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Copyright 2016, SPE/IADC Managed Pressure Drilling and Underbalanced Operations Conference and Exhibition
This paper was prepared for presentation at the SPE/IADC Managed Pressure Drilling and Underbalanced Operations Conference and Exhibition held in Galveston,
Texas, USA, 12–13 April 2016.
This paper was selected for presentation by an SPE/IADC program committee following review of information contained in an abstract submitted by the author(s).
Contents of the paper have not been reviewed by the Society of Petroleum Engineers or the International Association of Drilling Contractors and are subject to
correction by the author(s). The material does not necessarily reflect any position of the Society of Petroleum Engineers or the International Association of Drilling
Contractors, its officers, or members. Electronic reproduction, distribution, or storage of any part of this paper without the written consent of the Society of Petroleum
Engineers or the International Association of Drilling Contractors is prohibited. Permission to reproduce in print is restricted to an abstract of not more than 300 words;
illustrations may not be copied. The abstract must contain conspicuous acknowledgment of SPE/IADC copyright.
Abstract
Managed Pressure Drilling (MPD) and wireline logging under pressure were both successfully
employed while drilling a pre salt, exploration well offshore Angola. The well was drilled with a 6th
generation drillship using an integrated, Below Tension Ring (BTR) MPD package with the drilling
contractor’s Riser Gas Handler (RGH). Drilling exploration wells in pre-salt formations presents a
plethora of challenges, with severe drilling fluid losses, often due to the natural fractures and/or
vugular porosity encountered. This paper discusses the challenges faced drilling the desired hole
section, managing severe losses, a downhole cross flow regime and high surface gas levels. Concern
for exiting the salt section and taking total losses in a possible vugular carbonate is addressed and the
contingent plans developed are discussed. Fluid loss management was critical and discussion is
provided on the remediation methods used to limit losses. The paper describes how considerable gas
was detected, handled and eventually controlled using the available surface equipment and method-
ology for preventing continuous gas influx and prolonged, off bottom circulating for removing the
gas from the wellbore. Extensive wireline logging was completed, both at an intermediate stage and
at total depth (TD). Most of the wireline logging was performed under minimal pressure with a
logging adaptor installed in the rotating control device (RCD), 9 5/8⬙ casing shooting nipple back to
surface and wireline pressure control equipment (WPCE). The paper concludes with a series of key
lessons learned that can be taken from this experience and considered when planning similar deep
water, pre-salt exploration wells with the use of MPD equipment.
Introduction
This paper discusses four key aspects of a deepwater, pre-salt exploration well drilled in 2015,
whereby MPD techniques were successfully employed on a dynamically positioned floating drilling
rig. All aspects were influenced by the project location, logistics and the relatively short time line to
deliver solutions.
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The first aspect considers the potential problems associated with drilling out of a thick, potentially
mobile salt section into a carbonate formation and encountering total losses. Iterations of contingency
plans were worked through to determine how best to manage whichever event that may have occurred.
While total losses did not occur, the challenges faced and calculations undertaken are discussed.
The second and third aspects describe the MPD planning and subsequent integration and deploy-
ment of MPD equipment on the drill ship. After drilling into a severe loss zone, a downhole
Challenge faced.
Drilling the 14 ½⬙ ⫻ 16 ½⬙ hole section through the base of salt (BOS) and into the carbonate formation
posed several challenges. The plan was to drill into the pre-salt formation and set the casing below the salt
thus putting all of the salt formation behind the casing to eliminate future salt creep issues into the
wellbore. This plan was based on offset well information showing a potential layer of competent
formation directly below the salt prior to entering the potentially loss-prone carbonates. Formation
pressure of the carbonate was unknown, having a 1.4 ppge uncertainty range (dependent on formation
fluid) as determined from the Pore Pressure Prediction analysis. The possibility for total drilling fluid
losses also existed. Considerable planning was completed ahead of drilling through the BOS and it
addressed several permutations that considered both logistical and commercial viabilities. Such consid-
erations included:
1. Mud weight in the well when exiting the salt and drilling into the carbonate. The main objective
being to prevent salt creep when drilling the 2,000 m salt column while minimizing the potential
pressure overbalance in the pre-salt should vugular carbonates be encountered prior to reaching
TD.
SPE/IADC-179188-MS 3
2. Mud weight required for the pre-salt section. This was originally 9.4 ppge (aquifer gradient
through the reservoir) to 10.8 ppge (gas gradient) but was subsequently revised to 10.1 – 10.6
ppge.
3. Available mud capacity onboard the drill ship for storing and mixing mud.
4. Local onshore mud mixing capability and the availability of dry bulk and liquid materials to supply
sufficient quantities in the event of severe mud losses and/or pressurized mud cap drilling
Figure 2—Mud level drop in the event of total losses into a formation of either 9.4 or 10.8ppg EMW
SPE/IADC-179188-MS
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Solutions
Closing the rig’s annular preventer or pipe rams would restrict a dropping fluid level in the riser, but
expecting the BOP equipment to hold pressure from above, could not be guaranteed by the BOP supplier.
The planned solution was to close a pipe ram at such a time so as to hold a fluid level in the riser that
imposed less than 1,500 psi on the now closed BOP and yet maintain a pressure difference with the
external sea water gradient across the collet connector, greater than the negative 300 psi differential. The
The anticipated condition discussed above can occur, and be valid, for future deep water, pre salt
exploration wells.
in the wellbore where the BHP is maintained constant. Typically, on wells drilled using MPD technology, the
BHP is maintained constant at the bit. Analyzing the pore pressure and fracture pressure window, as shown in
Figure 6, since they were showing a regression trend (as is typical in carbonate reservoirs), it was thought best
to maintain 10.70 ppg eBHP at the 14⬙ shoe. Analysis showed that SBP between 560-900psi was required to
maintain an anchor point of 10.70 ppge BHP at the 14⬙ shoe. During connections or any planned / unplanned
mud pump shut down event, it was agreed to maintain circulation with the booster pump. This would ensure
Most often the engineering analysis is conducted at the front end engineering phase of the well and
procedures developed accordingly. Since these analyses were revised while drilling the salt section on the
well, it was essential that a detailed, yet simple to understand, plan was developed. Table 1 shows the
approach established to relay the information to the operational staff. Results indicated that while drilling
the 14⬙ shoe, SBP of ⫹/⫺ 560 psi to ⫹/⫺ 900 psi would be required to maintain BHP of 10.70 ppge.
Additionally, a simple step down chart shown in
Drilling cement and shoe 10.70 ⫹/⫺ 560 ⫹/⫺ 900 By-pass Coriolis flow meter
5660 6025 10.70 ⫹/⫺ 560 ⫹/⫺ 900 Anchor point at 14⬙ shoe
Table 2 was developed to ensure that BHP is maintained at 10.70 ppge in the event where the mud
pump rates were to be varied or when the pumps were turned off.
SPE/IADC-179188-MS 13
were to be used, the saturated gas migrating would be due to a density difference as opposed to a bubble rising
in the annulus, thus reducing the migration rate. As a result, pressure increase on surface would most likely be
less dramatic when compared to using a water based mud (WBM). Figure 8 shows the decision tree that was
developed in case there was a need to drill the section using PMCD drilling technique.
Since the rig was equipped with two independent BOP stacks, the auxiliary BOP on surface required
mandatory testing during normal drilling operations. This included BOP pressure testing. The manifold
supplying hydraulic fluid for functioning the auxiliary BOP could be linked to the hydraulic supply of the
RGH.
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To drill the 14⬙ shoe the MPD chokes were set to maintain the required BHP in automatic mode. On
one occasion while drilling, a sudden decease in SBP was observed while the MPD choke started to close
to try and maintain the BHP constant. The well was then shut in at the MPD chokes to try and pin point
the issue. It was noticed that the hydraulic supply to the RGH was showing low hydraulic pressure
warning on the panel. On investigation it was revealed that the hydraulic supply to the RGH was low due
to the fact that it was being used to function the standby BOP and therefore it automatically closed the
The same procedure was implemented to acquire a loss free ECD. The new ECD was close to the pore
pressure higher up the well or around the 14⬙ shoe. This resulted in top down cross flow scenario where the
bottom of the well was taking mud while higher up the ECD was very close or equal to the pore pressure. This
resulted in circulating gas that entered the wellbore through the MPD system. Since SBP was applied and the
fact that the BHP was higher than the reservoir fluid bubble point, gas was breaking out of solution almost at
surface. PMCD drilling techniques could have been implemented, but it required assurance that the formation
While stripping to surface, the returns were initially lined up from the mud bucket to the active pits.
Consequently, it was taking a long time to register any volume change. While the fluid was traveling to
the active pit, the next stand of drill pipe was already being pulled and drained using the mud bucket. This
resulted in an assumption that the well was not taking the correct volume of fluid. To eliminate this,
returns from mud bucket were lined up to the trip tank. The smaller trip tank capacity allowed for
improved monitoring of pipe displacement.
A tapered drillstring was used to drill the carbonate section of the well. This presented an issue as the
transition point occurred with the bit still below the BOPs. As a result, the RCD bearing had to be replaced
with a new rubber size to accommodate the smaller OD drill pipe. Since changing the RCD bearing on
a deepwater drillship can be time consuming, it was decided to try and use the bearing that had
accommodated the larger OD drill pipe to be used on smaller OD drill pipe. This worked well and saved
quite a bit of valuable time and reduced the cost.
With the drillstring and bit out of the hole, the choke line was lined up at surface to monitor wellbore
pressures. Figure 14 shows various pressure trends over time. It can be seen that the choke line pressure
increased very little over time. The data showed that it only increased around 20 psi over 10 hours which
proved that gas migration in the SBM was very low. The riser pressure and trip tank were also monitored
to ensure that the BSR on the BOP was not leaking as it was used to trip out of the hole.
SPE/IADC-179188-MS 19
a maximum gas peak of 18%. To limit any potential high gas peaks, washing down was limited to
ten minutes per stand with the objective of dispersing the gas throughout the mud returns (cutting gas
volume by a ratio of 10:1 while washing down). While drilling with pump rates downhole of between
800 - 850 gpm and 300 - 350 gpm on the boost line, gas peaks of 20% were measured. The SBP was
continually being adjusted in efforts to reduce mud losses. Such peaks again caused the Coriolis
meter to produce erroneous readings.
For BHA#11, it took 30 hours to trip approximately 6,000 m of drill pipe out of the well. The average
mud loss rate was 30 bbl/hr, but this was necessary to reduce gas ingress into the wellbore. Mud losses
for the period can be clearly seen on the 17th and 18th April in Figure 16.
Downloaded from http://onepetro.org/SPEMPDU/proceedings-pdf/16MPDU/All-16MPDU/SPE-179188-MS/1417690/spe-179188-ms.pdf by Repsol Services Company user on 15 August 2022
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Figure 16 —Mud losses, BHA runs and depth drilled vs time for the carbonate section
SPE/IADC-179188-MS
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BHA #12 was run in hole (RIH) to TD with limited regard for surge and greater emphasis on managing
the total losses. While surge obviously creates losses, the applied surface back pressure and the reduced
time to reach TD was having a greater influence on minimizing total losses. More importantly, the more
time spent off bottom (BHA not at TD) and not circulating, the more gas entered the wellbore and the
more time would be spent circulating the gas out.
The drill string was washed down for the final 400 m to TD. The running speed again limited to ten
by this stage, standpipe pressures were being continually referenced along with the MWD annular
pressure sub to maintain the desired BHP. Total circulation time was reduced to 8 ½ hours before drilling
resumed. While drilling, the MPD choke was continually manipulated both while circulating, and on
connections, in order to maintain a loss rate of between 30-40 bbl/hr. This was less than that experienced
with BHA #12, which was 120-150 bbl/hr. Gas still came to surface and, assisted by the low ROP in the
hard and abrasive formation, it was possible to either reduce or shut down the booster pump, thus allowing
nipple up through the rig floor. A single wireline BOP ram and dual pack off assembly were installed at
the top. The WPCE was made up and run as two sections with the lower section comprising of the logging
adapter and casing joints, sufficient in length to provide a stick up at the rig floor. The upper section
comprised of more casing joints, the wireline BOP ram and dual packoff. Figure 17 shows the
configuration. The logging adapter had the same profile as the RCD bearing assembly and, when latched,
provided the same external seal rating.
Figure 17—Logging adapter and shooting nipple to rig floor - Upper and Lower Assembly
SPE/IADC-179188-MS 27
The length of casing joints was configured such that the lower section with the logging adapter could
be run below the rig floor and suspended just short of the RCD housing. Suspending the lower section in
the rotary table kept the opening (connection point) stationary relative to the rig floor – i.e. to remove the
effect of rig heave for making up and running the wireline tool string. The space out was such that any
heave would prevent the adapter clashing with the RCD housing.
The logging tools were run through the lower section and hung off on the casing stick up using a C
The reason for using a multi fluid pill as opposed to a single weight pill was to control the pill interface
and provide better control on the well. Heavier fluids were placed higher up in the riser, with an adequate
column of 9.8 ppg mud positioned at the BOP and base of the riser in order to prevent any heavier fluid
dropping below the BOP. Had this happened, the well would go onto slight losses until the heavy fluid
entered the casing with increased losses due to the reduced internal diameter (I.D.) of the casing.
While logging, the well was monitored from surface using the MPD equipment. A 9.8 ppg mud was
Due to the need to later run logging tools with slightly larger O.D.’s than the shooting nipple would
allow, it was necessary to modify the procedure for running the tools. The OD of certain components was
greater than the shooting nipple casing I.D. and as such, the tools had to be run and hung off on the rig
floor with the lower section of shooting nipple installed over the tools. This was a more challenging
method, and the ideal choice would have been the use of a larger I.D. casing shooting nipple and
associated crossovers.
A further challenge faced, was expansion of the elastomeric packers on certain logging tools. CO2 gas
was becoming entrained in the elastomers resulting in explosive decompression of the packers. This meant
the uniform O.D. of the tools was becoming distorted.
Logging data provided a valuable insight on the loss zone show and cross flow in Figure 21. It is
evident how losses occurred after drilling the 14⬙ shoe. It was initially thought that the losses occurred due
to a couple of loss zones, but the logs provided a unique insight and showed that the single loss zone span
over 200ft in length.
30 SPE/IADC-179188-MS
5. The use of SBM as a drilling fluid, while more expensive to lose, was still the preferred option
when considering the alternative consequences of a water based mud with high gas levels and
extended shut in periods increasing the risks of hydrate formation. .
6. Closer review of every aspect of the equipment being used during MPD Operations. Hindsight
showed the need to analyze in more detail, the seals used in the BOP and the pressure relief valve
(PRV) installed for the riser over pressure protection as being variable as opposed to fixed.
Acknowledgements
The authors thank Repsol and Blade-Energy Partners for their permission to present this paper and also
all who contributed to the success of this project.
Nomenclature
Abbreviation
References
1. Email showing Logging data and the loss zone
2. Modeling for carbonate section
3. R. Ho, D. Moore, D. Pirie, Marathon Oil Company ⬙Drilling DeepWater Carbonates using MPD on a Dyn Pos
Drillship⬙ SPE-167995-MS
4. Andre Alonso Fernandes, Danilo Signorini Gozzi, Emmanuel Franco Nogueria, Felipe de Souza Terra, Guilherme
Sirqueria Vanni, Rafael Schettini Frazao Filho, Petrobras ⬙MPD/MCD Offshore Application on a Dynamic Position-
ing Rig⬙ SPE-173825-MS
5. Repsol End of Well Report, Rev 0, September 2015