W ell Engineering Experts.

Managed Pressure Drilling

Managed Pressure Drilling Seminar
Steve Nas
What is Managed Pressure Drilling
Managed Pressure Drilling
IADC has defined Managed Pressure Drilling 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.
Managed Pressure Drilling
What Pressures are Managed ?

Formation Pressures Wellbore Pressures

(not controllable) (controllable)

• Overburden Pressure • Hydrostatic Pressure

• Pore Pressure • Fluid Density

• Fracture Pressure • Fluid Height

• Hole stability Pressure • Hydrodynamic Pressure

• Flow rate
• Wellbore geometry
Managed Pressure Drilling
Wellbore Pressures Conventional Drilling
Static (No Pumping)

Pressure = Depth x Fluid Density x Constant

Depth = 3000m

Drillstring

Annulus
Fluid density = 1.20 sg

Pressure = 3000 x 1.20 x 9.807= 35304 kPa = 5120 psi

Circulating (Pumping)

Pressure = Depth x Fluid Density x Constant + Friction losses

Friction pressure = 250 psi

Pressure = (3000 x 1.20 x 9.807) +250 = 5370 psi

Bit
Managed Pressure Drilling
Wellbore Pressures Conventional Drilling
Pressure
Depth

Drillstring

Annulus
Bit
5120 psi 5370 psi
Managed Pressure Drilling
So what is different in Managed Pressure Drilling

Instead of having the well open at the top, the well is closed at the
top using a rotating seal.

The seal allows the pipe to be rotated and moved up and down.

It forms a pressure seal at the top of the well installed on top of the
blowout preventer.
The well is now a pressure vessel, sealed at the top.
Fluid can still be pumped
Pipe can still be moved

PRESSURE CAN BE APPLIED AT THE TOP OF THE WELL

Managed Pressure Drilling
So what is different in Managed Pressure Drilling
Pressure
Applying pressure at the top
allows control of the pressure in
Depth

the well bore.

Drillstring

Annulus
With that control we can quickly
adjust the pressure in the well
up or down

Bit
5120 psi 5370 psi
Managed Pressure Drilling
So what is different in Managed Pressure Drilling

Conventional Drilling (wellbore is open)

Bottom hole pressure = Fluid Density + Annular Pressure Losses

Managed Pressure Drilling (wellbore is closed)

Bottom hole pressure = Fluid Density + Annular Pressure Losses + Surface Back Pressure
Managed Pressure Drilling
• Wellbore is sealed at the top.
• Managed Pressure Drilling Choke is used to
apply pressure to the top of the well.
• With a closed system flow is measured using
a Coriolis mass flow meter.
• The well control equipment remains as
secondary barrier.

Closing the well at surface and the ability to apply

pressure provides two advantages

1. Pressure can be applied quickly

2. Allows more accurate measurement of

return flow from the well.
Managed Pressure Drilling
• Objectives
To ascertain the downhole pressure environment limits and to manage the annular hydraulic
pressure profile accordingly.

• Well remains overbalanced (Wellbore pressure is above formation pore pressure)

MPD is intended to avoid continuous influx of formation fluids to the surface.

• Well Control remains the same as in conventional drilling

Any influx incidental to the operation will be safely contained using an appropriate process.
Managed Pressure Drilling

Managed Pressure Drilling

Managed
Performance Underbalanced Dual Gradient
Pressure
Drilling Drilling Drilling
Drilling

Closed Well Bore

Air / Gas Drilling Flow Drilling Floating Mud Cap
Drilling

Gasified Fluid Constant Bottom Pressurized Mud

Mist Drilling
Drilling Hole Pressure Cap

Foam Drilling Gas Lift

Aerated Drilling
Managed Pressure Drilling Conventional Drilling:
Pressure is determined by static fluid
density and frictional pressures
Adjustments
Flow rate or Fluid density change

Managed Pressure Drilling:

Pressure is determined by static fluid
density, frictional pressure and Applied
Surface Back Pressure
Adjustments
Pressure can be immediately increased
or decreased
Influx detection is enhanced
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MPD Applications
Managed Pressure Drilling Applications
Why use Managed Pressure Drilling

Primary application is for wells where there is a small margin between formation pore pressure
and fracture pressure.
Much better control of wellbore pressures so able to drill and avoid losses and influxes

Secondary application is to provide enhanced well control

Much better detection of losses or influxes, well is isolated from surface and flow in and flow out can
be accurately measured and controlled.

Other applications
Ability to measure pore and fracture pressures
Ability to drill with lower mud densities
Ability to cement casings/liners without losses
Advantages of MPD
Management & • Improve fluid density management
Risk Reduction • Improved influx detection
• Closed system for drilling in H2S gas zones
• Less risk when finding casing set points in exploration wells
• Use pressure to control problematic shales
• Better management of pore pressure uncertainties

Environment • Reduce risk of spills

• Reduce blow-out risks

Cost Reduction • Reduce or eliminate casing strings

• Reduce fluid cost by eliminating mud losses
• Reduce time waiting on mud (mixing & delivery)
• Reduce stuck pipe incidents, mitigates differential sticking
• Reduce well bore ballooning
Challenges with MPD
Management & • All Pressures to be reviewed not only during drilling.
Risk Reduction Tripping drill string (Surge and Swab Pressures).
Logging Operations (well must be static).
Running casing (Surge and Swab and circulating Pressures).
Cementing (Circulating and displacing cement).
• Well Control procedures get more complex.

• Increased complexity.

Cost Reduction • Extra Equipment and people.

• More complex drilling and tripping procedures.
• More detailed planning.
• More training required.
Well Control
Managed Pressure Drilling
MPD Well Control
Operating limit:
Increasing Pressure Kick Intensity
Operations continue up to this

Increasing Return Flow

limit without actions required

Planned limit: Influx Volume

Operations must be shut down
and the well closed in.

Influx volume and pressure limits

The pressure limits of the MPD equipment determine if
Decided during well design the influx is managed with the rig BOP & Choke system
process or with the MPD system
Well Control Influx Management Envelope
Surface Pressure after an influx is taken

Limits based on

• Shoe strength
Influx volume
• Surface Equipment
Pressure limits

• Mud Weight

• Pressures required
Well Control Influx Management Envelope
MPD Well Control Matrix, Procedures and Well Control Bridging Documents required.
For floating rigs this needs to include riser limits
Hydrate formation and mitigation for certain wells
The well control bridging document must cover the integration between Drilling Contractor and
Operator well control policies
Well Control Influx Management Envelope

Detection Limit

Circulated using
MPD system

Circulated using
BOP & Rig
system
Well Control
Influx detected as increase in return flow
Stop drilling but maintain circulation
Pick up and space out at same time Increase surface back pressure until flow in = flow out

Record volume gained (Kick volume)

Record pressure added (Kick intensity)

Add safety margin to annulus pressure 50 psi

Decision time Continue Circulation

Drillers method
Circulate with MPD system
based on kick
Decision point intensity and
volume
Close BOP use rig system Stop pumps close BOP
Pumps are still at
drilling speed

27-May-20 24
MPD Well Control
Well Control Operational Modes

Auto-Control On:
This mode enables the automatic reaction of the choke to a detected influx. If an influx is detected,
then the system will proceed to “kick modes” to automatically operate the choke to control and
circulate the influx out of the wellbore.

Auto-Control Off:
This mode disables the automatic reaction of the choke. If an influx is in progress, it will still be
detected and the operator will be warned. However, the choke will take no action to stop the influx.

Who decides the MPD operating mode and when ??

MPD Equipment
MPD Equipment
Rotating Control Device
The Rotating Control Device provides the seal around the drillstring
It allows the drillstring to be rotated and moved up and down
It allows pressure to be applied to the annulus.

There are three different types of rotating control devices:

1) Well pressure energized seals – Passive

2) Hydraulically energized seals – Active

3) Non-rotating grease packed seals - Passive

Rotating Control Device
Passive Sealing Devices Sealing Force
Flow from annulus
Devices with the self energized seal are
currently much more widely used.

The pressure in the wellbore ensures that the

seal retains integrity.

Working pressure generally 1500 psi

Static pressure rating 5000 psi
Rotating Control Device
Active Sealing Devices

Devices where the seal is energized based on

the pressure in the wellbore.

The complexity of these systems and the new

API testing requirements have phased out most
of the active RCD systems.

Working pressure generally 2000 psi

Static pressure rating 5000 psi
Rotating Control Device
Non Rotating Sealing Devices

A newer development are the non rotating RCD

systems.

It operates more like a stripping rubber with

multiple seals installed.

Multiple rubbers with reducing pressures in

between the sealing elements

Working pressure generally 1500 psi

Static pressure rating 5000 psi
Rotating Control Device
Pressure Limitations

Most RCD’s have a lower pressure rating

at higher pipe RPM.

This reverse pressure chart is normally

supplied by the RCD Manufacturer
Rotating Control Device
Sealing Elements

Four types of sealing elements are used

1) Natural Rubber
2) Polyurethane
3) Nitrile
Temperature
4) Butyl Elastomer Application
Limit (°F)
Limitations

Can used for some oil-based

Natural Water Based systems if temperatures are
150
Rubber Fluid less than aniline point.
Testing recommended
Not recommended for hot
Polyurethane Oil Based Fluid 150
water-based systems
Nitrile Oil based Fluid 275
Butyl Geothermal 300 Geothermal Only
Rotating Control Device
Sealing Elements

Sealing elements are changed on a regular basis, normally

every trip

New elements are installed and standby ready for use in the
well.

Elements will last around 75 to 100 hrs of drilling depending

on conditions.
Choke Manifold
A dedicated choke manifold is used for Managed Pressure Drilling
This avoids using and possibly compromising the rig choke manifold which is part of the secondary
well control equipment.
Choke A
Pressure rating for MPD Manifolds is typically 5,000 psi

MM4
P

MM1
Configuration usually a 5-valve manifold
MM3
Dual chokes with isolation valves

MM2

MM5
Isolation valves may be automated or manual Choke B

Choke manifold may have a 3rd leg as a pressure relief valve

Choke wear usually minimal in typical MPD operations

Choke Manifold
The MPD Choke manifold is generally arranged
with two chokes in two legs with a bypass line
through the middle.

It allows flow from well to be choked (restricted)

allowing manipulation of surface pressure.

The choke manifold usually has 2 legs with a

central bypass (‘gutline’) built to allow minimum
resistance to flow when choke valves not being
used.

A variety of configurations are available from

various manufacturers and suppliers.
Choke Manifold
For offshore and deepwater operations choke manifolds and MPD equipment can be fully integrated
into the rig or installed as separate skid units

37
Metering Manifold
The Coriolis mass flow meter has become the most used
flowmeter in MPD systems

• Factory calibrated
• Accurate down to a few gpm
• Meter can plug or become partially plugged
• On older meters gas entrainment can cause spurious
signals
• Sensitive to spurious vibrations

Two smaller tubes inside the meter vibrate with the

mass flow based on the Coriolis effect.

The vibration is measured and mass flow rate is

calculated and transmitted.
Managing Pressures
Managing Pressures
When Drilling and Circulating

Bottom Hole Pressure

=
Hydrostatic Pressure (Mud Weight)
+
Annular Frictional Pressure (ECD)
+
Applied Surface Pressure (Choke Pressure)

27-May-20 40
Managing Pressures
When Tripping and Running Casing

Bottom Hole Pressure

=
Hydrostatic Pressure (Mud Weight)
+
Surge / Swab Pressures
+
Applied Surface Pressure (Choke Pressure)

The surge and swab pressure still occurs when moving pipe.
Surface Pressure does NOT eliminate surge and swab.

27-May-20 41
Managing Pressures
Connection Data from PWD tool

10000 600

9900
Ensure PWD data is
9800 500
recorded and analyzed
9700

Lessons to be learned to 9600

400
Bottom Hole Pressure (psi)

improve procedures 9500

Flow rate (gpm)

9400
300
9300

9200

200
9100

9000

100
8900

8800

8700 0
Pressure Pore Pressure flow

27-May-20 42
Standards
MPD Standards
Most important standards are

API RP 92 M Surface Wellheads

API RP 92 S Subsea Wellheads
API RP 92 P Pressurized Mud Cap Operations
API RP 92 C Controlled Mud Level Operations

API SPEC 16 RCD Rotating Control Heads

API SPEC 17 NRV Non Return Valves
API RP 53 Well Control Equipment
API SPEC 16 C Choke and Kill Equipment

27-May-20 44
Managed Pressure Drilling
Challenges
Manage Pressure Drilling Challenges
Well Control is no longer a problem with MPD installed.

Detecting and influx quickly and acting remains an essential part of

managed pressure drilling.

Even with automated systems the crew needs to understand the

system responses.

Lost of problems have occurred when an influx is taken

Pressure limits for MPD are 1,500 to 2,000 psi

MPD system is generally not considered as a blowout control system.

No standard requirements for periodic testing.

MPD system is a pressure control system not a well control system.

27-May-20 46
Manage Pressure Drilling Challenges
There are only 2 MPD methods
• Constant Bottom Hole Pressure
• Pressurized mud cap operations
• MPD is only applicable for narrow margin (Drilling Window) or for drilling with total losses.

Application of surface pressure combined with accurate flow measurement allows many different
approaches.

It requires a full understanding of pressures in the wellbore and the formation.

Use of Coriolis flow meters also allows fluid density and temperatures to be tracked accurately
(generally not used).

Losses Reduce Surface Pressures

Influx Increase Surface Pressures

27-May-20 47
Manage Pressure Drilling Challenges
Operational Challenges.

Communication who does what ?

MPD operator narrow focus on MPD pressures
Driller focus on drilling
Who has responsibility for influx detection (driller or MPD operator)
Well Control approach (Use BOP or MPD for influx circulation)
Company representatives often unaware of system capabilities
MPD pressure not always integrated in drilling program
Drilling program flexibility to operations
MPD Competency

27-May-20 48
MPD Operations Planning
Managed Pressure Drilling Well Design
Drilling
Drilling is the simplest part in MPD operations.
The bit on bottom and circulation allows pressure to be applied.

• Fingerprinting requirements What is required

• Drilling out the casing shoe
• Fluid weight requirements
• Pump rates & Pump Pressures
• Leak off Testing
• PWD/ LWD requirements
• Gas detection and monitoring
• Gas handling at surface
• Making Connections
• Influx Detection
• Event Handling
Bypass MPD or use metering only (Risks)
Mud weight and Surface pressure when increasing what
Flow rates for LWD and ECD
Conventional or Dynamic
LCM, Signal Failure
Sensor location and values
When to use the MGS ?
Pressure limits both surface and downhole
Volumes and Pressures
plugged string, washouts, hole collapse, stuck pipe, LWD

27-May-20 50
Managed Pressure Drilling Well Design
Tripping Operations
• Back reaming
• Surge & Swab Pressures
• Pumping slug
• Pressure Requirements
• Keeping hole full
• Influx Detection
• Loss Detection
27-May-20
Pressures and Flow rates
Tripping speeds
Tripping with pipe dry
Back pressure when tripping
Trip tank operations and back pressures
Swabbing
Surge
51
Managed Pressure Drilling Well Design
Casing Operations

The use of the RCD is limited to 7” or smaller tubulars

RCD and as such MPD cannot be used to run casing until the casing is on the drillpipe.

Requires well to be open and stable (No losses / No Kicks)

Casing running speeds need to be planned with a view to minimizing surge and swab issues.

Casing annular losses (ECD and Circulating Rates)

MPD is no longer active so Influx & Loss detection is now back to conventional methods.

27-May-20 52
Managed Pressure Drilling Well Design
Cementing Operations

Cementing the casing using cement weights higher than drilling fluid densities can pose pressure
challenges with cement displacement

• MPD can be used to circulate to a lower fluid density prior to cementing.

• Fluid density is lowered and back pressure is applied to maintain bottom hole pressure.

• Cement can be mixed and pumped

• During cement displacement, back pressure is adjusted to ensure that bottom hole pressures
remain within the operational window.

• Relatively simple but requires some planning and modelling.

27-May-20 53
Managed Pressure Drilling Well Design
Cementing Operations

Engineering Required
• Determine pump rates and associated ECD
• Determine displacement rate and ECD associated with Cement and spacers
• Determine mud weights, cement weights and surface pressures required
Note: Different models give different results………understand what each model does

Once casing or liner is at TD

• Circulate well to lower mud weight.
• Use back pressure to maintain bottom hole pressure within PP-FP window
• Mix and Pump Cement at pre-determined rates
• Displace cement at predetermined rates
• With cement entering the annulus adjust surface back pressure and pump rate to maintain
bottom hole pressure.
• Once plug bumps hold back pressure until cement hardens or seal assembly is set

27-May-20 54
Managed Pressure Drilling
Future
Manage Pressure Drilling Future
Floaters MPD
Transocean 51 17 Drilling contractors moving to MPD equipped vessels
Valaris 28 9 with permanently installed MPD systems, some with fully
Seadrill 27 6 integrated MPD control systems.
Diamond Offshore 17 6
Ocyan 6 5
Constellation Oil Services 8 5
Maersk 8 5
Stena Drilling 6 4
Noble 11 4
COSL 13 2
Pacific Drilling 7 2
Saipem 5 2
Dolphin Drilling 5 1
Vantage Drilling 4 1
Caspian Drilling 1 1

27-May-20 MPD Well Design Training 1 56

Manage Pressure Drilling Future
AFGlobal MPD manifold. Weatherford MPD manifold
Noble Globetrotter II Drillship Seadrill West Capella Drillship

SafeKick MPD manifold Weatherford MPD manifold

Maersk Valiant Drillship Noble Clyde Boudreaux Semi Submersible

27-May-20 57
Managed Pressure Drilling

Any Questions
?