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The diverter and its use

Shallow Gas

Introduction to shallow gas

Shallow Gas has clamed more lives and rigs than any other type of Blowouts it is therefore imperative the drilling crew understand the dangers associated with shallow gas Petro genesis is the process where Kerogen is degraded to hydrocarbons (oil and gas) at to high pressure and temperature. Kerogen is a complex hydrocarbon which is created due to biological degradation of organic material. Shallow gas formed by biogenesis is mainly composed of methane (CH4) (+/99%), 0.5% carbon dioxide (CO2), less than 0.5% nitrogen (N2), and less than 0.5% ethane (C2H6). Hydrogen sulphide (H2S) can also occur in small amounts.

Shallow gas formed by petrogenesis is mainly made up of the heavier hydrocarbons, ethane, propane, butane, rather than methane. Shallow gas usually occurs in small, isolated sand lenses at shallow depths (O - 1000 meters), with a thickness seldom greater than 15 meters.
Due to the limited horizontal extent of these sand lenses, it is dangerous to assume that a given area is free from shallow gas, even though several offset wells have shown no trace of shallow gas.

The Gullfaks field in the Norwegian sector of the North Sea is an example of this. The first 9 exploration wells were more or less fee of shallow gas, but the 10th well experienced a shallow gas blowout. The well was drilled with the semisubmersible drilling platform Nordskald (later Glomar Biscay II) in 1980.

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Sand lenses which contain shallow gas usually have normal pressure at the base of the formation, and a small overpressure at the top. The vertical thickness of the formation determines the size of the overpressure. This is due to the difference in density between the gas and the formation water. Such formations usually have high porosity (>40%) and high permeability (0.5 50 Darcy). that leads to very high productivity when first penetrated and the well becomes underbalanced, that often cause a very rapid evacuation of mud from the well. Time available between the identification of possible shallow gas and the execution of the necessary corrective actions is therefore very short. For example, when the semi-submersible 'West Vanguard' had a shallow gas blowout on Haltenbanken offshore Norway in 1985. it only took between 20 and 30 minutes from the identification of shallow gas to the first explosion Due to all the problems connected with drilling through formations containing shallow gas, it is necessary during the planning phase to attempt to map the potential drilling locations for indications of shallow gas. Organic material (kerogen) broken down by bacteria becomes hydrocarbons. (oil and gas) when subjected to high pressure and high temperature. Gas then migrates along fault surfaces to shallower sand layers. If shallow gas is identified as being probable, the surface location can then be moved. Even if there are no indications of shallow gas at a drilling location, precautions for the possible occurrence of shallow gas should still be taken. Good procedures are necessary to ensure a safe drilling operation in case shallow gas should occur.

So how do we deal with it we divert over the side

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Diverters
There are basically two types of diverter, over the past 5 years we have installed both on our new build The bell nipple The fixed diverter Rotary and rig floor Diverter housing or fixed housing over board lines Fill up line Handling tool

Connection
Return flow line Extension This is the best system cost a little more but save a lot of work, and is a lot safer Not all Bell nipples have a fixed housing Overshot Joint

Overshot packer

hydraulically operated valves and diverting spool

Annular Preventer Over board line

Surface casing and well head or drive pipe

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Introduction to the fixed Diverter system

The Diverter Nipple System contains the flow of well bore fluids as they enter and/or return from the well to the surface. Such a system is not designed to control pressure and is open to the atmosphere at the Diverter Nipple Housing. The system is specifically designed for jack up drilling operations, however such systems are now being used on floating rigs

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The Diverter
the fixed housing
500 psi test line
Port side overboard line Salt water inlet line

Return flow line

Fill up line from trip tank

Starboard side overboard line

The Support Housing is the uppermost component of the diverter nipple system. This unit is bolted to the rotary support beams below the drill floor. The housing is configured with outlet pipes of various sizes and orientation. These outlet pipes connect the Housing to the mud fill-up line and the over flow line. The lower end of the Housing is configured with a landing shoulder, bulk seals, and hydraulic cylinders that support and lock the over shot adapter to the housing.

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Valves
All valve in the system are Hydraulically operated with the exception of the main testing line on the stand pipe manifold The overboard valve seen here is in the open in the open position, all valves can be operated from 3 main positions on the rig, Remote panels The rig floor Toolpushers office Main control unit Accumulator control unit 14 Overboard line Note: straight run from diverter to overboard

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Diverter used with BOP

Overshot packer and hydraulic line
Inner barrel, slides up inside the overshot allowing the overshot packer to close and seal

This may or may not be the BOPs on your rig, they are just to show the final configuration when using the diverter with the BOP,

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Fixed diverter Housing

The diverter complete with extension and overshot are lowered through the rotary until the overshot slips over the inner barrel that is mounted on the top of the annular preventer

Hydraulics Shutoff Valve Rotary skid Main rotary beam

Hydraulics Shutoff Valve

Doubler Plates

Fixed diverter Housing

Overboard line

Pressure Ratings
500 PSI - 4 DOG 1000 PSI - 4 DOG 2000 PSI - 6 DOG

Overboard line

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KFDJ Diverter Lockdown Options

There are two different type of locking system, a) the use of locking dogs, b) Jay and turn

Hydraulic Lockdown
Hydraulic pressure pushes the dog in to seat into the element housing

Model J Locking System

Differences between systems based upon pressure ratings

End flange ratings

Pipe wall thickness

Diverter housing wall thickness

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A Fixed diverter housing with the diverter assemble installed ready to move, the diverter is often left install for rig move the extension and overshot are laid down and tied off

Doubler Plates
Doubler Plates are used as a mounting bracket for the diverter housing.

Threaded profile to receive mounting bolts. Beveled profile for welding the Doubler plates to the rotary beams

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Used as slips: They are opened up and raped around the joint once the lower pad eye has passed they are connected up and the joint is lowered and sits on the upper pad eyes, The hanging assembly is then lowered and connected up

This is the manufacture recommended way of picking up the joints however this way you need two clamps one to sit down on the other to pick up with

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EC-6 Handling Clamp

The handling clamp is used to pick-up and land out the overshot packer and spool assemblies in the rotary during the make-up and break out phases.
The handling clamp is split and hinged for ease of operation. Here you see the clamp sitting on the rotary and being used a slips to make up the system See make up sequence to see the easy way of doing thing Pin

Split Clamp

Rotary table

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The overshot
Protector, protecting threads on box end Internal seal: check before making up Overshot Packer: A tubular device or riser with a rubber packer element on the lower end and typically an EC-6 box on the upper end. The Overshot Packer stabs over a plain pipe extension or mandrel. In a standard system, two Overshot Packers are normally furnished. One is for 30 pipe and a smaller unit to be used over the adapter or Overshot Mandrel that connects to the top of the wellhead or BOP. The packer element is energized by hydraulic pressure from the diverter control system. The Overshot Packers also come equipped with wash out ports to clean the annulus above the seal and in between the 0D of the pipe or mandrel and the ID of the Overshot Packer housing.

Top pad eyes can be used to sit on clamp when making up

rubber packer element

Overshot outer barrel

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Overshot Mandrel:
Overshot Packer over this end Overshot Mandrel is a piece of plain end pipe or tube with an API compatible flange or a customer specified connection on the lower end. The Overshot Mandrel, when flanged up to the top of the BOP or wellhead, provides a means for the Overshot Packer to seal off the wellbore. Note the marking on the Overshot Mandrel Before the overshot is installed the top 5 or 6 feet should be well greased

The diverter assembly laid out on deck ready to be picking up and run

Well head or Bop this end

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EEC-6 Coupling
EC-6 coupling with 50 ft-Ib torque.

This stab type connector utilizes a large lip seal.

Box protector never pick up without it

EC-6 box with external thread

The EC-6 Coupling is used to connect the diverter assembly to the overshot spool and overshot packer. After the connector is stabbed, a coarse acme thread on the EC-6 pin is made-up to the EC-6 box external thread.

EC-6 female box pin with rotating threaded

Pin protector never pick up without it Before making up the connection check the internal seals are in good condition any damaged seal need to be replaced

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EC-6 Handling Clamp

The EC-6 handling clamp is used to pick-up and land out the overshot packer and spool assemblies in the rotary during the make-up and break out phases. The handling clamp is split and hinged for ease of operation. Used as slips: They are opened up and raped around the joint once the lower pad eye has passed they are connected up and the joint is lowered and sits on the upper pad eyes, The hanging assembly is then lowered and connected up

EC-6 box with external thread

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Starting ..
Lower pin into box gently so as not to damage the seal

Screw on connetion

External threads Pin

Wedge Shape seal counter sunk into grove, always check before making up connection and always apply a light coat of fine greases before making up

Make up the connection to 50 ft/lbs using a round bar about 18 long through the make up holes Box End

Pick up on load, there should be no movement

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Overshot packer

Pressure line connection

30 overshot packing as is being installed on many of the rigs we are building

Sealing area maximum pressure used to close the packer is 750 PSI

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Overshot
There are a few point that have to be taken into consideration. If installed as the riser with the BOPs the bell nipple flange connecting to the annular must be made up tight. The overshot pack off must never be closed without pipe inside and the right size overshot must be used. Always clean and greases the stump the overshot is to go over.

Too Long It will fill with cuttings

If drilling out a lot of cement or fast soft drilling, take a little time to flush out the diverter lines once a day Never ever allow welder to weld around it and drop the rod end on the rotary "Having to pull the inner diverter from the housing with half a ton of old burn of welding rod down the side is a sure way to wreck the block and hook Always clean before installing Click for animation

Casing

Too Short The packer will collapse

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Diverter Assembly
The diverter assembly is either hydraulically locked or locked with right hand J which positively aligns the outlets of the diverter with the outlets in the support housing.

Hydraulically actuated seals to isolate the flow lines, overboard lines and fill-up lines between the diverter and the support housing.
Flow line Seals: Elastomer seals used to provide a seal between the Diverter and the support housing. They are energized with hydraulic pressure from the diverter control system. They may either have integral lip seals or o-rings for pressure retention. J-Ring: Mechanical device that provides a means to retain the Insert Packer in the Diverter Assembly.

Here we see the diverter assembly made up and ready to run , below it hangs the extension outer barrel and overshot sections

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Heavy duty construction of outlet ports offers improved erosion protection from high velocity multi-phase flow. Here we can see the overboard lines, these are often used to pick up the overshot packer

Overboard Lines There are two overboard lines, one port the other to starboard the system is designed so that both can not be opened at the same time unless you use the override or test function Return Flow Line

There is a test port leading from the stand pipe manifold that allows the system to be tested after installation

Fill-up or trip tank Line

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Diverter Insert Packers

Diverter Packer and Insert Packer: are rubber bag type elements used to close around drill pipe and casing.. They are energized with hydraulic pressure from the diverter control system.

Split Insert Packer

Solid Insert Packer

17-3/4 Insert Packer closed on 9 5/8 casing

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Test Tool
The function of the test tool is to test the entire diverter system and valves. The KFDJ Test Tool is made up to the bottom of the 10 ID insert running tool. It is lowered and locked into the diverter support housing along with the insert packer assemblies. Maximum test pressures with the test tool installed on standard handling tools are: 37 R.T., 27.50 ID ------ 500 PSI 49 R.T., 27.50 ID -500 PSI 49 R.T., 36.50 ID -400 PSI API minimum recommended test pressure is 200 PSI. Diverter handling tool

Hydraulic lockdown with tool

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The real thing

Diverter handling tool, designed to pick up the complete diverter system, insert into packer insert, turn jay to right, drop down locking lever and install safety pin , pick up and install on test tool

packer insert can be solid or split

Test tool screws into handling tool to test diverter install tool complete system into diverter housing and pressure up from stand pipe manifold

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Handling Tools
J ring is bolted to diverter assembly and subsequent insert packers. The right hand J profile allows for easy installation and removal of subsequent insert packers. ( IE 22, 17 , 15 and 10 Insert packers). Use to lift the complete assembly

Safety Latch and pin

Use to insert the packing element A J type tool is used to run and retrieve the diverter assemble as well as the 22, 17- and 15 ID packer inserts. This J profile also allows the mechanical locking of the test tool to the diverter. A separate tool is used for running the 10 ID packer insert inside the 17 ID insert packer and also used in conjunction with the Test Tool for pressure testing the Diverter assembly.

The standard tool is supplied with 4 IF box up and pin down J profile in insert ring to accept J type tool.

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Piping and Manifolds Conformity of Piping Systems

Knowing the piping under the rig floor and in the pump room is being professional.

Different rigs may have different systems and drawworks but they all do the same job.
It wont take an hour of your time to check it out, testing the BOP properly cost the industry millions a year.

Why? people do not know their piping and the basic equipment. All piping components and all threaded pipe connections should conform to the design and tolerance specifications ANSI B 2.1.
All rigid or flexible lines between the control system and the BOP stack should be fire-resistant including end connections, and should have a working pressure equal to the design working pressure of the BOP control system. All control system interconnect piping, tubing, hose, linkages, etc., should be protected from damage from drilling operations, drilling equipment movement and day-to-day personnel operations

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Stand pipe manifold

Pipe size = 6.75 * 5 7500 psi CWP Stand pipe Stand pipe

To choke manifold

Test manifold

Stand pipe from pump room

Stand pipe from pump room

To cement manifold

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Test Line
The line leading from the stand pipe manifold into the diverter housing

Also seen here are the hydraulic line that open and close the valve

The 4 inc hydraulically operated valve can be remotely operated from the drillers cabin, toolpushers office or the main accumulator unit and is used to test the diverter , the line comes off of the stand pipe manifold , the valve on the stand pipe is a manual valve there should be to as the stand pipe is 7500 psi and this line is rated at 500 psi

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Trip tank line or fill up

The trip tank line should be designed in such a way that you can circulate the trip tank across the wellhead while at the same time fill the second trip tank the line normally 4 should continue on to the casing fill up and as a hot line to the Mud gas separator, the valve leading to the diverter should be hydraulically operated from the diverter control penal in the drillers control room . It is very important that the trip tank line be flushed through every so often while drilling for long periods or after a cement job if cement has been brought back to surface, over the years I have had the misfortune of having to cut out lines or chip cement from the diverter due to the lack follow up after cementing

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Trip tank syste m

Finishing Point
Starting Point

Piping system

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