MPD Fundamentals DPA Rio

2/18/2011
MPD Fundamentals
Rio de Janeiro, Brazil Feb 2011
Agenda

About MPD MPD Classification & Techniques The MPD Engineering Process How does MPD solve pressure related problems during drilling operations? Equipment used in MPD Operations Operational considerations when doing MPD Automated MPD Operations
2010 Schlumberger. All rights reserved.
MPD Fundamentals - Calgary, AB. Dec 2010
2/18/2011
What is NOT MPD?
Independent of the fluid system, MPD IS NOT A TECHNIQUE TO DRILL UNDERBALANCED. By definition, MPD operations are planned to keep the bottomhole pressure above the pore pressure at all times.
What is MPD? IADC defines MPD 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.
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Why MPD?
Extends casing setting depth Use of a lighter mud weight in cases where high mud weights is a concern Dynamic management of small influxes Immediate Pressure Profile change by modifying WHP Increases ROP Reduces Formation Damage Limits or avoids Lost Circulation
Avoids Differential Sticking

Avoids cavings associated with geomechanical instability
MPD/UBO IADC Classification

The International Association of Drilling Contractors (IADC) has established an MPD/UBO Classification System based on three digits, each digit indicating:
Risk Level Classification Application Category Fluid System Classification
0 Performance Enhancement only. No hydrocarbons 1 Well incapable of natural flow to surface 2 Well capable of flowing to surface but control can be done conventionally 3 Geothermal and non-hydrocarbon bearing formations 4 Hydrocarbon bearing formations. MASP < MPD Equipment Rating 5 Hydrocarbon bearing formations. MASP > MPD Equipment Rating
A MPD B UBO C Mud Cap Drilling
1 Gas 2 Mist 3 Foam 4 Gasified Liquid 5 Liquid
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MPD Variations
Constant Bottom Hole Pressure Pressurized Mud Cap Drilling Dual Gradient Drilling HSE & Performance Drilling Low Head Drilling
The MPD Engineering Process Planning Phase I

Engineering
Data Gathering Candidate Screening Flow Modeling Technical Peer Review Feasibility Study Feasibility Study Approval
Operations
Client Ops Data Collection
Equipment Pre-Selection
P&ID
Equipment List
Personnel List
Execution Phase
1. Well Supervision 2. Management of Change 3. Reporting
Planning Phase II
UBD/MPD Program Technical Peer Review Develop Basis of Design Fine Tune Operating Window
Evaluation Phase
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Case 1. Narrow Mud Weight Windows

How is it done conventionally in Normal Mud Weight Window?
Surface Pressure = Atmospheric Pressure
Depth
Static Pressure Gradient (ESD) Dynamic Pressure Gradient (ECD)
1. Static condition (pumps off) 2. Dynamic condition (pumps on)
Pore Pressure
Fracture Gradient
Friction Losses Pressure
Pressure

How is it tried to be done conventionally in Narrow Mud Weight Window?
1. Static condition (pumps off) 2. Dynamic condition (pumps on)
Depth
Pore Pressure
Fracture Gradient
Loss of circulation!!!!!!
Pressure
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Solution: Constant BHP MPD Narrow Mud Weight Window
1. Static condition (pumps off)
Depth
2. Dynamic condition (pumps on)
Pore Pressure
Fracture Gradient
BHP is constant at all times
Pressure
Case 2. Formations that lose circulation at low pressure gradients

Conventional vs. MPD Approach
1. Water Gradient
Gradient were losses are observed
Depth
Tried curing the losses No success 2. Diesel Gradient Tried curing the losses No success
Loss Loss of of circulation!!!!!! circulation!!!!!!
3. Water + Nitrogen Success
Fracture Gradient
Pore Pressure
Pressure
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Other techniques that can be applied

Non-existing Mud Weight Window
EMW (kg/m3)
800 900 1000 1100 1200 1300 800 900
EMW (kg/m3)
1000 1100 1200 1300
Losses
Influx
Losses
Underbalanced Drilling
Used when a Mud Weight Window does not exist (BHP is always lower than the pore pressure at some point in the well) Influx flow rate can be controlled dynamically using the WHP Requires surface fluid handling facilities In the case of corrosive fluids from the reservoir, proper measurements must be taken to avoid corrosion
Mud Cap Drilling

Used when a Mud Weight Window does not exist (BHP is always higher than the losses pressure at some point in the well) A variation called Pressurized Mud Cap Drilling (PMCD) is used for safety reasons Requires high volumes of sacrificial fluid Fractures wide enough to inject cuttings must exist
Conventional Approach vs. MPD In the previous slides, one of the most applied MPD techniques known as Constant Bottom Hole Pressure has been shown. One of the limitations of this technique (among other MPD techniques) does not come from any technical, operational or logistic issue but from an old paradigm:
The presence of pressure on surface during drilling operations is undesirable

2/18/2011
Conventional Approach vs. MPD
Losing the control of the operation (and eventually, of the well) is what is undesirable, independently of the used drilling technique. Independently of the well condition, you will detect any pressure-related anomaly quicker using MPD than during conventional operations.
MPD: Technology for extreme environments
Deep Water
ERD Horizontal
Mature Depleted On & Off Shore
HPHT Wellbore breathing avoidance Kick detection Narrow margin Wellbore stability Loss avoidance Pressure environment detection (Dynamic Flow-in/Leak-Off)
Fractured Reservoirs
Kick detection Narrow margin ECD reduction Loss avoidance Wellbore stability
Narrow margin ECD reduction ECD reduction Loss avoidance Loss avoidance Stuck pipe avoidance Wellbore stability Kick detection Hole cleaning Drilling optimization Drilling optimization Reservoir damage
Kick detection Controlled losses Reservoir damage
2/18/2011
Examples of MPD Systems Applications
MPD Equipment Diagram

Equipment for Conventional Operations
Standpipe Rig Pumps Bell Nipple Flow Line Mud Pits BOP Stack Shakers
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Equipment for MPD Operations
Standpipe Rig Pumps Rotating Flow Head Shakers
Primary Line
Mud Pits
BOP Stack Separator
MPD Choke Manifold
To Rigs Poor Boy

Equipment for MPD Operations
Standpipe Rig Pumps Rotating Flow Head Shakers Nitrogen Generation Unit
Primary Line
Mud Pits
BOP Stack Separator
Flare
MPD Choke Manifold
Line to shakers
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Constant Bottom Hole Pressure (CBHP) Operations The CBHP technique aims to compensate any condition that could change the bottom hole pressure by adjusting the Surface backpressure. Among these events that could modify the bottom hole pressure are changes in: Mud Flow Rate Mud Properties (Density, Rheology) Well depth BHA Tripping Velocity
Constant Bottom Hole Pressure (CBHP) Operations

Basic Operations for the CBHP Technique
1. BHP Measurement / Computation

To be able to execute CBHP operations, it is necessary to know the BHP value, which is the parameter to control. It can be done by two means:
Direct Measurement: Using PWD tools. Analytic Computation: Using hydraulic simulators that process the real-time data from the rig data acquisition system and compute the BHP.
2. Surface Back Pressure Adjustment

Assuming that the flow rate has to remain constant, the only parameter to compensate for pressure-related events that cause a variation in the bottom hole pressure is the Surface Back Pressure.
To adjust the Surface Back Pressure a choke valve on surface in the MPD equipment area is used.
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How is it done manually?
Information Input by user
Rig Info Input by user (updated manually) MW Depth Flow Rate etc
Drilling Parameters are read and entered manually into a hydraulic simulator. Simulations are run offline by a trained engineer, who needs to constantly check the parameters and run simulations if necessary. There is an important time gap between any event and the adjusting time to compensate for those events. A choke operator is necessary 24 hours a day to adjust the choke valve to keep the surface pressure at the desired value while drilling. Used when MPD techniques are necessary, but a very precise surface control and bottomhole pressure is not mandatory.
Well Geometry BHA Geometry BHCP (Set Point)
Conventional Offline Hydraulic Simulator (not updated in Real Time)
Calculate WHP Flow to Shakers or Separator
Calculated WHP <> Actual WHP?
Yes
Instructor Choke Operator to Set new WHP (A dedicated operator is necessary)

How is it done automatically?
Information Input by user
Well Geometry BHA Geometry BHCP (Set Point)
Rig Info Input via WITS (continuously updated)

MW Depth Flow Rate etc
Drilling Parameters are fed into a real-time hydraulic simulator. Simulations are run continuously in real time without human intervention. The system reacts immediately to any event and adjusts the surface backpressure to compensate for those events with a very small lag time. No dedicated choke operator is necessary to keep the surface pressure at the desired value when drilling or tripping. Used when MPD techniques are necessary and a very precise surface control and bottomhole pressure is mandatory
RT Hydraulic Simulator Calculate WHP Flow to Shakers or Separator No dedicated operator is necessary
Calculated WHP <> Actual WHP?
Yes
Set new WHP remotely
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Automated Event Detection

Process Flowchart
Flow In = Vol. Stroke Displacement x Strokes / Min
Real Time Data

Flow In (SPM) Flow Out (Coriolis Meter) PVT etc Event Detection Software
Event Probability > Threshold ?
No
Yes
ALERT ON Flow Out = Direct Reading from Coriolis Meter Take action to properly manage the event
MPD Automated Variation:

Semi-Automated Operation
Remote Console (Engineers Trailer)
Autochoke #2 Local Console (Manifold Area) Autochoke #1
Play Video
Composed of three main components: Autochokes, Local and Remote Consoles Rated to 1,500 psi (choke body pressure rating = 10,000psi) System Energy Redundant Backup (Electric and Pneumatic) Set Point Backpressure can be set either at the local or remote console (1 controlling the Autochokes at the time) and the system automatically adjusts the Autochokes to keep it at the set value.
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Equipment used in MPD Operations

Actual Equipment Distribution
Rotating Control Device MPD Choke Manifold Separator Line to Flare
Primary Line (flow from the well)
Line to shakers

Actual Equipment Distribution
Nitrogen Injection Line Nitrogen Generation Package
Vertical Separator Flare Line (Blooie Line) Returns Line (to shale shakers) MPD Choke Manifold
ESD
Primary Line (flow from well)
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Automated System Process Diagram
Automated MPD System Actual Set Up
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Rotating Control Device (RCD)
Flow Line Hydraulic Valve 7 1/16 x 5K 4/6 x 5000 Line to UBD Choke RCD
RCD5 RCD3
Optimal (Schlumberger)
HOLD2500
7100
7800
Smith (SLB)
Weatherford
Strata

Rotating Control Device (RCD)
Play Video
RCD3 Model 1000 psi @ 100 rpm

Model RCD3 RCD5 Pressure Rating psi / MPa 3,000 20.68 5,000 34.47 Bottom Flange Size in / mm 11 279.4 13 5/8 346.1
RCD5 Model 2000 psi @ 100 rpm

Bore Diameter with bearing without bearing in / mm in / mm 7 1/16 11 179.4 279.4 9 1/16 13 5/8 230.2 346.1
Lateral outlet size in / mm 7 1/16 179.4 Two: 7 1/16 & 2 1/16 179.4 & 52.4
Height in / mm 40 1/2 1028.7 44 1/2 1130.3
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Operational considerations when doing MPD

Space (height) for the RCD MWD/LWD Signal Attenuation when Gas is Injected (Mud Pulse Systems) Connections Procedure
Equivalent Liquid Flow Rate Limit for Mud Motors

Hole Cleaning (Multiphase environments) Layout (extra space for equipment) BOP Stack / Rig Misalignment Drill String condition Crew Training
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2/18/2011
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2/18/2011

2010 Schlumberger. All rights reserved.

MPD Fundamentals - Calgary, AB. Dec 2010

What is NOT MPD?

MPD Fundamentals - Calgary, AB. Dec 2010

Avoids Differential Sticking

MPD/UBO IADC Classification

A MPD B UBO C Mud Cap Drilling

1 Gas 2 Mist 3 Foam 4 Gasified Liquid 5 Liquid

2010 Schlumberger. All rights reserved.

MPD Fundamentals - Calgary, AB. Dec 2010

The MPD Engineering Process Planning Phase I

MPD Fundamentals - Calgary, AB. Dec 2010

Case 1. Narrow Mud Weight Windows

Static Pressure Gradient (ESD) Dynamic Pressure Gradient (ECD)

1. Static condition (pumps off) 2. Dynamic condition (pumps on)

Friction Losses Pressure

Case 1. Narrow Mud Weight Windows

Static Pressure Gradient (ESD) Dynamic Pressure Gradient (ECD)

MPD Fundamentals - Calgary, AB. Dec 2010

Case 1. Narrow Mud Weight Windows

2. Dynamic condition (pumps on)

BHP is constant at all times

Case 2. Formations that lose circulation at low pressure gradients

Loss Loss of of circulation!!!!!! circulation!!!!!!

3. Water + Nitrogen Success

MPD Fundamentals - Calgary, AB. Dec 2010

Other techniques that can be applied

Mud Cap Drilling

2010 Schlumberger. All rights reserved.

The presence of pressure on surface during drilling operations is undesirable

MPD Fundamentals - Calgary, AB. Dec 2010

Conventional Approach vs. MPD

2010 Schlumberger. All rights reserved.

MPD: Technology for extreme environments

Mature Depleted On & Off Shore

Kick detection Controlled losses Reservoir damage

2010 Schlumberger. All rights reserved.

MPD Fundamentals - Calgary, AB. Dec 2010

Examples of MPD Systems Applications

2010 Schlumberger. All rights reserved.

MPD Equipment Diagram

2010 Schlumberger. All rights reserved.

MPD Fundamentals - Calgary, AB. Dec 2010

MPD Equipment Diagram

Standpipe Rig Pumps Rotating Flow Head Shakers

BOP Stack Separator

MPD Choke Manifold

To Rigs Poor Boy

2010 Schlumberger. All rights reserved.

MPD Equipment Diagram

BOP Stack Separator

MPD Choke Manifold

MPD Fundamentals - Calgary, AB. Dec 2010

Constant Bottom Hole Pressure (CBHP) Operations

1. BHP Measurement / Computation

2. Surface Back Pressure Adjustment

MPD Fundamentals - Calgary, AB. Dec 2010

Constant Bottom Hole Pressure (CBHP) Operations

Well Geometry BHA Geometry BHCP (Set Point)

Conventional Offline Hydraulic Simulator (not updated in Real Time)

Calculate WHP Flow to Shakers or Separator

Calculated WHP <> Actual WHP?