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Successful Testing of Single Gradient Subsea MudLift Drilling Technology in Deep Water Gulf of Mexico
Successful Testing of Single Gradient Subsea MudLift Drilling Technology in Deep Water Gulf of Mexico
Abstract
Subsea MudLift Drilling (SMD) technology is a form of Managed Pressure Drilling (MPD). Similar to
other MPD systems the SMD technology offers early detection of influxes (kicks) and minimizes
downhole losses to weak sub-surface formations. However, very significant and beneficial differences are
built into the SMD system.
Two variations of Subsea MudLift Drilling techniques are currently being tested in deepwater Gulf of
Mexico:
1. SMD Dual gradient (SMD-D) technology also known as dual gradient drilling, and
2. SMD Single gradient (SMD-S) technology also known as single gradient managed pressure
drilling.
In deepwater drilling operations, the effect of annular friction pressure (AFP) often reduces the drilling
window between pore pressure and fracture pressure. The SMD-S technique allows for the reduction of
the dynamic bottom hole pressure by pumping off a portion of the AFP while drilling. Through greater
management of the bottom hole pressure, this technology enables efficient navigation between the pore
pressure and fracture gradient profile. As a result, tremendous value can be realized through reduction of
non-productive time and the drilling cycle time. Further, the technology may enable drilling highly
deviated extended reach wells in a deepwater environment, which can potentially increase total recovery
with reduced well count.
The SMD-S system was successfully tested on one of Chevrons Deepwater GOM exploration wells.
This deployment was the penultimate step in an extensive testing and qualification process to ensure the
equipment functioned in accordance with all required design conditions, and that the operational
procedures allowed for delivering a well safely. In addition to training key operator personnel, rig
contractor, and service company personnel, engagement of third party reviewers and regulatory agencies
was critical throughout the process.
Lessons learned were recorded and corrective actions implemented throughout the process, from initial
testing at the component level through the subsea deployment of the entire system. As these items are
addressed and incorporated back into the equipment design, training, and operational procedures, a plan
is in development to drill an entire well utilizing the SMD-S technology.
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This paper will highlight the benefits of SMD-S technology, the execution of the most recent
deployment and test results that are the final steps in moving towards continued managed pressure drilling
operations in the deepwater GOM.
Introduction
Subsea MudLift Drilling is a sophisticated subsea managed pressure drilling technology development and
commercialization project that has just completed its fourth offshore deployment. With every deployment,
the learnings were captured and successfully addressed. The most recent deployment in deep water Gulf
of Mexico (GOM), has demonstrated that the technology works as designed by successfully accomplishing nearly all test objectives. The confidence is now very high that the industry will see the successful
commercial delivery of a world class drilling technology that offers potential for a more efficient drilling
operation. In addition, this technology will ultimately lead to enhanced production and recovery from deep
water assets.
Technology description
The Subsea MudLift Drilling (SMD) system has two operational modes (Figure 1).
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Pressure can be pumped off during circulation or trapped during connections with the MLP by reducing
or adding pressure below the SRD to offset the effect of annular friction pressure as the rig pumps are
ramped up to the drilling flow rate. This effectively allows the system to maintain a dynamic bottom hole
pressure (BHP) in the well which is approximately equivalent to the static BHP, thereby providing greatly
improved stability through tight pressure windows as commonly seen in the deep water Gulf of Mexico.
Note that a unique attribute of the SMD-S system is the ability to pump off AFP from under the bearing
latch assembly (BLA) in the SRD. In this configuration, the well is always hydrostatically over-balanced,
even in the event of an equipment failure or unplanned loss of power to the system.
SMD equipment testing
In order to safely and reliably perform SMD-S drilling, the SMD system hardware and operating
procedures were required to satisfy a number of basic requirements. The system needed to demonstrate
defined performance criteria of all routine drilling operations, safely manage non-routine drilling operations (e.g., well control and lost circulation events, etc.) and maintain the well in a safe condition in the
event of equipment failure.
Overall, cased-hole testing results were very positive and the technology concept was successfully
validated along with the mechanical and operational viability of the MLP and the SRD to perform
single-gradient managed pressure drilling operations. 44 test objectives were attempted during the testing
sequence and successfully passed 43 test objectives.
The main focus of the testing program for SMD-S was to determine the stability of the MLP inlet
pressure and the ability to manage the wellbore pressure profile within a controlled and predictable range.
Routine drilling procedures were tested in cased-hole, with special emphasis on the start and stop
circulation procedure while controlling AFP. Further, an assessment of the MLP inlet pressure control
while tripping pipe through the bearing latching assembly (BLA) installed on the SRD was done, as well
as verifying the ability of the pump to maintain a close to constant bottom hole pressure during these
operations. Within the non-routine operations, the ability to detect a kick and respond to a potential
equipment failure was also tested.
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sequence, logic errors were noticed during MLP ramp up which needed the manual intervention of the
system operators to correct.
The BHP tracked the MLP inlet pressure during the connection procedure test. This test demonstrated
that the bottom hole static density (ESD) and bottom hole circulating density (ECD) can be precisely
controlled by using the SMD-S technique (Figure 3).
Kick Detection
The purpose of this test was to verify the kick detection mechanism with the SMD system and test the
ability to shut in and line up to circulate out a kick conventionally. During the test, the drill crew was able
to identify the influx in less than a 2 bbl gain in the system, even with the low influx rate of only 25 gpm.
The kick detection capability of the pump worked as designed (Figure 4).
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Benefits of SMD-S
The cased hole test results proved the operational concept of the SMD system and the effectiveness of the
drilling procedures as they were designed and risk assessed.
Wells currently on the deepwater Gulf of Mexico portfolio will benefit from the application of the
technology in the following areas:
SMD-S will improve the likelihood of accessing the top of the Wilcox formation with larger drift
by eliminating the contingency casing strings that are set as a result of dealing with losses and
kicks encountered while drilling through tight pressure windows.
By adjusting the MLP inlet pressure, SMD-S will allow better management of the BHP to mitigate
or eliminate losses when drilling through tight margins.
Ballooning can be mitigated by maintaining near constant BHP during drilling.
Figure 6 depicts typical deepwater Gulf of Mexico lower tertiary well where the application of SMD
can potentially allow extending the open hole by mitigating the encountered drilling hazards.
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Once the SMD-S technology is successfully implemented, testing of SMD-D (Dual Gradient Drilling)
will commence. It is notable that the equipment used for SMD-D is unchanged from SMD-S, so testing
of the dual gradient capabilities is effectively an operational procedure test.
SMD-D remains the ultimate objective, as this is the only technology available today that offers the
ability to eliminate casing strings in a deepwater well while maintaining all conventional drilling margins.
While eliminating casing strings does save drilling time and reduces mechanical risk in deepwater wells
from tight mechanical clearances, the real value-adding benefit is that it offers the ability to reach a
reservoir with larger casings than conventional single gradient MPD systems can. This opens the door to
production enhancement opportunities not available today.
Abbreviations and Definitions
AFP (psi): Annular Friction Pressure
BLA : Bearing Latching Assembly
ESD (ppg): Equivalent Static Density.
ECD (ppg): Equivalent circulating Density
Drilling Window (psi or ppg): Difference between pore pressure (PP)
and fracture gradient (FG).
Drilling Margin (psi or ppg): Difference between leak-off test/formation integrity test
(LOT/FIT) at the previous shoe and
the MW (Downhole).
References
1. K.L. Smith, P.E., SPE, Conoco, A.D. Gault, P.E., SPE, Conoco, D.E. Witt, SPE, Conoco; and
C.E. Weddle, P.E., SPE, Cherokee Engineering, SubSea MudLift Drilling Joint Industry Project:
Delivering Dual Gradient Drilling Technology to Industry, SPE 71357, SPE Annual Technical
Conference, New Orleans 2001.
2. J. P. Schumacher, SPE, Texaco, Inc.; J. D. Dowell, SPE, Texaco, Inc.; L. R. Ribbeck, SPE,
Texaco Inc.; and J. C. Eggemeyer, SPE, Conoco Inc., Subsea Mudlift Drilling: Planning and
Preparation for the First Subsea Field Test of a Full-Scale Dual Gradient Drilling System at Green
Canyon 136, Gulf of Mexico, SPE 71358, SPE Annual Technical Conference, New Orleans 2001.
3. J.D. Dowell, Chevron, Deploying the worlds first commercial dual gradient drilling system, SPE
137319, SPE deepwater drilling and completions conference, Galveston, TX 2010.