SPE 102851
The Continuous Circulation System—From Prototype to Commercial Tool
A. Calderoni, SPE, Eni E&P Div.; J.D. Brugman, SPE, and R.E. Vogel, SPE, Natl. Oilwell Varco; and J.W. Jenner, SPE,
Coupler Developments Ltd.
Copyright 2006, Society of Petroleum Engineers
This paper was prepared for presentation at the 2006 SPE Annual Technical Conference and
Exhibition held in San Antonio, Texas, U.S.A., 24–27 September 2006.
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Abstract
This paper follows the evolution of the Continuous
Circulation System (CCS™) from the prototype to the
first models available for commercial application. It
reviews the mechanical and control system changes
introduced following the prototype trials to make the
CCS more user friendly and mechanically reliable. It
also discusses the approach of the constructor to the
introduction of the system to the drilling industry and its
determination to provide reliable and fit for purpose
equipment.
Utilisation of the CCS could significantly change the way
that drilling operations are carried out in certain "difficult
to drill" formations. The ability to maintain uninterrupted
circulation while making connections with jointed drillpipe
is of considerable benefit when drilling formations where
there is a narrow margin between fracture pressure and
pore pressure gradients. With continuous circulation a
steady ECD can be maintained and the positive and
negative pressure surges, associated with making a
connection under normal drilling conditions, avoided.
Improved hole cleaning and the elimination of
connection gas kicks can also be achieved.
Introduction
The first commercial application of the CCS was the re-
entry and deepening of an exploration well offshore
Egypt in 2005. The previously undrillable reservoir
formation was successfully drilled, logged and
suspended for re-entry and testing. Details can be found
in SPE paper No. 102859¹. The success of this
operation was to a large part made possible by the
outstanding reliability of the system, which resulted from
the detailed re-engineering of the prototype, careful
preparation by the operating team and the application of
a rigorous data recording and reporting program.
Recognising that the CCS would be used to drill with a
mud weight below that required to balance the pore
pressure and that malfunction or failure could result in
the implementation of emergency well control
procedures, the system must operate with the same
reliability as Blow Out Preventer equipment.
Reliability goals were achieved with a single, three
minute interrupted circulation event during five months of
operations on the first project offshore Egypt. This,
together with no interruptions to circulation on the
second project offshore Norway, demonstrated that
exceptional reliability of new, complex oilwell drilling
equipment can be achieved on the very first projects.
The ability to drill well sections with uninterrupted
circulation and using the ECD to manage downhole
conditions is now a reality. A tool that is fit for purpose,
with demonstrated reliability and backed up by top level
engineering support has been developed and is now
available to the industry.
The Prototype
In late July 2003 the prototype CCS (fig-1) was installed
on a rig drilling for BP in southern Oklahoma for its first
test under field conditions. This marked the culmination
of three years of development engineering backed by a
Joint Industry Project (JIP) supported by six major oil
companies², with the engineering and construction effort
supplied by Varco Shaffer, now National Oilwell Varco,
Pressure Control Group (NOV).
The trial while drilling 12-¼-in.hole was a success, with
the system achieving everything that was expected at
this stage of development. Some 72 connections were
made while circulating at 800gal/min and between 2800
and 3000psi, drilling 1085ft. in a formation where drilling
problems were normally not experienced. The 4-½-in.
drillpipe used in the test was inspected before and after
being handled by the CCS and no unusual or abnormal
damage was found. The specially formulated thread
lubricant had also worked satisfactorily and no tool joint
thread damage was detected. The concept had been
proven; drillpipe connections had been successfully
made while maintaining circulation to the wellbore.
Full details of the rig trial can be found in SPE paper
90702³
Post Trial
Following the successful trial the system components
were returned to NOV’s base in Houston where a “post