MPD Presentation PMCD CBHP With Marine Diverter PDF

Managed Pressure Drilling
Technology
Felbert Palao
MPD Project Engineer - Vietnam
© 2004 Weatherford. All rights reserved.
1
IADC Definition
“Managed Pressure Drilling (MPD) is 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.”
1st MPD Forum Definition: “Walking the line” between frac-pore margins to
a deeper depth with fewer interruptions to drilling ahead.
MPD will not drill the well underbalanced
TOOLS REQUIRED –
At the very least, a surface, subsea, or offshore variation of a
rotating control device plus other equipment as dictated by specific
MPD objectives.

2
Equipment used for Managed Pressure Drilling
RCD
Gas Handling
Choke Manifold
Float Subs
MPD
RCD = Rotating Control Device
3
MPD Equipment
The most obvious change

in the equipment
requirement for MPD is
the addition of RCD to the
BOP stack
RCD
4
What is a Rotating Control Device?
• Rotating Diverter - Diverts annular flow of the well
• Barrier between the well and rig floor – Safety
• Allows pressure held on the wellhead while rotating drillpipe and

drilling
• Called a Rotating Head – Rotating Diverter - Rotating BOP - Rotating

Pressure Control Head
• Standard is defined by API 16-RCD

5
Why MPD ?
• Use closed-system feature to more precisely manage & control wellbore

pressures. Precise wellbore pressure management can overcome many
drilling related barriers facing conventional offshore drilling…
• Positive HSE consequences - closed vs. open-to-atmosphere mud returns
system.
• Often total losses are experienced when fractures and vugs are
encountered and once fluid hydrostatic is lost, gas in the upper part of the
formation migrates rapidly to surface resulting in a well control situation.
BOP is often closed and the well displaced to heavier fluid, resulting in
more losses – a classic loss/kick scenario.
MPD allows continuous drilling with severe losses, reducing drilling time
and fluid costs.

6
Why MPD ?
Main applications of Offshore MPD in SE Asia are:

• Drilling of the severe loss fractured formations such as:
– Baturaja and Kujung carbonates in Indonesia
– Karst formations in Malaysia
– Fractured carbonate gas-bearing formations in PNG, Indonesia,
Malaysia and Brunei
• Control formation losses:
– Fractured granite basement in Vietnam.

7
MPD Variations
PMCD
Pressurized mud-cap MPD enables high ROP, less
flat time and lower-cost drilling in extreme-loss
situations. Fractured, vugular formations.
The goal of managed

CBHP
pressure drilling (MPD)
Constant bottomhole pressure MPD reduces NPT
is to use a closed and and enables fewer and deeper casing strings when
pressurizable mud- pore- to fracture-pressure gradient windows are
return system to narrow, ERD, slim hole,
control bottomhole
pressure (BHP) in a
DG
way that eliminates
many of the drilling and Dual gradient MPD enables total well depth in the
wellbore stability issues right hole size in deep-well and deepwater drilling.
that are inherent to
conventional drilling
HSE
Returns-flow-control (HSE) MPD reduces risk to
personnel and the environment from drilling fluids
and well control incidents.
8
MPD Variations
Pressurized Mud Cap Drilling (PMCD)

This method is used to control wells with loss / kick scenario’s
Widely used in fractured and vugular reservoirs where total fluid losses are
experienced.
Losses must be large enough to take all of the fluids pumped down the
drillstring together with all of the cuttings
Constant Bottom Hole Pressure (CBHP)

Used when the bottom hole pressure needs to be accurately controlled
Narrow pore pressure and fracture pressure window.
ECD is compensated when circulation is stopped.
RCD allows surface pressure to be applied

9
MPD Variations
HSE or Returns Flow Control (RFC)
Used as a safety measure.
Flow diverted to the rig choke if influx is taken.
Prevents a potential hydrocarbon release onto the drill floor and it allows
pipe movement whilst circulating out the influx.
The RCD avoids closing of the BOP
Dual Gradient (DG)

Dual gradient is best known for deepwater applications
Marine riser is displaced to seawater to simulate the rig being placed on the
seabed
Avoids the high overbalance and the potential loss of circulation.
No deepwater dual gradient operations have yet been conducted in Asia.
Other Techniques are often mentioned as MPD but these are considered
sub categories of the four mentioned categories.

10
Variables that are manipulated
Mud density
Trapped Pressure Rotating Control Device

Choke
Friction Pressure Downhole pump

11
MPD Projects – Asia Pacific
Main MPD Drivers:

Drilling Fluid Losses
Kick-Loss scenario’s
Formation Types:
Carbonates – fractured/vugular
limestones
Fractured basement (granite &
schist)
The Most Common MPD Technique

in Asia are:
• Pressurized Mud Cap Drilling
• Constant Bottom Hole Pressure

12
Back to Basics
Bottom Hole Pressure (psi)

0 1000 2000 3000 4000 5000 6000 7000 8000
0
1000
2000
3000
4000
Depth in ft TVD
9 ppg
5000
6000
7000
10 11 12 13 14
8000
9000
10000
13
Constant Bottom Hole Pressure
With MPD, BHP can be quickly changed
Conventional Drilling:
• BHP = MW + AFP
–Only adjustment available with mud in the hole = pumps on, pumps off
and pump speed
MPD:
• BHP = MW + AFP + Backpressure
–Effective BHP can be changed significantly with fewer interruptions to
drilling ahead.
–Applied annulus backpressure is controlled by a dedicated choke
allows maintaining BHP at a constant value or range.
–Loss of ECD when pumps are turned off during connection will be
compensated by adding choke pressure at surface to maintain BHP
14
BP
With an RCD and Choke,

back pressure can be added
at surface
Dynamic
BHP =MW + AFP +BP
Static
BHP = MW + BP
AFP + BP
15
Back Pressure
Tight Margins:
Possible solution;
Use lower density and impose
back pressure when static
Static
BHP = MW + BP
Dynamic
BHP = MW + AFP

16
MPD (CBHP) Rig Up
Option 1: A Rotating Head and Isolation Valves are Installed. This allows
drilling with a lighter fluid and holding pressure at surface on connections.
Sample Project: Hoan Vu JOC, Vietnam
Flow meter
Gas out
0
HCR
valve
MPD Choke Manifold
Two Phase
Separator
1
To shale shakers
Rig Choke Manifold

17
MPD (CBHP) Rig Up
Option 2: A Rotating Head and a Choke Manifold are installed. This allows
drilling with surface pressure controlled by the choke, providing greater
control of the Bottom Hole Pressure.
Sample Project: InterOil, PNG
Flow meter
Gas out
0
HCR
valve To Shakers / Separator
MPD Choke Manifold
Two Phase
Separator
1
To shale shakers

Rig Choke Manifold 18
MPD (CBHP) Rig Up
A 2-phase separator may also be included in the rig-up. This will allow
continuous drilling if gas enters the wellbore or the cuttings have a high
gas content.
Flow meter
Gas out
0
HCR
valve
MPD Choke Manifold
Two Phase
Separator
1
To shale shakers
Rig Choke Manifold

19
Conventional Drilling No Losses
• Drilling fluid is pumped down

the drillstring, and returns to
the surface via the annulus
• The annulus hydrostatic

column is weighted to exceed
the reservoir pressure and
prevent any flow into the
wellbore

20
Conventional Drilling with Mud Losses
• Drilling fluid is pumped

down the drillstring, as
further loss zones are
uncovered
• BHP > Fracture Pressure
• LCM material to heal hole
• Increased losses mean little

or no mud returns to the
surface

21
Conventional Drilling with Total Losses
• Drilling fluid is pumped down the

drillstring, but nothing returns to
the surface
• The fluid column in the well drops,
reducing BHP, compromising
primary well control and leading to
a kick
• The BOP has to be closed and the
kick circulated out – but increasing
the mud weight leads to more
losses and kicks
• Ultimately cement may have to be
pumped or the well abandoned

22
What is Mud Cap Drilling?
• A Technique used to Drill with Total Loss of Circulation

• Does not try to prevent Loss Circulation
• Does not try to cure Loss Circulation
Two Types:
• Pressurized MudCap Drilling
• Floating MudCap Drilling

23
Pressurised MudCap Drilling (PMCD)
• The annulus is closed at

surface with the rotating
control head.
• Drillstring injection is
switched to sacrificial fluid.
• Light Annular Fluid is
pumped down the annulus to
maintain hole fill and prevent
gas migration up the annulus.
• Sacrificial fluid and cuttings
are lost to the formation.

24
Pressurized Mud Cap Drilling
PMCD
• Permits safe & efficient drilling in
severe or total loss zones
Key Features:
• No returns to surface (returns flow
into the formation)
• Viscous mud is pumped at low
rate down the annulus at just
Light Annular Fluid
below reservoir pressure
Fluid Interface
• Disposable drilling fluid (normally

sea water) is pumped down
drillstring
Sacrificial fluid
enters
• Back-pressure on the annulus is formation with
cuttings
used to balance the reservoir
pressure and maintain system
balance
25
Floating Mud Cap
Floating Mud Cap
Advantage:
• No additional equipment required
Disadvantages:
• Fluid level can not be monitored
• No surface pressure
• No indication of gas migration
until well flows.
• Drilling fluid weight required for
annulus fill up is higher than
formation pressure gradient (if pore
pressure is 10ppg, annulus fluid
should be 10.1ppg or higher).
• If well flows, requires closing on
BOP to bullhead more heavy mud
• Gas to surface will go to rig floor
and not diverted
26
MPD (PMCD) Rig Up
A PMCD Rig-up Includes

an RCD, a flowline and an
Trip Fill Up / 6” Flowline to Shaker
annulus injection line. RCD Bleed Off
Line
A choke manifold maybe

added to this rig-up which 4” Annulus Injection
will provide the flexibility 4” Line to Rig Choke

Manifold
of switching between
CBHP and PMCD as
required for the drilling
operation.
Sample Project with CBHP and PMCD: Reliance Energy, India

27
MPD on Floating Rigs
Model 7100 –
2500psi rated
Rotating Control 6” Line for
6” circulating well
Device
HCR either thru an MPD
2” Fill-up Line from Trip
choke of direct to
Tank Pump
the shakers.
4”
HCR
4” PMCD Line from Mud
Pump
4” Kill Line to Choke
4” Manifold
HCR
Riser Tensioners support

full riser weight and PMCD
equipment
Riser Slip Joint is
used in the
collapsed position
Limited by the pressure

rating of the riser and
slip joint
28
MPD Equipment Considerations
Depending on the MPD method required, the rig up will vary.
RCD
Space requirements between the RCD and the bottom of the rotary table.
Bottom and top connections to and from the RCD.
Flow line and bleed off line connections
Location and connections for the RCD power unit
Location and connections for the RCD control unit
Rig up for Logging, casing and cementing operations
Marine riser issues for riser cap operations
Drillpipe sizes that are to be used
Pressure bleed-off lines

29
Flow line
Return flow line for conventional drilling
Flow line routing and tie-in for MPD operations
Annular injection requirements for PMCD operations
Choke Manifold
Location and configuration of choke manifold if required
Choke control panel location
Air and Power requirement for Choke control panel.

30
Separator
Location and set up of the two phase separator if required
Transfer pumps and solids lines to shakers
Gas out line to flare or burner booms
Cutting collection and sample catchers
Gas or liquid flow meters
Marine Risers
Size and manufacturer of the marine riser and slip joint specifications
Slipjoint locking mechanism and pressure ratings
Slipjoint top connector
Bad weather hang off ability
Rig heave and motion characteristics
Top connection of slip joint.
31
MPD Equipment Requirements
Data Collection Requirements

Pressure sensors on standpipe
Pressure sensors on Choke manifold and annular
Flow meter requirements
Drilling data collection
Utilities
Utility tie-in points for power and air.
Any other rig specific requirements
Drilling riser requirements for conventional drilling or shallow MWD testing

32
RCD Options
 2500 psi
 5000 psi
 Working Pressure
 2500 psi
 Static Pressure
 5000 psi
 1000 psi
 1500 psi
 500 psi
 500 psi
Model 9000 IP 1000 Model 7100 Model 7800

BA – 9” BA – 7” BA – 7” BA – 8-3/4”
BA: Bearing Assembly ID

33
Rotating Control Device Model 7100
• Dual Rotating Stripper Rubbers

• Universal Bearing Assembly
• Positive Oil Lubrication
• Bearing Cooling System
• Forged Steel Bowl c/w Dual Cylinder HD Clamp
• Mechanical Safety Locking System
Working Pressure
• 2,500psi
Static Pressure
• 5,000psi
Max Tooljoint OD
allowed:
• 6-3/4”
RCD 7100 Control System
Hydraulic Valve Control Panel

35
RCD Model 7100 R-1 Big Bore Bearing
• Williams 7100 RCD with a big bore

R1 can accommodate the 5-1/2”
drillpipe size
• RCD Bearing ID is 8-1/4”
• Max Tooljoint OD allowed: 7-7/8”
• Single Rubber Element
• Static Rating: 1500psi
• Dynamic Rating: 1000psi

36
RCD Model 7800
- 8-3/4” Bearing Internal ID

- Max tooljoint size allowed: 8-1/2”
- 5000 psi Static Pressure Rating
- 2500 psi Dynamic Pressure Rating
- Dual Rubber Element

37
Choke Manifold
Semi-Auto Choke
Semi-Auto Choke
Control Panel
Choke Manifold

38
Float Valve
Floats valves or non-return valves (NRV’s) are required to

prevent back flow back up the drills string and ensure well
control is maintained when making connections
39
Downhole Deployment Valve
PROBLEM: Although MPD allows the

well to be drilled easily, the well still has
to be killed before tripping out of the
hole – unless there is a way to close the
annulus. The DDV is the perfect solution
(5,000psi rated)

40
Flapper Valve Section (1)
Actuator Mandrel moves downward pushing Flapper open. When Actuator

Mandrel is returned to the upward position, Flapper Spring closes Flapper.
Flapper
Flapper
Springs
Actuator
Mandrel

41
Flapper Valve Section (2)
Flapper
recess
Flapper

42
DDV Section Drawings
Flapper Valve Section : Seals off wellbore and formation pressure.
Flapper Valve Section
Closed Position
Actuator
Mandrel
Flapper
Open Position

43
Tripping with the DDV
Trip in Open Deployment Open Pipe rams Strip drill string out Close Deployment
conventionally until Valve. and strip into well. of hole until bit is Valve and bleed
drill string is above Flow well at surface above Deployment casing pressure
Begin drilling
Deployment Valve. to reduce surface Valve. above valve.
procedure.
Equalize pressure pressure to safe Trip drill string out of
across valve. flowing pressure. well conventionally.

44
MPD in SE Asia + Oceania for the Past 3
Years (2006-2008)
Country Job Type Project Rig Type
Duration
Vietnam PMCD 1 Well Jack-Up
CBHP 2 Wells + ongoing Jack-Up
RFC Multiwell Jack-Up
Malaysia PMCD 24 wells Jack-Up, Semi Sub, Tender,
Drillship
RFC 1 well Jack-up
CBHP 1 well Jack-up
Indonesia PMCD 27 wells Jack-Up, Semi Sub, Tender,
Drillship, Land Rig
PMCD + DDV 7 wells Jack-up, Land Rig
PNG PMCD 2 Wells Land Rig
CBHP 1 Well Land Rig
Myanmar CBHP 1 Well Drill Ship
Brunei HSE - HPHT 3 Wells Land Rig, Jack-Up
Australia HSE Multiwell Land Rig
CBHP 1 Well Land Rig
New Zealand HSE 3 Multiwell Contracts Land Rig

45
Offshore MPD in Southeast Asia
Malaysia – PMCD (Semi-

submersible Rig)
Indonesia – PMCD (Semi-

submersible Rig)

46
Indonesia – PMCD (Drill Ship)
Malaysia – PMCD (Semi-

Tender Rig)
47
Indonesia – PMCD (Jackup)
Vietnam – PMCD (Jack-Up)

Using RCD 7800
48
Indonesia – PMCD + DDV (Jack-up)
• Combination of PMCD and Downhole Deployment Valve

– to avoid well kill time after drilling
RIH until bit is Equalize Continue to Strip drill string Close DDV
just above pressure trip drilling out of hole until and vent off
DDV across DDV assembly bit is above casing
into well DDV (2nd pup pressure
Increase Open DDV
joint marker above DDV
Rotating Commence
Use pup joint reaches the drill
Control UBD Trip drill string
marker above floor)
Device operations out of well as
& below DDV
closing normal
pressure

49
Vietnam Projects

50
Vietnam Projects
Nam Con Son Basin – PMCD
• Location – Nam Con Son Basin

• Formation – Nam Con Son Limestone
• A nearby well had severe loss problems plus
gas migration problems while drilling the same
formation.
• Rotating Head was rigged-up for insurance to
enable switching to PMCD when severe losses
are encountered.
• A Williams 7800 RCD (new big bore RCD
model) was used to accommodate the 5-7/8”
XT57 Drillpipe
• Drilled 1 Well

51
Vietnam Projects
Cuu Long Basin – CBHP
• Location – Cuu Long Basin

• Formation – Fractured Granite Basement
• Reservoir has a small pore pressure – fracture
pressure margin
• High brine usage are experienced during
circulation due to ECD increase. Brine is a very
prime commodity especially during the rainy
season.
• Rotating Head was rigged-up to enable drilling with
an Underbalanced Fluid
• ECD is maintained slightly overbalanced to
minimize losses
• Surface pressures during connection are handled
with the well closed on the RCD
• A Williams 7100 RCD with a big bore R-1 bearing
was used to accommodate the 5-1/2” Drillpipe
• Drilled Total 3 Wells
52
Vietnam Projects
Phu Khanh Basin– PMCD – SemiSubmersible
• Location – Block 124

• Formation – Possible Fractured Carbonate
• Exploration Well
• First ever Semisubmersible rig-up for RCD
7800 in Asia Pacific.
• Rotating Head was rigged-up for insurance
to enable switching to PMCD when severe
losses are encountered.
• Finished Drilling 1 Well, programmed for 4

53
Vietnam Projects
Cuu Long Basin - Returns Flow Control
• Location – Cuu Long Basin

• Reservoir – Fractured Granite Basement
• Oil column – up to 1,000metres
• Partial to total losses experienced while drilling
– normal procedure to fill annulus with seawater
at high rate (fill rate up to 3000bbls/hour on
some wells)
• Periodic gas migration to surface still
experienced despite high annulus fill rates
• Adopted use of Rotating Diverter Insert Control
Device to allow continuous drilling while
diverting gas – started 2003
• High annulus fill rate allows some back-
pressure to be exerted on annulus

54
Model 9000 Marine Diverter Converter

55
Model 9000 Marine Diverter Converter
• Model 9000 Bearing

Assembly
• Static Operating pressure:
500 psi
• Dynamic Operating
pressure: 250 psi
• 9” Bearing Bore
• Inserts into the Vetco KFDJ
Diverter

56
Stabbing the Bearing Assembly

57
Oiler / Lubricator
15 psi air supply

Oil: 90
Bearing assembly should

receive oil at all times

58

59
Managed
Pressure
Drilling
60
Makes
Problems
Disappear
61

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Managed Pressure Drilling

MPD will not drill the well underbalanced

© 2004 Weatherford. All rights reserved.

Equipment used for Managed Pressure Drilling

The most obvious change

• Rotating Diverter - Diverts annular flow of the well

• Barrier between the well and rig floor – Safety

• Allows pressure held on the wellhead while rotating drillpipe and

• Called a Rotating Head – Rotating Diverter - Rotating BOP - Rotating

• Standard is defined by API 16-RCD

© 2004 Weatherford. All rights reserved.

• Use closed-system feature to more precisely manage & control wellbore

© 2004 Weatherford. All rights reserved.

Main applications of Offshore MPD in SE Asia are:

© 2004 Weatherford. All rights reserved.

The goal of managed

Pressurized Mud Cap Drilling (PMCD)

Constant Bottom Hole Pressure (CBHP)

© 2004 Weatherford. All rights reserved.

Dual Gradient (DG)

© 2004 Weatherford. All rights reserved.

Trapped Pressure Rotating Control Device

© 2004 Weatherford. All rights reserved.

Main MPD Drivers:

The Most Common MPD Technique

© 2004 Weatherford. All rights reserved.

Bottom Hole Pressure (psi)

With MPD, BHP can be quickly changed

With an RCD and Choke,

© 2004 Weatherford. All rights reserved.

MPD Choke Manifold

Rig Choke Manifold

MPD Choke Manifold

© 2004 Weatherford. All rights reserved.

MPD Choke Manifold

Rig Choke Manifold

© 2004 Weatherford. All rights reserved.

• Drilling fluid is pumped down

• The annulus hydrostatic

© 2004 Weatherford. All rights reserved.

• Drilling fluid is pumped

• BHP > Fracture Pressure

• LCM material to heal hole

• Increased losses mean little

© 2004 Weatherford. All rights reserved.

• Drilling fluid is pumped down the

© 2004 Weatherford. All rights reserved.

• A Technique used to Drill with Total Loss of Circulation

© 2004 Weatherford. All rights reserved.

• The annulus is closed at

© 2004 Weatherford. All rights reserved.

• Disposable drilling fluid (normally

Floating Mud Cap

A PMCD Rig-up Includes

A choke manifold maybe

will provide the flexibility 4” Line to Rig Choke

Sample Project with CBHP and PMCD: Reliance Energy, India

Riser Tensioners support

Limited by the pressure

Depending on the MPD method required, the rig up will vary.

© 2004 Weatherford. All rights reserved.

© 2004 Weatherford. All rights reserved.

Data Collection Requirements