Drilling and Well Completion Rotary System Rotary System The rotary system includes all the equipment used to rotate drillstring, and therefore the drillbit ‘The rotary system consists of: Swivel Kelly Kotary drive Rotary ble Drill otringTop Drive system Has its own hive sPart of the hoisting system *Does not require kelly and kelly bushing A top drive system consists of a power swivel, driven by de electric motor. This power swivel is connected to the — traveling block and both components run along a vertical guide track which extends from below the crown block to within 3 yy meters of the rig floor. Rotary System The advantages ‘Lop Drive It enables complete 90° stands of pipe to be added to the string rather than the conventional 30' singles. This saves rig time since 2 out of every 3 connections are eliminated. When tripping out of the hole the power swivel can be easily stabbed into the string to allow circulation and string rotation when pulling out of hole, if necessary (e.g. to prevent stuck pipe)Top Drive system Has its own hive sPart of the hoisting system *Does not require kelly and kelly bushing A top drive system consists of a power swivel, driven by de electric motor. This power swivel is connected to the — traveling block and both components run along a vertical guide track which extends from below the crown block to within 3 yy meters of the rig floor. Rotary System The advantages ‘Lop Drive It enables complete 90° stands of pipe to be added to the string rather than the conventional 30' singles. This saves rig time since 2 out of every 3 connections are eliminated. When tripping out of the hole the power swivel can be easily stabbed into the string to allow circulation and string rotation when pulling out of hole, if necessary (e.g. to prevent stuck pipe)Rotary System Functioning of Top Dri (Adding a Stand) + Suspend the drillstring from slips, as in the conventional system, and stop circulation Break out the connection at the bottom of the power sub Unlatch the elevators and raise the block to the top of the densick Catch the next stand in the elevators, and stab the power sub into the top of the stand Make up the top and bottom connections of the stand Pick up the string, pull slips, start pumps and drill ahead Rotary System Disadvantages of Top Drive + Increase in topside weight on the rig + Electric and hydraulic control lines must be run up inside the derrick When drilling from a semi-submersible under heaving conditions the drillstring may bottom out during connections when the string is hung off in the slips. This could be overcome by drilling with doubles and a drilling sub which could be broken out like a kelly, This method however would reduce the time-saving advantages of the top drive systemWell control system Well control ; Prevention of uncontrolled flow of formation fluids from the wellbore. If pore pressure > hydrostatic pressure. influx of formation fluids (oil, gas or water) in the borehole is known as a kick. The well control system is designed to: + Detect a kick * Close-in the well at surface + Remove the formation fluid flowed into the well * Make the well safe Well control system Type of Well Control + Primary well control : Keeping the hole filled with mud to ensure that the hydrostatic mud pressure is sufficient to overcome formation pressure. Hydrostatic pressure P = 0.052 x MW x TVD Secondary well control : Using valves to prevent the flow of fluid from the well until such time as the well can be made safe.Well control system Detecting a kick * Sudden increase in the level of mud in the pits. + Mud flowing out of the well even in the stopped circulation system Well control system Detecting a kick * Alter removal of drillstring during a trip the well is filled with the mud. If the lesser mud consumption indicates kick a. 142—Twp alternative vitae arangemants fr ck a 12 Siar ain epamn epeseWell control system Detecting a kick + After removal of ... drillstring during a ~ wip the well is filled with the mud. If the lesser mud consumption indicates kick Fi. U2 Two stra Well control system Closing in the Well Blow out preventors (BOPs) are used Two tyes of BOP Annular preventor Ram type BOP Blind rams. Pipe rams Shear ramsWell control system Closing in the Well Annular seals off the annulus between the drillstring and the side of hole These are made of synthetic rubber which, when expanded, will seal off the cavity Figs 14 yi anne BOP Couey of yi) Well control system Closing in the Well Annular seals off the annulus between the drillstring and the side of hole These are made of synthetic rubber which, when expanded, will seal off the cavity Fig. 44 Example annulartype blowout preventerWell control system Closing in the Well Ram type BOP + blind rams - seal off in open hole + pipe rams - seal off around drillpipe + shear rams - sever drillpipe Well control system Closing in the Well BOP stackRia Components.) 5.4 Top Drive Systems Most offshore drilling rigs now have top drive systems installed in the derrick. A top drive system consists of a power swivel, driven by a 1000 hp dc electric motor, This power swivel is connecter to the travelling block anv hath components rn along a vertical guide track which extends from below the crown block to within 3 metres of the rig floor. The electric motor delivers aver 28000 ficlbs torque und ccan operate at 300 rpm, ‘The power swivel is remotely controlled from the driler’s console, and can be set back if nocoscary to allow conventional operations to be carried out, Apipe handling unit, which consists of 500 tonelevator system and a torque wrench, is suspeuntaal botow the power swivel, These ane usta io Lavah vut vonuvctions. A hydraulically actuated valve below the power swivel is used as a kelly cock. Atop drive system replaces the functions ofthe rotary table and allows the drillstring to be rotated rrom the top, using the power swivel Instead of a Kelly and rorary table (Figure 13). The power swivel replaces the conventional rotary system, although a conventional rotary table would generally, also De available as a back up. (The advantages of this system are: + Ttenables complete 90" stands of pipe to be added to the string rather than the conventional 30' singles. This saves rig time since 2 out of every 3 connections are eliminated. It also makes coring operations more efficient a1‘+ When (ripping out of the hole the power swivel can be easily stabbed into the string tallow citculation and string rotation when pulling ant afhole. iF necessary (cg, to prevent stuck pipe) + When tripping into the hole the powerswivel can be connected to allow any bridges to be drilled out without having to pick up the kelly 106-4 Ceneral Arrangement & Components Figure 13 Top drive system (Courtesy of Varco) ‘The procedures for adding a stand, when using a top drive system is as follows: 1. Suspend the drillstring from slips, as in the conventional system, and stop circulation 2. Break out the connection at the bottom of the power sub 3. Unlatch the elevators and raise the block to the top of the derrick nd in the elevators, and stab the power sub into the top of the 22.Ria Components.) '5. Make up the top and bottom connections of the stand, 6. Pick up the string, pull slips, start pumps and drill ahead ‘Top drive systems are now very widely used. The disadvantages of a top drive ‘+ Incroace in topeide weight on the rig + Bloctrio and hydraulic control line must be run up inside the derrick: + When drilling from a semi-submersible under heaving conditions the dilltring may bottom out during connections when the string is hung off in the slips. This, ‘could Leuvercomse by diiling widh doubles aun] adilling sub which ould be bavkeu ‘out like a kelly. This method however would reduce the time-saving advantages ‘oF the top drive system ©. WELL CONTROL SYSTEM The function of the well control system is to prevent the uncontrolled flow of formation fluids from the wellbore. When the drillbit enters a permeable formation the pressure in the pore space of the formation may be greater than the hydrostatic pressure exerted by the mud colom. If this is so, formation fluids will enter the ‘wellbore and start displacing mud! from the hole, Any influx of formation fluids (oil, sas or water) in the borehole is known as a kick. ‘The well control system is designed to: + Detect a kick + Close-in the well at surface 4+ Remove the formation fluid which has Rowe inte the well Make the well safe Failure to do this results in the uncontrolled ow of fluids - known as a blow-out which may cause loze of lives and equipment, damage to the envionment and the loss of oil or gas reserves. Primary well control is achieved by ensuring that the hydrostatic mud preasute is sufficient to overcome formation pressure. ydrostatic pressure is calculated from: 0,052.4 MW a TVD \ydrostatic pressure (pst) MW = mud weight (pe) retical height of mul column (tt) 23,Primary control will only be maintained by ensuring that the mud weight is kept at the prescribed value, and keeping the hole filled with mud. Secondary well control is achieved by using valves to prevent the flow of fluid from the well until such time as the well can be made safe, 61 Detecting a kick ‘There are many signs that a driller will become aware of when a kick has taken place. The first sign that an kick hay taken place could be a sudden inerense in the level of mud in the pits. Another sign may be mud flowing out of the well even ‘whoa the pumpe are chut down (io. without cizeulating). Mechanical devices ouch as pit level indicators or mud flowmeters which trigger off alarms to alert the rig crew that an influx has taken place arc placed on all rigs. Regular pit drills are carried out to ensure that the driller and the rig erew can react quickly in the event via hich 6.2. Closing In the Well Blow out preventors (BOPs) must be installed to cope with any kicks that may occur. SOPs are basically high pressure Valves which seal olf the top oF the well. On land rigs or fixed platforms the BOP stack is located directly beneath the rig floor. On floating rigs the BOP stack is installed on the sea bed. In either ease the valves are hydraulically operated from the rig oor. ‘There are two basic types of BOP. Annular preventor- designed to seal off the annulus between the drillstring and the side of hole (may also seal off open hole ifkick occurs while the pipe is out of the hole). These are made of synthetic rubber which, when expanded, will seal off the cavity Figure 14). yen Oh en Se \ XQ nace Figure 14. Hydtil annular BOP (Courtesy of Hydtril*) 24Ria Components.) Ram type preventor - designed to seal off the annulus by ramming large rubber- faced blocks of steel together. Different types are available: bind rams - seal off in open hole Pipe rams - seal off around drillpipe (Figure 15) shear rams - sever drillpipe (used as last resort) Sea Rng Groove Figure 15. Ram type BOP (Courtesy of Hydril*) ‘Normally the BOP stack will contain both annular and ram type preventors ( Figure 16). rere anita Fiure 16 BOP stackup 25To stop the flow of fluids from the drillpipe, the kelly cock valves can be closed, or an internal BOP (basically a non-return check valve preventing upward flow) can be fitted into the drillstring. 6.3 Circulating out a kick ‘Tavremave the fremation fh sow trapped inthe annulus high precen ing system is used. A choke manifold with an adjustable choke is used to control flow rates during the circulation. Basically heavier mud must be pumped down the trillpipe to control the formation pressure, and the fluids in the annulus circulated to surface. As the kick etarte moving up the hole the choke opening is retrictod to hold enough back pressure on the formation to prevent any further influx. The fluids are circulated out via the choke Fine, through the choke manifold out to a ‘gas/mud separator and a flare stack (Figure 16). Once the heavier mud has reached suave die wll should Le dead, Well control procednes will be alt with avis fully later. 7. WELL MONITORING SYSTEM Safety requires constant monitoring of the drilling process, If drilling problems are detected early remedial action can be taken quickly, thereby avoiding major problems. The driller must be aware of how drilling parameters are changing (e.8. WOB, RPM, pump rate, pump pressure, gas content of mudi etc.). For this reason there are various gauges installed on the driller’s console whete he can read them easily. Another useful aid in monitoring the well is mudlogging. The mudlosser carefully inspects rock cuttings taken from the shale shaker at regular intervals, By calculating lag times the cuttings descriptions can be matched with the depth and hence a log of the formations being drilled can be drawn up . This log is useful to the geologist ing this well with others in the vicinity Muulloggers also moniter the gas present in the mud by using gas chromatography. 26