Introduction to Dynamic Pressure Management Services for Talisman UK
Atul Singh Bhadauria Drilling Engineer
[email protected] © 2011 Schlumberger. All rights reserved.
Topics Covered • Introduction to DPM Segment • Overview of MPD Technology • Global Experience • Drilling engineering services • MPD systems and products • Integrated D&M –DPM Services
• Constant Bottom Hole Pressure Case Histories • Faster Response • Unplanned Events • Drilling • Connections • Pump Failure Event • Emergency Events • Close Loop Kick Detection
Confidential – do not distribute.
Introduction to DPM Segment The Schlumberger DPM segments provides MPD and UBD products and services . This segment was started after merger with Smith International. DPM Segment provides Rotating Control Devices –High Pressure RCDs, Intermediate Pressure RCDs and Low Pressure RCDs. Control Systems- Automated , Manual systems for reactive and proactive pressure control systems , Dynamic swab and surge compensation Kick detection with multiple automated indicators Separation -Multiphase separation vessels Nitrogen generation and injection Pressure Control Equipment- Chokes, Chokes Consoles, Carbon tracker, Pressure and fluid management, D-Gasser
Confidential – do not distribute.
Introduction to DPM Segment In addition to the MPD and UBD products and services, the Schlumberger DPM offers 1. UBD / MPD Drilling Engineering 2. UBD/MPD Well planning 3. UBD/MPD Project Management 4. UBD/MPD Drilling Optimisation 5. Trainings
Confidential – do not distribute.
GeoMarket Operations NAL
EAF
NAO
SLR
AKA
NSG
CAL
RUS
USL NAG
NGC
CHG ARM
MCA PCE
LAM
BRZ
ASE
EAG
ING
MEA
ASA
Confidential – do not distribute.
Overview of MPD Technology Pressure Related Drilling Risks • • • •
Lost circulation Gas influx / kicks Ballooning / breathing Wellbore instability – Stuck pipe – Annular pack-off – Twist-off
• Swab / surge • Unplanned cement jobs • Unplanned sidetracks
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Proactive MPD Methods to Mitigate Risks – Constant bottom hole pressure • Requires RCD & automated control
– Mud cap (pressurized or floating cap) • Requires RCD & manual control • Drill without returns
– Downhole Pumps • No RCD required but limits drilling
– Continuous Circulation • No RCD required but requires backup BHP control
– Dual Gradient • Technology unavailable
Confidential – do not distribute.
MPD Technology for extreme environments Deep Water
• Kick detection • Narrow margin • ECD reduction • Loss avoidance • Wellbore stability
8
ERD Horizontal
Mature Depleted On & Off Shore
HPHT
• Wellbore breathing avoidance • Narrow margin • Kick detection • ECD reduction • ECD reduction • Narrow margin • Loss avoidance • Loss avoidance • Wellbore stability • Stuck pipe avoidance • Wellbore stability • Loss avoidance • Hole cleaning • Kick detection • Pressure • Drilling optimization • Drilling optimization environment • Reservoir damage detection (Dynamic Flow-in/Leak-Off)
Fractured Reservoirs
• Kick detection • Controlled losses • Reservoir damage
Confidential – do not distribute.
Performance Benefits Summary • Extend the life of a mature producing fields • Increase productivity in tight pressure margins
• Expand drilling in marginal fields • Prevent reservoir damage • Construct wells with difficult, even impossible, to drill margins • Eliminate lost circulation in narrow margins • Increase wellbore stability • Minimize risk of costly, unplanned well control events • Improve drilling safety • Avoid unplanned sidetracks • Reduce non-productive time
• Increase drill rates • Risk of influx
Confidential – do not distribute.
Global Experience
10
Confidential – do not distribute.
Deepwater Experience
Global DW experience: • 1st approved use by MMS (Minerals Management Services) of automated MPD system in GOM • 1st approved use of automated MPD with statically underbalanced mud in DW GOM • 1st closed loop automated bottomhole pressure control with PWD on WDP • 1st use of automated MPD in west Africa Confidential – do not distribute.
HPHT Experience
Global HPHT experience: • 1st use of automated MPD geothermal reservoir • 1st use of automated MPD in North Sea HPHT • 1st use in south Texas to drill HPHT with CwD • 1st use of automated MPD in southern Mexico HPHT Confidential – do not distribute.
HPHT Experience 7 Projects (300-400 Deg F)-10k to 20k psi BHP 3 Projects (400 – 500 Deg F) – up to 25k psi BHP
Confidential – do not distribute.
HPHT Experience
Confidential – do not distribute.
Primary Pressure Barrier Conventional Drilling Pumps-off
BHPstatic = Pmud
Pumps-on
BHPdynamic = Pmud + Pfriction
Managed Pressure Drilling Pumps-off
BHPstatic = Pmud + Pbp
Pumps-on
BHPdynamic = Pmud + Pfriction + Pbp Confidential – do not distribute.
Pressure Limits
Known limits
Plot of PP, stability, and FP showing depleted zone in 6” hole. Maximum allowable margin is 0.8 ppg. Confidential – do not distribute.
Pressure Limits
High mud weight required for stability – makes ECD greater than FP. Lost circulation is unavoidable. Confidential – do not distribute.
Pressure Limits
ECD 1.0 ppg
Safety margin 0.3 ppg
MPD solution: reduce ECD by reducing MW below PP. Use MPD for constant BHP control. Confidential – do not distribute.
MPD Back Pressure Principle Dynamic Surface Back Pressure Surface Back Pressure (BP) 0
Conventional
Pressure
Higher dynamic gradient, therefore reduce Back Pressure while drilling
Static Pressure Dynamic Pressure
MPD Static Pressure Static Pressure + BP Dynamic Pressure + BP
Drilling window
19
Depth
Confidential – do not distribute.
Existing Rig System for Conventional Drilling
Rig Pump BOP Rig Mud System
20
Confidential – do not distribute.
Additional Equipment for MPD
Rig Pump RCD
Choke
BOP Rig Mud System
21
Confidential – do not distribute.
Rotating Control Device
Rig Pump RCD
Choke
BOP Rig Mud System
22
Confidential – do not distribute.
RCDs In Wellhead
Optimal RCD 5000 psi
HOLD RCD 5000 psi Confidential – do not distribute.
Choke Manifold
Rig Pump RCD
Choke
BOP Rig Mud System
24
Confidential – do not distribute.
Additional Equipment for @balance Automated MPD
Hydraulic Model & Automated Control
Rig Pump RCD
BOP
Automatic Choke
Flow meter
Rig Mud System
Back Pressure Pump
25
Confidential – do not distribute.
Typical Modular MPD Surface Equipment
26
26
Confidential – do not distribute.
MPD Systems Layout
Confidential – do not distribute.
MPD Systems Layout
Confidential – do not distribute.
Drilling Engineering Services • Opportunity assessment • Engineering analysis • Well planning • Well execution
• Well summary
Confidential – do not distribute.
Drilling Engineering Services • Opportunity assessment – Identify drilling problems – Define client objectives – Gather offset & planned well data – Perform engineering quick look recommendation
• Engineering analysis
PP
Surface MW
PPECD
FG
– Develop well pressure profile – Hole section analysis and design – Configure system – Recommend rig interface Static BHP
Confidential – do not distribute.
Drilling Engineering Services – Assessment • Review – Offset drilling data and reports – Anticipated pressure related problems – Potential trouble zones and well control hazards
• Analysis – Well plan and geometry – Pressure profile and margins – Hydraulics and drilling fluids
Confidential – do not distribute.
Drilling Engineering Services – Assessment • Recommendations – Rig survey – preparation and installation – Pressure limits and equipment requirements
• Planning – HazID / HazOP – Procedures and contingencies – drilling, tripping, testing – Personnel training
Confidential – do not distribute.
Drilling Engineering Services • Well planning – Rig survey
– Equipment layout – Define roles and responsibilities – Develop procedures and contingencies – Hold HazID / HazOP workshops – Train rig crew – Conduct contingency scenarios
Rig elect-tech to spot j-box & pwr supply for DAPC manifold & pump 480v/225amp
Place MPD control in ML unit, if room.
Spot DAPC choke, pump and flow meter here, aft end of cantilever deck, near Shaker Box Possible location of spares container and cabin if no room in ML unit.
Confidential – do not distribute.
Drilling Engineering Services • Operations support – Hydraulics model updates
– Engineering program updates – Plan and supervise dynamic leakoff / flow tests – Manage and analyze drilling events
27,800ft
Confidential – do not distribute.
Drilling Engineering Services • Well summary – Performance summary
– After action review – Event analysis – Best practices and lessons learned – Operations and drilling recommendations
Mud roll-over
Confidential – do not distribute.
DPM – MPD Systems • Rotating control devices • Control Systems • Kick detection
Confidential – do not distribute.
Rotating Control Devices
Flow line Hydraulic valve 7 1/16” x 5K
4”/6” x 5kpsi line to choke manifold RCD diverter RCD
Confidential – do not distribute.
Rotating Control Devices • HOLD 25 – Two piece design
– Hydraulically operated remote lockdown RCD – Eliminates need for RCD personnel to climb the wellhead
– Low pressure riser connects to rig bell nipple – Dual sealing elements
HOLD 25 RCD Operating Parameters Parameter Value Rotating Test Pressure 2500 psi* Static Shell Test Pressure 5000 psi* Static Pressure Rating 2500 psi** Stripping Pressure Rating 1250 psi** Bearing through-bore ID 12 ¼” Mounting spool through-bore ID 13 5/8” Side Outlet - Diverter 7 1/16” Maximum RPM 150 rpm *w/ test plug. **API 16RCD (w/ 5 ½” SE p/n 80001278) Confidential – do not distribute.
Rotating Control Devices
HOLD 25 with Low Pressure Riser Confidential – do not distribute.
Rotating Control Devices • Optimal – Compact high pressure design
– Integrated sealed bearing RCD – Robust, long life seals – Dual sealing elements RCD5 2000 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
RCD3 1000 psi @ 100 rpm Bore Diameter with bearing in / mm 7 1/16 179.4 9 1/16 230.2
without bearing in / mm 11 279.4 13 5/8 346.1
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
Confidential – do not distribute.
Rotating Control Devices Especificaciones Presión Estática
5,000 psi
Presión Dinámica
2,500 psi @ 120 RPM
Alto y Ancho
44.5” (1.13 m) / 30” (0.76 m)
Paso
9 1/16” con balero 13 5/8” sin balero
Brida Inferior
13 5/8” - 5,000 psi
Confidential – do not distribute.
Rotating Control Devices
Optimal RCD5 rigged up on multiphase MPD jobs in Mexico Confidential – do not distribute.
Rotating Control Devices • Low Pressure RCD – Low pressure RCD for onshore applications – Sub-compact, single piece designs – Robust bearing assemblies
LP 7068, short profile, low pressure RCD
LP 7368, low pressure RCD for land rigs Confidential – do not distribute.
Control Systems • @balance DAPC
DAPC system rigged up on DW GOM platform
– High degree of control – Fast, precise automated response – Real-time hydraulics model – Automated back pressure pump – Safety critical Dynamic Pressure Relief to manage weaker zones – Safety critical Manual Over Ride
• M-I SWACO LPAC – Accurate, low pressure manual control – Small, economical footprint – Fast, precise autochoke response LPAC control console in front, manifold behind
Confidential – do not distribute.
Managed Pressure Drilling Systems
Confidential – do not distribute.
Managed Pressure Drilling Systems
Confidential – do not distribute.
Managed Pressure Drilling Systems EnSure DAPC system rigged up on HPHT well in Libya
Confidential – do not distribute.
MPD Early Kick Detection System • @balance Kick Detection – Coriolis meter measures flow out – Direct link to the MPD system eliminates delays – System monitors and tracks deltaflow and issues alarms when it exceeds preset limits – Early detection reduces kick volume – Meter active during connections when backpressure pump on – Early detection used for dynamic leak-off and flow tests
Flow detected with meter (step 8 & 9)
KDS used to detect flow during PP determination test with the DAPC system Confidential – do not distribute.
Integrated D&M –DPM Services Automated Rotary Steerable • Better bore hole Quality •Faster ROPs •Remote downlinks therefore Driller more focused •DD works remotely with well Engineering team •Improved Drilling Performance •Opportunity to assist younger DDs remotely Automated Pressure Control (DAPC)
Wired Drill Pipe •Addresses limitations of mud-pulse and E-mag •Enabler for ERD, UBD, MPD, deep water & automated drilling •Enabler for RT drilling optimization, well placement, wellbore stability •Maximize drilling efficiency and risk mitigation •Improved reliability via advanced real time troubleshooting •Enabler for active formation testing and sampling
Improved Drilling Performance , Improved Safety , Shared Knowledge
Automation & Remote Ops
Wired Drill Pipe Automated RSS,M/LWD
Remote Ops 24/7
Dynamic Annular Pressure Control (DAPC) •Safety critical process technology •Early kick detection •Automated choke operation & switching •Redundant, fast acting chokes •Automated backpressure pump •On-demand backpressure supply •Real-time hydraulics modeling •Continuous model calibration* •Remote operation and control •Pressure stability within +/- 50 psi •Programmable alarms and trend monitoring
Remote Operations The minimum requirements are: • Dedicated phone line with dedicated 256-kb/s bandwidth • Dedicated static internet protocol (IP) address • Remote access permission to wellsite IT staff • Ties to wellsite telecommunications systems beneficial to remote support. Confidential – do not distribute.
Case Histories
Confidential – do not distribute.
Example -1 Managing the Barrier during Transitions Connections
Confidential Slide 51 – do not distribute.
Example-2 Managing the Barrier during Transitions – Pump Failure
Confidential Slide 52 – do not distribute.
Example-3 Managing the Barrier during Transitions – Fire Drill Unannounced Fire Drill on Deepwater GOM Rig Unannounced Fire Drill
Confidential – do not distribute.
Example-4 Managing the Barrier POOH with Swab
Confidential – do not distribute.
Example 5: GOM HPHT - Loss Determination
EMW increased to 18.48 ppg Start of leak-off test EMW=18.38 ppg
EMW reduced to 18.48 ppg
Backpressure increased to 330 psi
EMW reduced to 18.38 ppg
Pumps on Backpressure increased to 185 psi
Pumps off EMW 18.22 ppg
Time (h)
Equivalent Mud Weight (pounds per gallon)
EMW increased to 18.58 Observed immediate losses
Confidential – do not distribute.
Example-6 Wellbore Breathing Eliminated
Connection #5 – wellbore breathing eliminated BHP constant
Confidential – do not distribute.
Example-7 Malay Basin Drilling Challenges • Borehole instability: requires high mud weight which gives high ECDs – up to 2000 psi overbalance • Severely depleted zones then create differential sticking
• Narrow margins (Stability v Frac Gradient) with losses • Coal beds: Unstable & troublesome in most wells • Hole cleaning Non-Productive Time (NPT): – Cuttings deposits & annular loading – Back reaming 3x per stand – High viscosity sweeps – Bottoms-up circulation
Confidential – do not distribute.
ECD in 8.5” Conventionally Drilled Hole
8.5” hole – upper section drilled conventionally with 10.2 ppg mud Highly variable ECD – swab/surge spikes - increasing from 11.0 to over 12.2 ppg through hole section
Confidential – do not distribute.
ECD in 8.5” Hole with MPD
8.5” hole – lower section drilled with automated MPD control & 9.0 ppg ECD steady between 10.5 and 11.0 ppg
Confidential – do not distribute.
Swab / surge in 8 ½” hole w/ MPD
ECD maintained between 10.3 to 11.3 ppg
Confidential – do not distribute.
Offset Non-productive Flat Time NPT due to hole cleaning
80 stands Back reaming: 2-3 Xs per stand 40-50 min/stand 53 hrs (2.2 days)
NPT / back ream cost: 2.2 days @ $375,000 per day = $825,000 Confidential – do not distribute.
BKC-WW ST Depth VS Time w/ MPD Reduced back reaming due to reduced cyclic stressing of formation while drilling using MPD
Reduced flat time for hole cleaning 35 stands Back reaming: 1-2 Xs per stand 30 min per stand +/-17.5 h
WW w/MPD: Drilled 520 m/d Offset w/o MPD: Drilled 275 m/d
Saved 1.7 days @ $375,000 per day = $637,500 Confidential – do not distribute.
Example -8 Far East Exploration Well Project Challenges: • Low shoe strength • Narrow Pore Pressure/Fracture Window • Shallow hazard depth • Potential Risks – Large volume of gas at shoe & in riser – Shut-in pressure breaks down shoe – Gas seepage to seafloor – HSE risk to people and rig Customer Decision: • Well undrillable within HSE management system with standard technology • Requires intelligent, rapid-response, automated bottom hole pressure control system 63
Confidential – do not distribute.
Well Location
• Operator evaluated 3 locations relative to gas cap • Final location (Opt 3) placed shoe 100 m below crest • Estimated pressure margin about 200 psi Confidential – do not distribute.
MWD Assembly with PWD Critical MWD features for closed loop MPD: • Update rate – 2 sec updates needed for Annular PWD • Power – Selectable sources – Flow independent battery power – Mud pulse turbine to save battery • Downhole programmable
Courtesy Baker Hughes INTEQ
Confidential – do not distribute.
Drill String Telemetry IntelliPipe Drill String
Courtesy IntelliServ Inc.
• • • • •
Data cable fixed in drill pipe Inductive coupler in each joint Battery powered repeater ~ 500m Telemetry rate of 57.6 kbps (up to 2 Mbps) Surface transmission via Swivel sub Confidential – do not distribute.
Highly Accurate Bottom Hole Pressure Control Pump rate (gpm) Bottom hole Pressure (psi)
Back pressure (psi)
Bottom hole pressure held within +/-50 psi at connections
Back pressure held within +/-15 psi during drilling
Fully automated system delivered
