well control exam scoring a 96% on the IWCF Principles and Procedures, and a 95% on the IWCF Equipment exam. Introduction: The intent of this study guide is to help you prepare for the IWCF Level 3 and Level 4 Supervisor Well Control Exam (Surface or Combined Surface and Subsea Qualifications). This guide does not replace the requirement to attend a certified well control school, instead, it is designed to supplement the training received in the classroom and to ensure the IWCF candidate is as prepared as possible PRIOR to attending the IWCF class. This guide assumes that you have a “general” idea how oil and gas wells are drilled and at least a basic understanding of common well control calculations from an introductory IADC or IWCF well control course and/or company provided training material. This guide also assumes you have at least a month to study BEFORE your IWCF exam. Strengthening the need for this guide, many companies and organizations (including the one I work for) are pushing for an “Enhanced Standard” of well control requiring students to obtain an average score of at least 80% to be recognized as having passed the course (even though the minimum IWCF passing grade is 70%). I’ll start with the “basics” and then break down each individual test (Simulator, Equipment and P&P) into its own section with some of the preparation tips that helped me pass the exam.

I’ll also add that this guide is NOT a well control manual. Instead, it is a tool to help you study for and pass the IWCF Level 3 and Level 4 well control certification exams using information that is already available to you on the internet and in my downloadable.

If you haven’t already, you can purchase my complete with an Appendix of over 400 IWCF sample questions, IWCF equipment diagrams and worked out IWCF formula problems with explanations. Basics: Firstly, the IWCF test is no joke. Whether you’re taking IWCF Level 2, Level 3, or Level 4, it is as difficult as everybody says it is. If you don’t prepare prior to the class and you’ve never been through IWCF advanced well control before you’re not going to do very well. This is especially true for students pursuing Level 3 or Level 4 certification as it adds a graded practical exam (simulator exercise) to the mix. The GOOD NEWS is you have control over your own destiny and it’s only a matter of how important passing is to you. You WILL PASS the class if you put the effort in.

EVEN BETTER, you can ACE the exam if you follow my techniques. By far the most IMPORTANT thing you can do to prepare for the IWCF exam is to review my “ “. Even if you know nothing about well control, you’ll pick up a great deal going through the questions over and over. At first it seems like you’re doing nothing but memorizing the answers, but after a while the questions start to “connect” and you begin to get a sense of what is actually going on. I would estimate that I went through every question in the at least 5 times (approximately 450 questions spread out over 8 sections).

After a while, there will be many questions that will become easier than others. I would highlight the most difficult and challenging questions with a red highlighter so I could focus more on those and not waste time studying the easier questions I already understood (it’s all about efficiency). The most effective way I found to do this was to hit the material in small 30-45 minutes blocks a few times each day. Not only will this prevent you from burning out, but it will also allow time for the material to sink in so you can build on it during the next study section.

I found it was also helpful to take a day or two off every once in a while to reset. The knowledge you gain from reviewing IWCF Study Pack questions will help you in all three exams required by IWCF Level 3 and Level 4 certification. The Simulation “Practical Exam”: If you’ve never had any real drill floor experience at the Assistant Driller or Driller level, you’re going to be out of your comfort zone when it comes to the simulator exercise. This is especially true if you’re taking the ICWF Level 3 or Level 4 supervisor exam.

By registering for the class, it is assumed that you’re comfortable with drilling operations and will know exactly what you need to do to line up the drilling equipment and give the driller “instructions”. The IWCF provides a general “outline” of what points you’ll be graded on but it offers absolutely no help with what you’re actually supposed to say during the exercises (you literally have to act out a scenario and give realistic instructions to the driller who is coming on “tour”).

This was a challenge for me since I’ve NEVER been directly involved in the drilling operation during my career. Not only did I not know much about lining up a choke manifold or standpipe manifold, I knew virtually nothing about what RPM to drill at, how much pressure to maintain on the drillpipe (or SPM on the mud pumps), how much weight to maintain on the drill bit while drilling, etc. Well Control Simulation Video: A great resource that helped me was a produced by the Arabian Drilling Company that walks you step-by-step through the IWCF well control drilling simulation process: I’ll be the first to admit that the video is a little cheesy but it follows the IWCF well control script perfectly and covers virtually every aspect of a well control situation that you’ll likely encounter during your IWCF simulation exam. I will add that the well control simulator used in the video is probably a lot more sophisticated than you’ll find in the well control school that you attend but the overall concept and theory is exactly the same. I basically memorized what the toolpusher’s instructions were to the driller in the video and repeated them during my time in the simulator. The best part about doing this is the “instructions” you give to the driller count for a very large percentage of your IWCF simulator score. Even if you don’t do so hot exercising the choke during the well kill simulation, you can still get a decent score by following the script outlined in the Arabian Drilling Company Well Control Video.

Sound Waves Simulation Worksheet Answers

During the week of my well control school I would practice the script in my hotel room by rehearsing what I was supposed to say into the voice recorder on my iPhone again and again until I could go all the way through the “driller instructions” without missing any of the “criteria” on the IWCF score sheet. I know this sounds lame to many of you reading this, but it HELPS!

Here’s a rough transcript of what I practiced saying to the driller during the initial set-up of the drilling operations. The good news is you don’t have to say these in the exact order as long you cover all the basic points as outlined in the IWCF criteria.

“Good morning, driller. I hope you had a good night’s rest. Today we’re going to be drilling at 100 RPM, 25,000 to 30,000 weight on bit with 2500psi on the drillpipe pressure gauge. However, before you get started I want you to check your equipment and make sure you have everything set up the way it needs to be.” “Please check your BOP panel for proper valve positions and ensure you have the appropriate pressure readings on your gauges. Check your standpipe manifold for proper valve alignment, we’re going to be drilling using mud pump #1 today. Also check your choke and kill manifold and ensure it is set up for a “hard shut-in since this is the method I want you to use as per company policy in the event we do need to shut the well in.” “You’ll also need to take your slow circulating rates at 25 and 30 strokes per minute (SPM) on mud pumps 1 and 2 as well as find the choke line friction losses for both pumps at 25 and 30 SPM as well.” “Once you have your pumps up and running.

Make sure you set your pit level and flow meter alarms and find your “space out” and “hang-off” positions. In the event we need to hang off, I’d like you to hang-off 50% of the string weight on the upper pipe ram.” “Finally, I want you to flow check all drilling breaks and shut the well in immediately if you have any concerns or doubts. DO NOT CALL ME FIRST.” TIP 1: If you have difficulty “memorizing” the well control instruction roll play script you’re supposed to give to the driller, you can also just use the well control equipment in the simulator room to “prompt” you with what to say. For example, the simulator equipment above is typical of what you might find at a common well control school. You can just work your way through each piece of equipment on the control panels and on the computer screen to help you to make sure you don’t miss any of the points covered in the video. On the computer screen you’ll see (from right to left) the choke manifold, drill pipe manifold, drillers panel and BOP panel.

You could give your driller instructions in the order the equipment is presented to make sure you don’t miss anything. “Driller, please check your choke manifold, stand pipe manifold, drillers panel, and BOP panel for proper alignment and settings.” BOOM, that’s probably 15-20% of your grade right there just using what’s available to you!

On the left hand panel, you’ll see the alarm settings for the flow meter and pit gain alarms. If you’ve missed these alarms during your instructions to the driller, you’ll remember them if you go through all the equipment gauges prior to starting up the exercise. TIP 2: Another invaluable thing to do is take a few pictures of the various screens and panels during your practice simulator exercise that you can review in your hotel room in the evening. Practice your “roll playing” again using these pictures as prompts and guides. It will be tremendously helpful!

TIP 3: On the IWCF practical exam (simulator), you get to decide which method to use to “kill” the well. I HIGHLY recommend that you use the “Drillers” method. The IWCF practical exam concludes after the initial influx is circulated from the well which means if you chose the drillers method, you’ll only have to make the first circulation and not have to worry about following the drillpipe pressure schedule you created on your killsheet (more on this later). You can fool around using the Wait and Weight method if you want to, but following the drillpipe pressure schedule on your kill sheet will make it much more difficult to detect one of the four “problems” (see next paragraph) that will be thrown at you during your exam by your instructor. The Four IWCF Simulator Problem Scenarios: As mentioned above, you’re expected to know what to do in the event you encounter any “problems” during your IWCF practical simulator exam. Fortunately, the Arabian Drilling Company well control video covers the four basic problems that you’ll likely encounter during your well control simulator exam. I’ve summarized each below but you’ll probably get more out of just watching the video a few times until you understand exactly what the choke operator is doing.

You can count on experiencing at least one of the below problems during your practical exam so mastering these concepts is time well spent and an easy way to pad your exam score. Choke is Washing-Out: Detecting a Washed-out Choke: If you have to keep closing the choke to maintain drillpipe, casing and kill-line pressure, you can reasonably assume that the problem is a washed-out choke (you’ll notice the casing and kill-line pressure start to drop first followed a short time later by the drill pipe pressure). If you use the driller’s method like I recommend, this scenario will be relatively straightforward to detect. Dealing with a Choke Wash-out: If you detect that your choke is washing out you should immediately order the driller to isolate the choke by closing a valve upstream of the choke.

Once the washed out choke is isolated, you need to quickly shut down the pump to avoid adding too much bottom hole pressure (from pumping against a closed choke). Once the pump is shut down you can line up on choke #2 (backup choke) and resume the kill.

(Note: This was the scenario I was given during my practical exam). Choke is Plugging: Detecting a Plugged Choke: If you have to keep opening the choke frequently to maintain drillpipe, kill-line and casing pressure, you can reasonably assume that the choke is plugging (you’ll notice the choke pressure and kill line pressure start to rise first, followed a short time later by the drillpipe pressure gauge). Again, if you elect to use the driller’s method during your IWCF simulator exercise this scenario will be much easier to detect. Dealing with a Plugged Choke: If you detect that your choke is plugging, you should immediately shut down the mud pump. After the pump is off, line up on choke #2 and start back up the well killing process. Mud Pump Trips Offline: Detecting a Tripped Mud Pump: Detecting a tripped mud pump is probably the easiest problem to detect during an IWCF well control simulator exam.

In this scenario, you’ll notice your strokes per minute counter either go to “0” or go blank and your drill pipe pressure drop off quickly. If the simulator room is equipped with sound effects (like the one I was in), you’ll also notice the room get very quiet. Dealing with a Tripped Mud Pump: If your mud pump trips offline during your well control scenario, all you have to do is immediately close the choke and then line up to use mud pump #2. Even if you chose to use the driller’s method to kill the well, you’ll need to remember to recalculate your Initial Circulating Pressures and Final Circulation Pressures, as well as your “step down” pressure schedule on your kill sheet since you’ll be using a different mud pump that likely has a different “slow pump rate” (more on this later). Plugged Bit: Detecting a Plugged Bit: The forth and final “problem” that could be thrown at you during your IWCF simulator exercise is the plugged bit. In this case, you’ll see your drillpipe pressure gauge increase sharply while the casing gauge and kill-line gauge (assuming you’re on a subsea well) will remain approximately the same. Dealing with a Plugged Bit: If you encounter a plugged bit, take note of the pump pressures.

It will be expected that you slowly stop the mud pump (gradually slowing the pump maintaining casing and kill-line pressure). Once you’re confident that the issue is indeed a plugged bit, you’ll start the pump back up and the new Initial Circulating Pressure will likely be whatever the drillpipe pressure gauge was reading before you started shutting the pump down. Creating Simulator Flash Cards: To help me prepare for any of the above issues, I made four flash cards (one for each possible scenario). On the front of the card, I drew little gauges with pressure readings with a brief description that represented the tell tales of each possible problem that the simulator instructor could throw at me. On the back of the card, I would write out what I needed to do to remedy the problem.

Every once in a while I would run through these cards until it became second nature to identify the problem and what would need to be done to solve it. Since you’re guaranteed to get at least one of these problems during your exercise, it is another excellent opportunity to master these areas to pad your final practical exam grade. Operating the Choke: The final piece of the simulator exam is learning to properly operate the choke to circulate out the influx while maintaining bottom hole pressure.

This was a very intimidating skill for me to obtain especially after the first day in the simulator (during one of the practice exercises) when I just couldn’t figure out how to keep the drill pipe pressure where I wanted to. Fortunately, as the week went on I got better and better. Remember, there is a “lag time” between opening or closing the choke and noticing a change in your drill pipe pressure gauge (approximately 2 sec for every 1,000 ft MD of the well). Most of the scenarios you’ll be doing in your simulator exercises are between 5,000 and 8,000 feet so you can expect a 10-20 second delay for choke adjustments to be reflected in your drillpipe pressure.

This was one of the most challenging aspects of the simulations for me until I learned to simply use the casing gauge and kill gauges (for subsea wells) to monitor and detect sudden changes in the annulus’s pressure. For example, if you close the choke, you’ll see the affect on the casing gauge almost immediately vs. Waiting 10-20 seconds to see the change in your drill pipe gauge.

Here’s the pressure graph from my actual IWCF Level 4 simulation exam. Click on picture for higher resolution. Minutes 0-40: The first 40 minutes or so of the exam was going over the “instructions” to the driller as well taking the slow pump rates (SPR) and choke line friction (CLF) values. Minutes 40-70: During this time frame, the driller starts actually drilling the well and the supervisor (Level 4 candidate) is actually out of the simulator room.

Sound Simulation Software

The blue line represents the drill pipe pressure and you can see he actually shut down the mud pumps a couple of times to “flow check” some drilling breaks that he recognized (Drilling Breaks: Drilling breaks are when the rate of penetration (ROP) of the drill bit increases dramatically over a short period of time). Minutes 70-73: The driller detecting a kick and the well is flowing. He shuts the well in and calls the supervisor (Level 4) into the simulator room. Minute 73-105: The mud pump is slowly brought up to kill rate speed in 5 SPM intervals while the Level 4 supervisor slowly opens the choke to maintain the original casing pressure. Once the mud pump is slowly brought up to the kill rate speed, you need to take note of the Initial Circulating Pressure to make sure it is close to what you calculated on your kill sheet (more on Kill Sheets in a bit).

Minute 105: At approximately minute 105, you can see where the black line (bottom hole pressure) started to drop off. This was when the simulator instructor initiated a “problem” into the scenario. The problem in my case was a washed out choke.

You can see where I had the driller isolate the choke and we lined up on choke #2 to resume the scenario. You’ll also note that bottom hole pressure (black line) never dipped below the formation pressure (green line). Minutes 105 to End: The rest of the simulation was simply adjusting the choke to account for the expansion of the gas from the well.

This gets particularly challenging once the gas enters the choke lines and you really need to pay close attention to your kill and casing gauges to “check” any sudden increases and decreases to ensure you can maintain drill pipe pressure constant (which will ensure bottom hole pressure remains constant). Don’t make the same mistake that I made near the end of the scenario where I was so excited to have gotten through “most” of the scenario that I let bottom hole pressure drop below formation pressure. The scenario isn’t over until the instructor says it’s over! Fortunately for me the scenario was over before any additional influx came which could have affected my score. The Equipment Exam: One of the biggest complaints I hear about the IWCF exam is that the equipment covered is outdated at best and even obsolete in some cases whether you’re taking the surface or subsea exam. This is especially true if you are fortunate enough to have started out offshore on a 4th, 5th, or 6th generation drilling rig. As I mentioned above, the most helpful thing for me was going through the equipment sections in the over and over.

You eventually start picking up on things and making connections between the questions and the various pieces of equipment (even if you’ve never seen or heard of the equipment before). As you learn more and more about the various equipment and their components, the next group of questions in the become easier and easier.

Approximately 25% of your test grade will be based on your ability to identify various components of well control equipment. Included in the is a section with diagrams and drawings of most (if not all) of the equipment that you’ll likely encounter on your exam.

Study the drawings and practice memorizing the various components. After a while, you can white out the labels on the equipment and test yourself to see if you can make it all the way through the equipment drawings without referring to an un-whited out version. When you can do this you’re ready for the exam. Because of the outdated equipment covered in the ICWF Level 2, Level 3 and Level 4 you’re best option for learning the material is to simply study as many of the questions in the IWCF Study Pack over and over again. I cannot emphasize this enough, you really do learn about the equipment by studying the questions and it all starts to make sense after a while. The P&P Exam: The P&P exam is probably the most difficult part of the test for most people I’ve talked to.

It is also the longest. Level 3 candidates are given 2 hours to complete the exam and Level 4 candidates are given 2 ½ hours to complete the exam (not really sure why Level 4 gets more time). The P&P test covers a variety of skills and knowledge including the completion of a “Kill Sheet”, gauge interpretation, various drilling formula calculations, and “general” theory questions. International 10 grain drill manual.

Practice the Kill Sheets: Another easy way to pad your grade on the IWCF Level 3 and Level 4 exam is to master filling out. Kill sheets may seem intimidating at first but they’re actually quite easy to learn using the IWCF preformatted kill sheets that you’re allowed to use during the test.

Sounds Manual Simulation Answer Sheet

I’ve included a sample IWCF Kill Sheet Exercise below to show you how to fill out a typical Kill Sheet similar to what you’ll find on an IWCF Level 2, Level 3 or Level 4 exam. You can download a blank IWCF Kill Sheet from the IWCF website to fill out and follow along over the next section of this study guide.