MPD Fundamentals DPA Rio

2/18/2011

MPD Fundamentals Rio de Janeiro, Brazil Feb 2011

Agenda 

About MPD



MPD Classification & Techniques



The MPD Engineering Process



How does MPD solve pressure related problems during drilling operations?



Equipment used in MPD Operations



Operational considerations when doing MPD



Automated MPD Operations

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What is NOT MPD?

Independent of the fluid system, MPD IS NOT A TECHNIQUE TO DRILL UNDERBALANCED. By definition, MPD operations are planned to keep the bottomhole pressure above the pore pressure at all times. © 2010 Schlumberger. All rights reserved.

What is MPD? IADC defines MPD as: “…an adaptive drilling process used to precisely control the annular pressure profile throughout the wellbore. The objectives are to ascertain the downhole pressure environment limits and to manage the annular hydraulic pressure profile accordingly. MPD is intended to avoid continuous influx of formation fluids to the surface. Any influx incidental to the operation will be safely contained using an appropriate process.” © 2010 Schlumberger. All rights reserved.

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Why MPD?  Extends casing setting depth  Use of a lighter mud weight in cases where high mud weights is a concern  Dynamic management of small influxes  Immediate Pressure Profile change by modifying WHP  Increases ROP  Reduces Formation Damage  Limits or avoids Lost Circulation

 Avoids Differential Sticking  Avoids cavings associated with geomechanical instability © 2010 Schlumberger. All rights reserved.

MPD/UBO IADC Classification The International Association of Drilling Contractors (IADC) has established an MPD/UBO Classification System based on three digits, each digit indicating: Risk Level Classification

0 – Performance Enhancement only. No hydrocarbons 1 – Well incapable of natural flow to surface 2 – Well capable of flowing to surface but control can be done conventionally 3 – Geothermal and non-hydrocarbon bearing formations 4 – Hydrocarbon bearing formations. MASP < MPD Equipment Rating 5 – Hydrocarbon bearing formations. MASP > MPD Equipment Rating

Application Category

Fluid System Classification

A – MPD B – UBO C – Mud Cap Drilling

1 – Gas 2 – Mist 3 – Foam 4 – Gasified Liquid 5 – Liquid

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MPD Variations

Constant Bottom Hole Pressure Pressurized Mud Cap Drilling Dual Gradient Drilling HSE & Performance Drilling Low Head Drilling © 2010 Schlumberger. All rights reserved.

The MPD Engineering Process Planning Phase I Engineering Data Gathering

Candidate Screening

Flow Modeling

Technical Peer Review

Feasibility Study

Feasibility Study Approval

Operations Client Ops Data Collection

Execution Phase 1. Well Supervision 2. Management of Change 3. Reporting

Equipment Pre-Selection

P&ID

Equipment List

Personnel List

Planning Phase II UBD/MPD Program

Technical Peer Review

Develop Basis of Design

Fine Tune Operating Window

Evaluation Phase © 2010 Schlumberger. All rights reserved.

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Case 1. Narrow Mud Weight Windows How is it done conventionally in Normal Mud Weight Window?

Depth

Surface Pressure = Atmospheric Pressure

1. Static condition (pumps off)

Static Pressure Gradient (ESD) Dynamic Pressure Gradient (ECD)

Pore Pressure

2. Dynamic condition (pumps on)

Fracture Gradient

Friction Losses Pressure

Pressure © 2010 Schlumberger. All rights reserved.

Case 1. Narrow Mud Weight Windows

Depth

How is it tried to be done conventionally in Narrow Mud Weight Window? 1. Static condition (pumps off)

Static Pressure Gradient (ESD) Dynamic Pressure Gradient (ECD)

Pore Pressure

2. Dynamic condition (pumps on)

Fracture Gradient Loss of circulation!!!!!!

Pressure © 2010 Schlumberger. All rights reserved.

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Case 1. Narrow Mud Weight Windows Solution: Constant BHP MPD – Narrow Mud Weight Window

Depth

1. Static condition (pumps off) Static Pressure Gradient (ESD) Dynamic Pressure Gradient (ECD)

Pore Pressure

2. Dynamic condition (pumps on)

Fracture Gradient

BHP is constant at all times

Pressure © 2010 Schlumberger. All rights reserved.

Case 2. Formations that lose circulation at low pressure gradients Conventional vs. MPD Approach

Depth

1. Water Gradient Gradient were losses are observed

Tried curing the losses  No success 2. Diesel Gradient Tried curing the losses  No success

3. Water + Nitrogen  Success

Loss Loss of of circulation!!!!!! circulation!!!!!!

Fracture Gradient

Pore Pressure

Pressure © 2010 Schlumberger. All rights reserved.

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Other techniques that can be applied Non-existing Mud Weight Window EMW (kg/m3) 800

900

1000

1100

EMW (kg/m3) 1200

1300

800

900

1000

1100

1200

1300

Influx

Losses

Losses

Underbalanced Drilling

Mud Cap Drilling

 Used when a Mud Weight Window does not exist (BHP is

 Used when a Mud Weight Window does not exist (BHP is always higher than the losses pressure at some point in the well)

always lower than the pore pressure at some point in the well)  Influx flow rate can be controlled dynamically using the WHP  Requires surface fluid handling facilities  In the case of corrosive fluids from the reservoir, proper measurements must be taken to avoid corrosion

 A variation called Pressurized Mud Cap Drilling (PMCD) is used for safety reasons  Requires high volumes of sacrificial fluid  Fractures wide enough to inject cuttings must exist

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Conventional Approach vs. MPD In the previous slides, one of the most applied MPD techniques known as Constant Bottom Hole Pressure has been shown. One of the limitations of this technique (among other MPD techniques) does not come from any technical, operational or logistic issue but from an old paradigm:

The presence of pressure on surface during drilling operations is undesirable © 2010 Schlumberger. All rights reserved.

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Conventional Approach vs. MPD

 Losing the control of the operation (and eventually, of the well) is what is undesirable, independently of the used drilling technique.  Independently of the well condition, you will detect any pressure-related anomaly quicker using MPD than during conventional operations.

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MPD: Technology for extreme environments

Deep Water

• Kick detection • Narrow margin • ECD reduction • Loss avoidance • Wellbore stability

ERD Horizontal

Mature Depleted On & Off Shore

• Narrow margin • ECD reduction • ECD reduction • Loss avoidance • Loss avoidance • Stuck pipe avoidance • Wellbore stability • Kick detection • Hole cleaning • Drilling optimization • Drilling optimization • Reservoir damage

HPHT • Wellbore breathing avoidance • Kick detection • Narrow margin • Wellbore stability • Loss avoidance • Pressure environment detection (Dynamic Flow-in/Leak-Off)

Fractured Reservoirs

• Kick detection • Controlled losses • Reservoir damage

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Examples of MPD Systems Applications

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MPD Equipment Diagram Equipment for Conventional Operations

Standpipe Rig Pumps Shakers

Bell Nipple Flow Line Mud Pits BOP Stack

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MPD Equipment Diagram Equipment for MPD Operations

Standpipe Rig Pumps Rotating Flow Head

Shakers

Primary Line

Mud Pits

BOP Stack Separator

MPD Choke Manifold

To Rig’s Poor Boy

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MPD Equipment Diagram Equipment for MPD Operations

Standpipe Rig Pumps Rotating Flow Head

Shakers

Primary Line

Nitrogen Generation Unit

Mud Pits

BOP Stack Separator

Flare

MPD Choke Manifold

Line to shakers © 2010 Schlumberger. All rights reserved.

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Constant Bottom Hole Pressure (CBHP) Operations The CBHP technique aims to compensate any condition that could change the bottom hole pressure by adjusting the Surface backpressure. Among these events that could modify the bottom hole pressure are changes in:  Mud Flow Rate  Mud Properties (Density, Rheology)  Well depth  BHA  Tripping Velocity © 2010 Schlumberger. All rights reserved.

Constant Bottom Hole Pressure (CBHP) Operations Basic Operations for the CBHP Technique

1. BHP Measurement / Computation To be able to execute CBHP operations, it is necessary to know the BHP value, which is the parameter to control. It can be done by two means:  Direct Measurement: Using PWD tools.  Analytic Computation: Using hydraulic simulators that process the real-time data from the rig data acquisition system and compute the BHP.

2. Surface Back Pressure Adjustment Assuming that the flow rate has to remain constant, the only parameter to compensate for pressure-related events that cause a variation in the bottom hole pressure is the Surface Back Pressure.

To adjust the Surface Back Pressure a choke valve on surface in the MPD equipment area is used. © 2010 Schlumberger. All rights reserved.

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Constant Bottom Hole Pressure (CBHP) Operations How is it done manually? Information Input by user

Rig Info Input by user (updated manually) MW Depth Flow Rate etc

Well Geometry BHA Geometry BHCP (Set Point)

Conventional Offline Hydraulic Simulator (not updated in Real Time)

Calculate WHP

 Drilling Parameters are read and entered manually into a hydraulic simulator.  Simulations are run offline by a trained engineer, who needs to constantly check the parameters and run simulations if necessary.

Flow to Shakers or Separator

 There is an important time gap between any event and the adjusting time to compensate for those events.  A choke operator is necessary 24 hours a day to adjust the choke valve to keep the surface pressure at the desired value while drilling.

Calculated WHP Actual WHP?

Yes Instructor Choke Operator to Set new WHP (A dedicated operator is necessary)

 Used when MPD techniques are necessary, but a very precise surface control and bottomhole pressure is not mandatory.

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Constant Bottom Hole Pressure (CBHP) Operations How is it done automatically? Rig Info Input via WITS (continuously updated)

Information Input by user

MW Depth Flow Rate etc

Well Geometry BHA Geometry BHCP (Set Point)

RT Hydraulic Simulator Calculate WHP Flow to Shakers or Separator No dedicated operator is necessary

Calculated WHP Actual WHP?

Yes

 Drilling Parameters are fed into a real-time hydraulic simulator.  Simulations are run continuously in real time without human intervention.  The system reacts immediately to any event and adjusts the surface backpressure to compensate for those events with a very small lag time.  No dedicated choke operator is necessary to keep the surface pressure at the desired value when drilling or tripping.  Used when MPD techniques are necessary and a very precise surface control and bottomhole pressure is mandatory

Set new WHP remotely

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Automated Event Detection Process Flowchart Real Time Data

Flow In = Vol. Stroke Displacement x Strokes / Min

• Flow In (SPM) • Flow Out (Coriolis Meter) • PVT •etc

Event Detection Software

Event Probability > Threshold ?

No

Yes

ALERT ON Flow Out = Direct Reading from Coriolis Meter

Take action to properly manage the event

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MPD Automated Variation: Semi-Automated Operation

Remote Console (Engineers Trailer)

Autochoke #2 Local Console (Manifold Area)

Play Video

Autochoke #1

 Composed of three main components: Autochokes, Local and Remote Consoles  Rated to 1,500 psi (choke body pressure rating = 10,000psi)  System Energy Redundant Backup (Electric and Pneumatic)  Set Point Backpressure can be set either at the local or remote console (1 controlling the Autochokes at the time) and the system automatically adjusts the Autochokes to keep it at the set value. © 2010 Schlumberger. All rights reserved.

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Equipment used in MPD Operations Actual Equipment Distribution Rotating Control Device

MPD Choke Manifold

Separator

Primary Line (flow from the well)

Line to Flare

Line to shakers

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Equipment used in MPD Operations Actual Equipment Distribution Nitrogen Injection Line

Nitrogen Generation Package

Vertical Separator Flare Line (Blooie Line) Returns Line (to shale shakers)

MPD Choke Manifold

ESD

Primary Line (flow from well)

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Automated System Process Diagram

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Automated MPD System Actual Set Up

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Equipment used in MPD Operations Rotating Control Device (RCD) Flow Line Hydraulic Valve 7 1/16” x 5K 4”/6” x 5000 Line to UBD Choke RCD

RCD3

RCD5

Optimal (Schlumberger)

7100

HOLD2500

7800

Weatherford

Smith (SLB)

Strata

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Equipment used in MPD Operations Rotating Control Device (RCD)

Play Video

RCD3 Model 1000 psi @ 100 rpm Model RCD3 RCD5

Pressure Rating psi / MPa 3,000 20.68 5,000 34.47

Bottom Flange Size in / mm 11 279.4 13 5/8 346.1

RCD5 Model 2000 psi @ 100 rpm Bore Diameter with bearing without bearing in / mm in / mm 7 1/16 11 179.4 279.4 9 1/16 13 5/8 230.2 346.1

Lateral outlet size

Height

in / mm 7 1/16 179.4 Two: 7 1/16 & 2 1/16 179.4 & 52.4

in / mm 40 1/2 1028.7 44 1/2 1130.3

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Operational considerations when doing MPD  Space (height) for the RCD  MWD/LWD Signal Attenuation when Gas is Injected (Mud Pulse Systems)  Connections Procedure

 Equivalent Liquid Flow Rate Limit for Mud Motors  Hole Cleaning (Multiphase environments)  Layout (extra space for equipment)  BOP Stack / Rig Misalignment  Drill String condition  Crew Training © 2010 Schlumberger. All rights reserved.

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© 2010 Schlumberger. All rights reserved.

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