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SPE DISTINGUISHED LECTURER SERIESis funded principally

SPE FOUNDATIONThe Society gratefully acknowledges

those companies that support the programby allowing their professionals

to participate as Lecturers.

And s ecial thanks to The American Institute of Minin Metallur ical

0

and Petroleum Engineers (AIME) for their contribution to the program

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Mana ed Pressure Drillin

SPE 2006 -2007 Distinguished Lecturer Series

A “ new” way of looking at drilling hydraulics…

…Overcoming conventional drill ing challenges

Don M. Hannegan, P.E.Director Emer in Technolo ies

1

2

Controlled Pressure Drilling & Testing Services

Weatherford International Ltd.

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Generic definition

Managed Pressure Drill ing

MPD is an advanced form of primary well controltypically employing a closed, pressurizable fluid

sys em a a ows grea er an more prec secontrol of the wellbore pressure profile than mud

weight and mud pump rate adjustments alone.

As opposed to a conventional open -to-atmospherereturns system, MPD enables the circulating fluids

system to be viewed as a pressure vessel.

Influx not invited - Conventional Well Control

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Pressure Vessel?

R

Enabling Tools

•Drill String Floats

•

Automatic Choke

313© 2006 Weatherford. All rights reserved.

Variations of Managed

Pressure Dril ling

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New way of looking at the hydraulics of dril ling?

• Well, maybe to the rest of the world, but not so new in the Arkoma Basin

– MPD was being practiced decades ago

• A rotating control device is required to practice MPD• Manufactured in Fort Smith since 1968, availabili ty of the tool facil itated:

– , , ,

– Underbalanced Drilling

– And over time, “necessity being the mother of invention”, spawned other uses“ ’ ’ ’ – . .,

got in the hole unless I make jointed pipe connections with casing backpressure.”

• Those “ other uses” identified as a technology within themselves in 2003 andlabeled Managed Pressure Drill ing

– Introduced to offshore drilling decision-makers – And to land programs globally…

• Where MPD is being seen and accepted as “ new and innovative”

4

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Connecting the dots – An extension of logical reasoning

1. U.S. Rig Count 1750, 600 RCD’s on locations – majority of land programsdrill ing at least one section with a closed mud return system on rig floor

. ,

• Dealing with “ dril ling trouble zones”

• Shorten the number of days from spud to TD

• Drill otherwise un-drillable prospects

3. Because MPD addresses NPT - Value to offshore operations much greater

4. Does not invite influx of hydrocarbons but one is tooled up to better deal with

5. Equipment “ kit” for all Variations of MPD fits aboard most offshore rigs

6. Drill ing offshore with a closed mud returns system vs. open-to-atmospheredrill ing or bell nipples is making uniquely good sense on many fronts

7. Conventional Well Control principals apply

8. UBD-type preplanning, training, discipline applicable to several Variations

9. “ Real time Well Control” mentalit also im ortant to several Variations

5

10. Onshore applications not capturing the full potential of the technology

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Formal Definition (IADC developed – SPE adopted)

“ MPD is an adaptive drilling process used to more precisely control the annular

pressure prof ile throughout the wellbore. The objectives are to ascertain the

downhole pressure environment limits and to manage the annular hydraulic

pressure profile accordingly.

Technical Notes

1. MPD processes employ a collection of tools and techniques which may

mitigate the risks and costs associated with dril ling wells that have narrow

downhole environment limi ts, by proactively managing the annular hydraulic

pressure profile.. , , ,

annular flu id level, circulating frict ion, and hole geometry, or combinations

thereof.

3. MPD may allow faster corrective action to deal with observed pressure

variations. The abili ty to dynamically control annular pressures facilitatesdril ling of what might otherwise be economically unattainable prospects.

4. MPD techniques may be used to avoid formation influx. Any flow incidental to

”

6

.

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“ Controlled Pressure Dril ling” Family of Technologies

Common Equipment

NRV’s

Choke

RCD

NRV

Choke

View circulatingfluids system as

7

one would apressure vessel

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MPD “ More Productive Dril ling” - “ Make Problems Disappear ”

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Problem Incidents -- GOM Shelf Gas Wells

Wellbores Drilled 1993-- 2002; Water Depth =

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Cost implications of NPT

$MM

Ultra-Deep GOM Well Cost ~60% More Than AFE

10

12$20 $40 $60 $80 $100 $120

Ave. AFE - $44MM Ave. AFE - $44MM14

16

t . B

M L Pre-drill AFE

Actual Cost

Ave. Cost - $71MM

18

20

, 1 0 0 0 ’

s

24

T

106

28ConocoPhillips DEA Presentation, 1st Quarter 2004

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Categories of MPD

• Reactive – Tooled u to more efficientl react to downholesurprises. (Common to U.S. land programs, using surfacebackpressure to adjust EMW, enhance well control, etc.)

• Proactive – Fluids and Casing programs designed, fromthe start, to drill with ability to:

– ahead

– Achieve a dee er o en hole

– Lowest hanging fruit when practiced onshore

– Greatest savin s when racticed offshore

11

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Variations of MPD

• PMCD (Pressurized Mud Cap Drilling)

– Offset wells have ex erienced total or near total losses

• CBHP (Constant Bottomhole Pressure) – Offset wells have experienced narrow margins, kick loss

“ ” “ ”, , , ,

• HSE (Returns Flow Control)

– Closed vs. Open-to-atmosphere mud returns at rig floor

• RC (Reverse Circulation)

• DG (Dual Gradient, several methods)

– g u s or so s n ec on n o cas ng or mar ne r ser – Riserless example – Demo 2000 Deepwater RMR Field Trials JIP

12

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MPD – The Value Proposition

MPD as a Solution to Real Drilling ChallengesValue

Proposition

CBHP

(Constant

Bottom Hole

Pressure)

PMCD

(Pressurized

Mud Cap

Drilling)

DG

(Dual

Gradient)

HSE

(Health,

Safety,

Environment)

MPD Method

Drill "Undrillable" Ultra-tight Pore/Frac Pressure gradients

Drill "Undrillable" Vuggy/Fractured carbonates where OBcirculation is impossible

Drill to target depth in wells with high insitu stresses.

Extend the Reach of ERD Wells

Drill to the

target…

Increase ROP - drilling closer to balanced.

Increase ROP - dril l throuh HP LV nuisance gas zones.

Reduce Number of Loss/Kick Occurances

Reduce Time Spent Dealing with Well Control Events.Detect kicks earlier.

Reduce pressure cycles that cause fatigue-related borehole

instability.

Reduce severe overbalanced pressure induced borehole

instability.

Reduce open hole exposure-time induced borehole

….while

saving

money

instability.Reduce mud costs.

Set casing deeper.

Reduce number of casing strings.

Reduce required rig size.

13

.

Remove H2S Hazard from Rig Floor

Remove HPHT Hazard from Rig Floor Positive Fluid Containment at Surface in Marine or other

Environmentally Sensitive Locations

…and

improvingsafety.

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Key tools for most Variations of MPD

• Rotating Control Device – Floating Rigs (wave heave)

– External Riser RCD

– u sea

– Internal Riser RCD (IRRCH)

- Fixed Rigs (no wave heave)

– Passive & Active annular seal design “ land” models

– Marine Diverter Converter RCD

– Bell Nipple Insert RCD

– IRRCH (in marine diverter or surface annular)

• NRV’s (Wireline Retrievable is an option worth considering)

• Choke Options (dedicated recommended, except perhaps for HSE Variation)

– Manual

– Semi-automatic

– PC Control led Automatic

14

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RCD’s are Key MPD Enablers

• Passive annular seal design shown

• 7/8-in. interference when new

API 16 RCD

• High pressure capable models have

redundant str ipper rubbers on acommon inner race of the bearingassembly

• Requires no external-to-tool source ofenergy to function

• Higher the differential pressure,tighter the annular seal

• Does not require a dedicatedtechnician

• This design is most commonly usedon MPD applications

• Best rubber performance

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• RCD friendly dr ill string

• Good stack alignment

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For Rigs with little or no wave heave

“ Passive and active annulus seal Marine Diverter Converter RCD – ,

barrier, low or high pressureCapable RCD’s

rotating diverter, also 2nd annular BOP.

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Bell Nipple Insert RCD No Wave Heave

•Single Stripper Rubber - 500 psi

• DNV Certi fied, COP Norway, Ekofisk

•

• No hose connections required

• Remote latching, unlatching

• 8.75” I.D. for large Tool Joint O.D.’s

•Dual Stripper Rubber – 5000/2500

psi•Requires lubrication & coolant hoseconnections to remove heat from thrust


and radial bearings when dril ling underhigh differential pressure conditions

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5000 psi static/2500 psi dynamic Bell Nipple RCD

Bearing Assembly

Bottom Stripper Rubber

Upper Marine Riser Seal Area

Flowline Outlets

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M7800 on

Field Trials,

Pemex

HT/HP well

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External Riser RCD for Floating Rigs

Al l Variations of MPD - PMCD, CBHP, HSE, DG, RC

”

Model 7100 – 2500psi rated

PMCD Shown

2” Fill-up Line from Trip Tank Pump

4” HCR

6” Line for circulating wellto Flow Line

4” PMCD Line from Mud Pump

4” Kill Line to Choke Manifold4” HCR

Riser Tensioners support f ull riserweight and PMCD equipment

Riser Slip Joint is used

201

n t e co apse pos t on

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Other Tools

• Downhole Casing Isolation Valve (Downhole Deployment Valve)

•

• ECD Reduction Tool

•

• UBD technology & mentality (except for the HSE Variation)

–

– Planning, HazId/HazOp’s

– Pro ect Mana ement

– Real time decision-making

• “ ” “ ”

22

• ECD Reduction Tool

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Conventional vs. Constant Bottomhole Pressure Variation

2311© 2005 Weatherford. All rights reserved.Uniquely Applicable – Narrow, Inconsistent, or Unknown P/F Margins

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Open Mud Returns SystemConventional Drilling - GoM

0

500

1,000 26" 1,300'

25 mudchanges to

1,500

2,000

2,500 b S e a

" '

TD

’3,000

3,500

D e p

t h

( f t ) T V D

S u

- , in narrowmargins

without4,000

4,500

5,000 7-5/8" 5,001'

exceedingfracturegradient

5,500

6,000

8.0 9.0 10.0 11.0 12.0 13.0 14.0 15.0 16.0 17.0 18.0

EMW (ppg )

5-1/2" 5,930'

ClassicKick-Lossscenario

24


Pore Pressure Conv Planned MWFrac Sand Frac Shale

FIT - OFFSETS LOT in Design Conv EMW

(MW + ECD)

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MPD Example - GoM Proactive CBHP Variation

Only threeEMW = MWHH + AFPCIRC + BPSURFACE

changes to

TD

Surface

backpressure

duringconnections

No lossesuponresuming

25

circulation

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Onshore Value Case - Proactive CBHP

Wild River/Cecil ia Dril ling Performance

$1,600,000 30

$1,200,000

$1,400,000

.

25

.

Increase ROP, Reduce NPT (kick-loss scenarios)

$800 000

$1,000,000

m S

p u d .

15

20

m S

p u d .

$600,000

C o s t f r o

10

a y s f r o

$200,000

,

5

26

2002 2003 2004

CFS* DFS

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Offshore Value Case – Proactive CBHP

CBHP Managed Pressure Drill ing Reduces Drill ingTime by 83%, Provides Operational Savings of1 Mill ion

Location: Chuc 172, southwest Gulf of Mexico

Formations: Medium Cretaceous, Lower Terciary

Depth: 12,457 ft (3,797 m)

Pore pressure: 2,844 PSI (196 bar)

Well type: Deviated

Hole size: 8-1/2 in.

No. of wells: 1

Objectives Results

• Drill the well without the total circulation lossexperienced in a previous well.

• Drill the well in less time than the 30 days allowed.

• The well was drilled with no loss of circulation, using the constant bottomhole pressure(CBHP) variant of managed pressure drilling (MPD).

• Drilling time was reduced from 30 days to 5 days(83 percent).

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PMCD on Fixed Rigs

• Photo – Jackup for Chevron Angola, drillingconventionally

• Upon encountering severelosses, RCD Bearing &

Stri er Rubber Assembl isinstalled, mud cap spotted…

• …Drill ahead with seawater

& no returns

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External Riser RCD w/Subsea BOP

• Riser telescoping slip jointlocked, seals pressured -

ps r ser sys em

• X-over spool connect toro rietar flan e of sli oint

Inner Barrel

• Note importance of hoses

cables in catenaries swing

• Taller spool or swivel flange

may be required on drillships to accommodatechanges in heading

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External Riser RCD w/Surface BOP

Pressure containment capabilityusually determined by that of flexibleflowlines

• Remote operated valves on manifolds?

• Length of hoses to compensate for heaveand reach hard piping?

• returns rate and desired redundancy?

• Annular BOP size?

• Drill pipe size and tool joint O.D.?

• Overpressure relief device to diverter dumpline?

• Hose flush by-pass to prevent cutting

periods?• Secondary spi lls containment device?

• Will drill string stabilizers be used?

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• Maximum temperature of returns?

• Moored Semi or DP Drillship?

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PMCD & CBHP MPD - Floater w/ Surface BOP

• Santos Indonesia

• -with seawater andno returns to dealwith near totallosses in cavernousvoids

below that troublezone, CBHP withmud in dee er o en

hole to deal withnarrow margins

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Asia Pacific Region MPD Activity – June 2006

MPD Type Country Operator Project Duration Formation Type Rig Type

HSE VietnamCuu Long

(ConocoPhillips)5 year program

Fractured GraniteBasement

Jack UpGALVESTON KEY &

ADRIATIC 11

HSE/CBHP VietnamJVPC

(Japan Vietnam)

6 month programFractured Granite

Basement

Jack Up

TRIDENT 9PMCD Malaysia Sarawak Shell 3 wells Carbonate

Semi-SubmersibleSTENA CLYDE

PMCD Malaysia Sarawak Shell 8 wells on 3 fields Carbonate

WEST ALLIANCE

PMCD Malaysia Sarawak Shell 2 wells CarbonateSemi-SubmersibleOCEAN EPOCH

PMCD Mala sia Sarawak Shell 2 wells Carbonate Jack Up

HSE Malaysia Petronas Carigali 1 wellFractured Schist

BasementJack Up

ENSCO 52

CHBP Malaysia Petronas Carigali 1 wellFractured Schist

BasementJack Up

ENSCO 52

PMCD Indonesia Santos 11 wells CarbonateSemi-Submersible

SEDCO 601

PMCD Indonesia KNOC 1 well CarbonateSemi-Submersible

SEDCO 601

Drillshi

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n ones a + we s ar ona eFRONTIER DUCHESS

PMCD-DDV Indonesia Pearl Oil 4 wells CarbonateJack Up

SHELF EXPLORER

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Asia Pacific MPD Activity to-date (March 2007)

• 84 drilling programs

• rom a ypes o r gs; an , ac up, p a orm, moore

semi-submersibles, dynamically positioned drillships

•

– HSE

– PMCD

– CBHP

• 13 operator companies

33

- ,

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Riserless Dual Gradient - Demo 2000 Deepwater Riserless Mud Recovery JIP

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Integrated Riserless Top Hole Drill ing Package

Subsea Rotating Control Devicew/ Guide Funnel

ROVHose connection

Class 4Torque Tool bucket

AGR NorwaySuction Module

SMO Running/Retrieving/Testing Sub

Vetco E H-4 Connector

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Conclusion

• The challenging hydraulics of the world’s remaining prospectsindicate MPD wil l evolve to become a key enabling technology.

• Adds technical, economic and HSE viability.

• Increases recoverable assets.

• Step-change technology.

• Synergistic with DwC and several other emerging technologies.

• Following U.S. example, onshore MPD is growing globally.

• Proactive MPD is lowest hanging fruit for U.S. land operations

• All “ first adopters” of MPD offshore plan future wells.

• A candidate technolo to deal with the Bo les Law challen es of

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drilling for commercial quantities of methane hydrates

Documents

MPD-CBHP