Dual Gradient Drilling: Has Its Time Finally Come?cargos-paquebots.net/Revue de...

Dual Gradient Drilling:

Has Its Time Finally Come?

AADE Emerging Technologies Forum

Ken Smith

Chevron Deepwater BU Project Manager, Dual Gradient Drilling Implementation

April 22, 2009

2© Chevron 1/2008 20090422, AADE Emerging Technologies Forum

Key Messages

• Deepwater Gulf of Mexico drilling is extraordinarily challenging

• Dual gradient drilling is the solution to the water depth-related challenges, and

• The Managed Pressure Drilling capabilities of the technology can solves a number of downhole problems related to annular pressure changes.

• What is DGD and why does it work?

• It’s been done before.

• We’re considering it again!

Deepwater Gulf of Mexico Situation Today

We routinely drill nearly “un-drillable”wells

>30,000’ deep

> 6,000’ water depth

> 9,000 MRI’s

Narrowing of the PP/FG window and ECD’s lead to MANY tight tolerance casings

New rigs capable of drilling to 40,000’ to enable industry’s large portfolio of deepwater projects

We’re just about against “The Wall”

Conventional Casing Program

Deepwater Casing Program

We’re nostalgic for the past!

4© Chevron 1/2008 20090422, AADE Emerging Technologies Forum 4

The Solution

Dual Gradient Drilling is a Form of Managed Pressure Drilling

It Removes the Impact of Water Depth

1996 through

1996 1996 through through

20012001

Single vs. Dual-Gradient Drilling

Dual Gradient

Heavier Mud w/ Seawater Above

Mudline

Same Bottom Hole

Pressure

SingleMud

Weight

Conventional

Seabed

SeawaterHydrostatic

Dual Gradient MudHydrostatic

Conventional Mud Hydrostatic

Why Does It Work?

Pressure, psi

Density

Seawater Hydrostatic

Single Gradient Density at TD

Casing Points – Conventional

Seafloor

Pressure

Fracture Pressure

5 Casing Points

TDPore Pressure

Fracture Pressure

Casing Points – Dual Gradient

Seafloor

Dual Gradient Density at TD

Pressure

4 Casing Points

Pore Pressure

Fracture Pressure

Seafloor

Casing Points – Dual Gradient

Pore Pressure

Pressure

3 Casing Points

Dual Gradient Density at TD

Application of Dual Gradient Drilling: Potential for Elimination of Casing Strings in Complex Wells

Potential Well Planwith DGD Application

Actual Casing Program

6 casing strings (yellow) potentially could have been eliminated had DGD technology been available

Simplified Well Design Allows More Completion Opportunities

13-3/8

(Conventional)5-1/2"

Tubing

36 3626 20

(SubSea MudLift)

7" Tubing

11-3/4

13-3/8

SWF Zone

How Will DGD Improve the Deepwater Business?

ENHANCE SAFETY AND ENVIRONMENTAL PERFORMANCE AND RISK

• Much better detection, reaction and control of kicks, which WILL be smaller

• Inherently safer wells

• Better environmental footprint

REDUCE DRILLING COST AND RISK

• Fewer strings of casing to reach TD

• Virtual elimination of lost circulation due to ballooning formations

• Significant reduction in “hidden downtime”

• Better cement jobs/fewer squeezes

IMPROVE WELL INTEGRITY

• Reduced casing loads

• Greater completion integrity

IMPROVE WELL PRODUCTIVITY

• Designer completions will become possible

IMPROVE EXPLORATION PERFORMANCE

• Easier geological sidetracks

• More effective reaction to formation “surprises”

IMPROVE PREDICTABILITY

• Improved reliability/reduced downtime, leading to

• More predictable outcomes

• Lower $/BOE Cost• Lower Minimum Economic Field Size

MudLift Pump (MLP)

Mud Return Line

Drill String Valve (DSV)

SubSea MudLift Drilling Defined Major Components

Subsea Rotating Device (SRD)

The Hydril MudLift Pump is Driven by Seawater

Displacing Mud to Rig

Seawater Pumped from RigSeawater Discharged to Sea

Mud Enters From Well

Test System Pumped for Nearly 2 Years

Solids Pumping Capabilities

Drill String Valve (DSV ) was Tested for LCM and MWD Signal Throughput

Subsea Rotating Device Testing

SRD HousingSRD Housing

Stripper Element TestingStripper Element Testing

Purpose: Provide a mechanical interface between the drilling mud in the well and the seawater in the riser. Also minimizes gas ingress to the riser. Insert below retrieves on drill string every trip.

Factory Acceptance Testing Began Feb 28, 2001

Test Well Drilled in Aug/Sept, 2001

Diamond OffshoreOcean New Era

2nd Generation,Built in 1975

Texaco WellGC 136 #8

Shasta Prospect

Driller’s Subsea Controls

Control / Monitoring Screens

Equipment is Only Half the Challenge

12 to 15 Man-Years Required to Develop DGD Operations and Well Control Procedures

Drilling Operations Unchanged Changedw/SMD Test

1. Circulation

2. Drilling ahead

3. Connections

4. Tripping

5. Displacing drilling fluids

6. Lost circulation treatment

7. Wireline logging

8. Running casing

9. Running liner

10. Cementing casing

11. Cementing liner

12. Balanced plug

13. High pressure squeeze

14. Stuck pipe procedures

15. Use and installation of packers

ALL Well Control Operations Change

Well Control Operations Unchanged Changedw/SMD Test

1. Kick detection2. Basic well control with DSV

(Driller's Kill)3. Basic well control w/o DSV: NO

shut-in4. Basic well control w/o DSV: WITH

shut-in5. Kick detection during tripping

6. Shut-in while tripping

7. Trapped pressure management

8. Volumetric well control

9. Lubrication kill

10. Stripping

11. Bullheading

12. Shut-in while running casing

13. Test casing seat

14. Dynamic kill

SMD Drilling Simulator

Training Materials and Process

Basic SMD Training (DGD)

Pre-Spud Materials

Drilling Program

Procedures Training

Well Control Training

Training Matrix

Advanced A

Intermediate I

Basic B

Position Wel

Operator OthersDrilling Manager I I I B Subsea Engineer I I A ADrilling Superintendent I I I B B Mudlogger I B BDrilling Engineer A A A B B Mud Engineer I I I IRig Supervisor I A A A I Cementer B B B B

Hydril Personnel B B B ADrilling Contractor Regulatory Agencies B A B I IRig Manager A I I I I DGD Consultant A A A A AToolpusher I A A A A Partners I I I I BDrilling Engineer I A A A ADriller I I A AAssistant Driller B B A ARig Mechanic I ADerrickhand B B B BFloorhand B B B

Training LevelsComprehensive understanding of all facets of DGD; ability to formulate, design and communicate DGD procedures and techniquesWorking understand of DGD concepts and relational impacts to drilling operations; ability to use knowledge to make real-time decisions regarding well and equipmentPractical understanding of DGD as related to his/her job functions

Pre-spud and Training Included Rig Crews, Service Personnel, MMS, Operator Representatives

and Engineers

Hoisting the MLP Through the Moonpool

Driller’s Main Panel

Moving in BOP

Landing SMD/ LMRP on BOP Landing SMD/ LMRP on BOP

Heading Down with the MLP

Field Test SMD System and Riser

•Auxiliary Lines on riser

Running Mud Line

Gumbo Drilling

Gumbo Dogs

All Important Objectives Met

• Manage Bottom Hole Pressure at All Times

Constant inlet pressure mode (Drill)

Constant rate mode ( Kick or Kill)

• Cuttings to Surface

• Verify Dual Gradient Operation Procedures

• “Kick” detected/shut-in <2 bbls

• All Equipment Operated as Designed

• Personnel adapted quickly, training paid off

• 90% of Field Test Objectives met

The Clear Leader

Dual Gradient Drilling: Has Its Time Finally Come?cargos-paquebots.net/Revue de...

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