Dgd the System Dea 2011

7/27/2019 Dgd the System Dea 2011

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2011 Chevron U.S.A. Inc. All Rights Reserved.

Dual Gradient Drilling

The System

DEA Presentation

June 23, 2011

David Dowell

Chevron North America Exploration andProduction Company


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With DGD, We

Literally Replace

the Mud in the

Drilling Riser witha Seawater-

Density Fluid and

Use a Denser

Mud Below the

Mudline.

2

Same Bottom

Hole Pressure

Dual Gradient Drilling:

Working WITH Nature,

Not Against Her

Dual Gradient

Heavier Mud w/

Seawater Density

Above MudlineSingle

MudWeight

Conventional


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Impact in Deepwater: Casing Point Reduction

3

Seawater

Hydrostatic

Single Gradient

Density at TD

Seafloor

Depth

Pressure

Fracture

Pressure

5 Casing Points Conventionally

TD

Pore Pressure


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Fracture Pressure

Seawater

Hydrostatic

Seafloor

Depth

Pore Pressure

Pressure

3 Casing Points

4

TD

Dual Gradient

Density at TD

Casing Points Dual Gradient


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5


Dual Gradient Drilling

Defined Major Components

5

Subsea Rotating Device (SRD)

MudLift Pump (MLP)

Mud Return Line

Drill String Valve (DSV)

Solids Processing Unit (SPU)


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Normal Drilling The U-tube Is Balanced

6

Sea Level

Mud Line

Drillstring Annulus

Bottom HoleBit


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DGD Drilling The U-tube Is Unbalanced

7

Sea Level

Mud Line

Drillstring Annulus

Bottom HoleBit


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The Drill String Valve Arrests the Natural U-Tube

Valve in BHA

3 Sizes

Evaluating two Major

Companies Designs

Will be Tested in

Top-hole Operations (JIP Design)


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About the Drill String Valve

9

Not essential

Makes operations easier

Arrests the U-tube

Faster connections

More certainty in kick detection

Easier to stop the MLP

Helpful in flow rate management

Helpful in well control pressure reading

Run above the BHA, you cant wireline through it

Two builders

Mechanism of operation, not intuitive


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DGD Subsea Component Stack-Up(Not to Scale)

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MudLift Pump (MLP)

Subsea Manifold

Standard BOP Stack


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The Worlds First DGD-Ready Rig, the Pacific Santa

Ana, will be Delivered in 1Q12.

11


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Surface Changes

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Six rig pumps

Three for power fluid and Three for mud

One back-up for each fluid stream

Additional trip tank (riser fluid)

More piping for handing up to 3 fluids at once

Pits divided for multiple fluids


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Return Line Manifold And A Drilling Choke

Provides a way to

divert mud to: The pits

MGS

Rig choke

Drilling Choke

Drilling Choke

prevents uncontrolled

expansion of return

line gas

Riser FluidTrip Tank

ChokeLine

MUD TRIPTANK

MUDLINE

Pit System

MGS

System

Drilling

Choke

To Rig ChokeTo Pits

Mud

ReturnLine

(MRL)


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Tripping and Displacement Manifold

Returns

Mud from Line A

Mud from Line B

Mud from Line C

Mud from Trip Tank

Choke

Line

MUDLINE

Kill

Line

Mud

Return

Line(MRL)

Allows for management of fluids in:

Choke and Kill Line

Riser


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The Drilling Riser is Modified

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MudLift Pump is Seawater-Powered, so Riser Modifications

are Needed

Two Six inch Lines

Seawater Power Mud Return

No Boost Line

3.5MM lb Flange rating

Standard 15K C&K lines

ChokeLine

Kill

Line

Hydraulic

Line

Mud Return

Line

Seawater

Power

Line

Drill Pipe

Hydraulic

Line

Flange End of Riser


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17



MudLift Pump (MLP)

Subsea Manifold

Standard BOP Stack


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The Subsea Rotation Device (SRD)

Provides a interface between riser and the wellbore

Has the SRD Bypass built into it

Mechanical latching mechanism on the Bearing insert

Rated for: Pressure from below - 2,000 psi Static 1,000 psi rotating

Pressure from above - 1,000 psi static and rotating

Controlled by the MLP control system

Choke and Kill lines pass through it


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19


SRD Joint and Insert


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Subsea Rotating Device Separates Mud from Riser Fluid

Located above the Solids Processing

Unit in the DGD System

The Active guts: seals and bearings

are retrievable

Seals pressure from both below and

above, typically 50 psi, up to 1000 psiWP

Maintains the gradient interface

Allows for rapid Managed Pressure

Drilling type operations

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21


This material is proprietary information of Chevron U.S.A. Inc. and is Confidential Restricted Access to specific,

authorized individuals only. Unauthorized modification, duplication or distribution of this material is expressly

forbidden.

SRD and SPU Must Fit Through the Rotary

Santa Ana has a 72 rotary


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22



MudLift Pump (MLP)

Subsea Manifold

Standard BOP Stack


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23


The Solids Processing Unit (SPU)

Part of a riser specialty joint

Provides feed of mud to MLP

Sizes solids to 1-1/2 or smaller

Controlled and powered by the MLP

control system

Choke and Kill lines pass through it


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Tears Everything to Pumpable Sizes

Sits in Riser below SRD Two separate feed paths

Can be flushed in multiple ways

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MudLift Pump (MLP)

Subsea Manifold

Standard BOP Stack


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The Heart: GEs MudLift Pump

Delivery in 3Q2011

(2) Triplex modules

80 gallon chambers

1800 gpm max rate

10,000 WD rating

18.5 ppg mud

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PUMP SECTION

HYDRAULICS

VALVEMANIFOLD


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About the MLP

Built by GE/ Hydril

Made the original unit that was field

tested

Modernized

About 18 x 18 x 30 high About 450,000 lbs

MULTIPLE redundancies

Operates with six cylinders, five,

four, three or even two in a pinch

Powered by SEAWATER


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Emergency Disconnect

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BOPE systems are NOT changed

Disconnect is at the LMRP and MLP comes with the

LMRP

Disconnected dynamics are similar to conventional


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Pump Modularization

Pump can be broken into

separate lifts for initial lift onto

rig

Triplex Modules are

Interchangeable Mirror Images

29


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Reliability -Initial Endurance Testing

Complete.

Second Phase Starting Pumping

Continuously

Pumped 500,000Cycles

The equivalent of 3wells/~1 year!

Tear Down and X-rays revealed NOCHANGES inDiaphragms

Phase II TestingUnderway

30
http://localhost/var/www/apps/conversion/tmp/scratch_3/MudliftPump_Function_Lg_Prog_001.wmvhttp://localhost/var/www/apps/conversion/tmp/scratch_3/MudliftPump_Function_Lg_Prog_001.wmv


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MudLift Pump (MLP)

Subsea Manifold

Standard BOP Stack


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Subsea Manifold

32

Most Valves are5K

Provides

Versatility

Most operations

conducted offline

Redundant Flow

Paths


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DGD Subsea Component Stack-Up

(Not to Scale)

33



MudLift Pump (MLP)

Subsea Manifold

Standard BOP Stack


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Subsea Stack

34

The BOP Stack is

unchanged

Once extra valve placed in

the Choke line for

improved operations Still have complete

conventional Well Control

available.


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People Preparation is Extensive

Drilling Engineers: How to Design DGD Wells and

Secure Permits

Drill Site Managers, Field Drilling Engineers, FDEs and

Rig Crews: How to Perform DGD Operations (Routine

and Well Control)

Offshore Support Personnel: How to maintain, trouble-

shoot and repair equipment


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People Preparation Starts with HAZOPS

HAZOPS

JIP Drilling

Procedures

Well Control

Procedures

TrainingSimulator

Permits

FORMS BASIS FOR:

New detailed procedures,

Well design tools/software,

Revised training material,

Improved simulator

Valve manifold layout,

Specialized drilling equipment mods,

DGD System Control philosophy andscreen layouts, etc.


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Initial HAZOPS Were Completed in 2010

9 months Effort

Feb 10 Oct 10

~ 22 All-Day HAZOPS

covering nearly 50 DGD

operations and wellcontrol procedures have

occurred.

Tremendously valuable

learning exercise.

Total Man-years todate: ~20!

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W B ildi W ll D i T l t F ilit t W ll D i f


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Were Building Well Design Tools to Facilitate Well Design for

our New DGD Drilling Engineers

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Control Philosophies are Agreed and Drillers Panel


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Control Philosophies are Agreed and Drillers Panel

Layouts are the Result

Setting Level

Alarms

Recording

Trends

Monitoring

Trends

Picking Mode

of Operation

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All f th Thi I t d i t T i i


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All of these Things are Incorporated into Training

Programs and the Pre-Spud Meeting

DGD P j t S h d l


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DGD Project Schedule

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Procure/Fabricate FAT/SITMudLift Pump

Procedures/Plans

Select Rig

HUC

Ship Fabrication

Pacific Santa Ana

Training/Pre-spud

Begin Ops

HAZOPS

Train/Pre-spud

Well Plans

SailFabrication at Samsung Heavy Industries, S. Korea

Commission DGD

4Q09 1Q10 2Q10 3Q10 4Q10 1Q11 2Q11 3Q11 4Q11 1Q12

DGD: The Future is Here!


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DGD: The Future is Here!

Its Only Just Beginning!

Documents

Dgd the System Dea 2011