OTC-25292-MS ECD Management Toolbox for Floating Drilling Units John-Morten Godhavn, Espen Hauge, Dag Ove Molde, Ivar Kjøsnes, Sturle Gaassand; Statoil Børre Fossli, Roger Stave; Enhanced Drilling Slide 2 Contents • • • Motivation ECD Management Toolbox • Controlled Mud Level Overbalance (Troll) • Controlled Mud Level Underbalance (GoM) • ECD Control (R&D) Summary OTC-25292-MS, ECD Management Toolbox for Floating Drilling Units, John-Morten Godhavn Motivation Lost time due to wellbore instability Well 1 Well 2 Well 3 Well 4 Well 5 Well 6 NCS std NCS HPHT GoM deep water 7500 ft 15000 ft 22500 ft 30000 ft 3 OTC-25292-MS, ECD Management Toolbox for Floating Drilling Units, John-Morten Godhavn ECD Management toolbox for Floating Drilling Units Controlled Mud Level Overbalance (CML-O): • Riser fluid level always maintains hydrostatic overbalance • EC-Drill - Piloted on Troll in March 2014 4 2014-03-23 Controlled Mud Level Underbalance (CML-U): • Riser fluid level may not provide hydrostatic overbalance • Fast closing annular • ECD-Management (ECD-M) • To be piloted in GoM Q3-14 Managed Pressure Drilling: • Riser always filled with mud • Subsea RCD • ECD-Control (ECD-C) • Potential next generation MPD for floater • No additional mud return line OTC-25292-MS, ECD Management Toolbox for Floating Drilling Units, John-Morten Godhavn Controlled Mud Level mud pit rig pump drill floor 0 Riser level subsea pump h Riser level reference • h ref pressure set-point Bottom hole pressure sp pdh depth ECD lookup table sp pdh fracture limit pore pressure PWD Control goal: pressure 5 OTC-25292-MS, ECD Management Toolbox for Floating Drilling Units, John-Morten Godhavn Controlled Mud Level mud pit rig pump drill floor 0 Riser level subsea pump depth h Riser level reference rpm h ref pressure set-point sp pdh h Level controller ECD lookup table fracture limit h ref sp pdh pore pressure PWD Control goal: pressure 6 OTC-25292-MS, ECD Management Toolbox for Floating Drilling Units, John-Morten Godhavn Controlled Mud Level mud pit rig pump drill floor 0 Riser level subsea pump depth h Riser level reference =h rpm ref pressure set-point h sp dh p Level controller ECD lookup table fracture limit h ref sp pdh pore pressure PWD Control goal: pressure 7 OTC-25292-MS, ECD Management Toolbox for Floating Drilling Units, John-Morten Godhavn ECD lookup table example 8 OTC-25292-MS, ECD Management Toolbox for Floating Drilling Units, John-Morten Godhavn Slide 9 Troll EC-Drill operation March 2014 • • • • Drill 8 ½” laterals with low level Conventional well control Drill pipe will U-tube on connections Success criteria achieved: • Deployment and recovery • +350 psi reduced BHP • Stable riser level • Control of gas in riser • Volume control • Reduced mud consumption • No severe losses OTC-25292-MS, ECD Management Toolbox for Floating Drilling Units, John-Morten Godhavn Equipment Installed EC-Drill Troll Mud funnel Gas sensors Umbilical Winch In both diverter lines In flow line Flow head Top fill pump Control and Office Container Modified Riser Joint & fixed return line Pump skid on casing trolley SPM OTC-25292-MS, ECD Management Toolbox for Floating Drilling Units, John-Morten Godhavn Pilot objectives and results 1 11 2014-02-24 OTC-25292-MS, ECD Management Toolbox for Floating Drilling Units, John-Morten Godhavn Pilot objectives and results 2 Fingerprinting graph on connection Baseline volume Connection volume Baseline flow rate Connection volume OTC-25292-MS, ECD Management Toolbox for Floating Drilling Units, John-Morten Godhavn ECD-Management system • • • ECD-M is a CML-U system developed by Statoil ECD-M consist of the following sub systems: – EC-Drill from Enhanced Drilling: Controlled Mud Level – DSRM (Delta Seal Riser Module) from MPO with quick closing annular to enable CML-U – Riser Gas Handler – Early Kick Detection with Coriolis Planned to be installed on the Maersk Developer Q2/Q3 2014 Mud Return Line Pressure Transducer DSRM Subsea Pump Module Riser Isolation Valves OTC-25292-MS, ECD Management Toolbox for Floating Drilling Units, John-Morten Godhavn ECD-M rig modifications Control Containers Office/Tool Container Umbilical winches, MPO and ED Riser Gas Handler DSRM 14 LARS Subsea Pump Module Flexible hose for Mud Rerun Line OTC-25292-MS, ECD Management Toolbox for Floating Drilling Units, John-Morten Godhavn CML–O or CML-U • Need for constant bottomhole pressure • Underbalance situation for pump shutdown: – If ECDred > MWDH – PP, then Fast annular required (CML-U) MW=BHPDyn CML annular not req. CML annular req. BHPPS = MW-ECD ECD PP 15 FG OTC-25292-MS, ECD Management Toolbox for Floating Drilling Units, John-Morten Godhavn ECD Control (ECD-C) RKB Statoil research project: builds on EC-Drill & ECD-M Riser manifold – – – – • • Subsea pump creates pressure differential across RCD Benefits compared to back pressure MPD: – – • May drill med overbalanced mud - hydrostatic overbalance all time Does not add back pressure in riser Benefits compared to CML: – – – – • • Subsea RCD A manifold with valves is fixed to the riser Boost line connected to manifold Return back into riser - no mud return line Fast regulation of wellbore pressure Elimination of potential problems with evacuated riser No mud return line or top fill pump required Flexibility to work drillstring in pack-off and lost circulation situations Main challenge: Reliable RCD, in particular in rough sea Feasibility studies ongoing Marine Riser Drillpip e Control Umbilical Subsea manifold P Pressure transmitter s SPM 300-400 m P RCD Booster Line • • Closed valve Open valve BOP OTC-25292-MS, ECD Management Toolbox for Floating Drilling Units, John-Morten Godhavn Comparison: simulated connections Connection 2: CML or ECD-M w/open URA - fill riser 600 Riser pressure Set-point 0 5 10 15 20 25 30 35 0 5 10 15 20 25 30 35 15 20 Pump Bit SPM Top-fill Boost 1000 5 10 15 20 25 30 35 Bottomhole pressure error Riser pressure error 0 5 10 15 20 Time [min] 5 10 25 30 35 Fill riser: ~15 min added time on connections. BHP +/-75 psi 40 15 20 25 ECD ESD PP 30 ShMin 35 0 5 10 15 20 25 30 35 5 10 0 Bottomhole pressure error Riser pressure error 0 5 10 15 20 Time [min] 25 30 Close riser annular to save time. BHP within +/-50 psi 35 40 0 5 10 2000 15 20 25 30 35 40 15 20 25 20 25 ECD ESD PP 30 ShMin 35 40 35 40 Pump Bit SPM Boost 1000 0 40 100 -100 0 16.5 16 40 Pump Bit SPM Top-fill Boost 1000 40 100 0 0 2000 0 0 Gradient [ppg] Gradient [ppg] 40 600 17 16.5 16 35 Riser pressure Set-point 800 400 40 Flow rate [gpm] 10 Pressure deviation [psi] Gradient [ppg] Flow rate [gpm] Pressure deviation [psi] 600 Pressure deviation [psi] 5 ECD ESD PP 25 30 ShMin Flow rate [gpm] 0 2000 -100 Riser pressure Set-point 17 16.5 0 800 400 40 17 16 1000 Pressure [psi] Pressure [psi] Pressure [psi] 800 400 Connection 4. ECD-C w/RCD Connection 3. ECD-M w/closed URA 1000 1000 0 5 10 15 30 100 0 Bottomhole pressure error Riser pressure error -100 0 5 10 15 20 Time [min] 25 30 35 40 ECD-C with RCD. BHP +/-40 psi OTC-25292-MS, ECD Management Toolbox for Floating Drilling Units, John-Morten Godhavn Summary New MPD concepts for Floating Drilling Units are being developed by Statoil 1. ECD-M: drill through narrow windows in deep reservoirs with reduced losses and influxes 2. ECD-C: next generation with further benefits, depend on reliable subsea RCD • We think this is the way we drill deep water wells in the future: – safe – efficient – enable advanced wells OTC-25292-MS, ECD Management Toolbox for Floating Drilling Units, John-Morten Godhavn Slide 19 Acknowledgements • • The authors are grateful to the Troll license partners Petoro, Shell, Total, ConocoPhillips and Statoil, for allowing this work to be published. The opinions expressed are those of Statoil and may not represent the views of the other partners. Thank You!
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