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Collaborating Authors
Pressure Management
Abstract Managed Pressure Drilling (MPD) enables safer operations and reduces non-productive time and thus provides the opportunity to reduce well costs. Many operators however, are not fully embracing the opportunity offered by the technology, due to strict regulatory requirements, and their perception that MPD is complicated and increases risk. A basis for this perception is that operator engineers in their designs, and contractor drilling crews in day-to-day operations, are insufficiently MPD experienced to fully and safely exploit the benefits of the technology. Today, the advanced, and field proven, engineering (mathematical) models that are part and parcel of the software used in well design are also available in state of the art simulators. These engineering models and model based simulators are used by engineers during the design phase of MPD projects to replicate the conditions that will be encountered during actual well construction; picking optimal casing setting depths, using different equipment set-ups, selecting optimal drilling parameters and demonstrating the integrity of the design under a wide scenario of well conditions. Once the well design is finalized, and before drilling operations commence, the same well design is programmed into a real-time drilling simulator. During subsequent simulator exercises,, rig personnel are exposed to the range of scenarios that can unfold during actual operations, taking into account uncertainties and unexpected events. Crews, at the hard end of operations, are able to hone their competence to deal with the unexpected in a team environment under the supervision and guidance of experienced coaches. During actual MPD operations, the same advanced models can be used for automatic simulation and well monitoring purposes; they can also be integrated into the MPD control system to accurately maintain the required well pressures. This paper describes the models used and both the classroom simulator-based engineering training and the real-time rig floor simulator training that will respectively provide operator engineers and contractor well site staff the in-depth understanding of MPD that will enable them to develop their respective skills to safely and cost effectively exploit the many benefits offered by MPD.
- North America > United States (1.00)
- Europe (1.00)
- Asia (1.00)
- Well Drilling > Pressure Management > Managed pressure drilling (1.00)
- Well Drilling > Drilling Operations (1.00)
Abstract Objective/Scope The rotating control device is an integral piece of equipment for managed pressure and underbalanced drilling applications. In 2005, a joint IADC/SPE committee, collaborating with American Petroleum Institute, authored specification guidelines first published as API-16 Specification RCD (API-16 RCD). Does applying a manufacturing specification as a control for operations really minimize risk, or does it limit liability? This paper will outline the journey toward API-16 RCD certification, gaps identified between testing results and operating guidelines, and methodology applied to field performance data to bridge test data with real-life performance expectations. Method/Procedure/Process Analysis of a large laboratory test data set has been accumulated for the API-16 RCD application process. Meanwhile, a much larger data set of field performance has been accumulated over several years from live operations throughout the world. In an effort to seek continuous performance improvement, interrogating the data to determine a proper base line for performance was initiated. It became apparent that determining this base line was challenging, given the wide range of variables. However, through systematic data analytics, along with improved field data capture guidelines, normalizing these variables enabled operating data to validate performance inferences drawn from the existing lab data. Results/Observations/Conclusions Several hundred field runs were compared against more than 50 independent lab tests to determine links. Through comprehensive data analysis, along with acknowledgement of the scientific limits understanding elastomer performance over conditions and time, RCD testing in the lab is better able to predict field performance, serving as a suitable alternative to costly fit-for-purpose field simulation testing. Additionally, this methodology better guides technology improvements required to expand performance criteria. Novel/Additive Information Replicating field conditions in controlled laboratory tests requires a significant range of variables beyond RPM, temperature and pressure. For example, field failures have resulted from chemical factors such as mud compatibility at a range of temperatures, or physical factors such as drillpipe condition and rig alignment. Some in industry view fit-for-purpose testing as a solution, but this can become cost prohibitive for service providers and operators alike. This paper will document viable alternatives.
Abstract A wide variety of annular pressure buildup (APB) mitigation techniques have been deployed in the past two decades. In the early 2000s, BP focused efforts on the development and implementation of rupture disks, nitrified foam spacers, syntactic foam modules and vacuum insulated tubing (VIT). Initiatives to simplify operations while maintaining well integrity have led to innovative techniques which expand the APB mitigation toolkit. BP's Gulf of Mexico Thunder Horse drilling team has recently pursued three APB mitigation techniques. One method is to fully-cement the annulus, thereby removing the fluid that is subject to thermal expansion in a trapped annulus. A second method uses a qualified port collar to equalize pressure across a casing string. The third method focuses on better acquisition and utilization of mud pressure-volume-temperature (PVT) data for a more precise prediction of the APB design loads. These methods and techniques have led to the removal of syntactic foam from some wells in the Thunder Horse field. The design change reduces installation time and operational complexity during well construction and abandonment. This paper provides a description and technical details around the planning and job execution for the fully-cemented annulus and the use of port collars for pressure equalization. It also discusses the motivation behind acquiring PVT data specific to a particular mud system and provides interpretation of laboratory data. The work may be useful for other operators as they plan and execute wells subject to the potential for APB.
- North America > United States > Gulf of Mexico > Central GOM (0.24)
- North America > Canada > Alberta (0.24)
- North America > United States > Gulf of Mexico > Central GOM > East Gulf Coast Tertiary Basin > Mississippi Canyon > Block 822 > Thunder Horse Field (0.99)
- North America > United States > Gulf of Mexico > Central GOM > East Gulf Coast Tertiary Basin > Mississippi Canyon > Block 778 > Thunder Horse Field (0.99)
- Well Drilling > Drilling Operations (1.00)
- Well Drilling > Drilling Fluids and Materials (1.00)
- Well Drilling > Casing and Cementing > Casing design (1.00)
- (5 more...)
Real-Time Borehole Condition Monitoring using Novel 3D Cuttings Sensing Technology
Han, Runqi (The University of Texas at Austin) | Ashok, Pradeepkumar (The University of Texas at Austin) | Pryor, Mitchell (The University of Texas at Austin) | Oort, Eric van (The University of Texas at Austin) | Scott, Paul (ConocoPhillips) | Reese, Isaac (ConocoPhillips) | Hampton, Kyle (ConocoPhillips)
Abstract Wellbore instability and stuck pipe incidents are large contributors to drilling-related non-productive time (NPT). Drilling cuttings/cavings monitoring is crucial for early detection and mitigation of such events. Currently, monitoring is done manually and lacks a streamlined approach. Automating this process would be very beneficial, and is possible due to recent advances in sensing technology. Real-time cuttings/cavings monitoring can be used to quantify cuttings volume, measure size distribution, and analyze shape. By correlating these measurements with ongoing drilling operations, the hole condition (in particular hole cleaning/cuttings transport efficiency, wellbore stability situation, etc.) can be automatically assessed in real-time. This makes pro-active prevention and mitigation of NPT related to hole cleaning and wellbore instability possible. In this paper, we detail a system designed and prototyped to allow us to measure cuttings/cavings in real-time. A highly portable device employs a 2D high-resolution camera and a 3D laser sensor to determine the physical properties of cuttings. The 3D point cloud/depth data obtained by this device provides cuttings size distribution, volume and shape characteristics. Comparisons and discrepancies between expected and sensed quantities can then be used for alarming purposes and taking appropriate corrective action. A prototype experimental setup was constructed to evaluate the ability to quantify relevant cuttings properties and profiles in the presence of drilling fluids. In a controlled environment, the cuttings slide down a shaker table's clearing chute while simulating various realistic external variable scenarios. The environmental impact on the accuracy, repeatability and robustness of the various sensors under investigation was determined to identify the sensors best suited for the task at hand. The optimum device configuration was then implemented and evaluated to verify that the system is viable for use in the field. The automated cuttings monitoring system can warn drillers to potential hazards associated with poor hole cleaning conditions, ongoing wellbore breakout, and the likelihood of stuck pipe events.
- Europe (0.93)
- North America > United States > Texas (0.28)
- Well Drilling > Wellbore Design > Wellbore integrity (1.00)
- Well Drilling > Pressure Management (1.00)
- Well Drilling > Drilling Operations (1.00)
- (2 more...)
Abstract A statistical method for improving the accuracy of predictive mathematical models used in drilling operations is proposed. The scheme can be applied in drilling automation, for example for improving accuracy in automated control systems such as managed pressure drilling (MPD), and for more reliable real-time monitoring and decision support systems. The proposed method is applied to a simulated case of MPD. Hydraulic model predictions of BHP are continuously compared to PWD readings. A short sequence with varying pump rate is run to train the statistics, which are collected at each pump rate, and refined considering also the pump rate derivative. This is visualized as a 3D surface giving a clear illustration of the error signature of the simulated case. The estimated error is added to the set point of the choke control system, demonstrating a clear improvement of BHP control. We proposed a new statistical method that uses real-time sensor data to perform automatic fingerprinting of the predictive performance of a given model. The principle is simple but powerful and can be applied to many cases. It can be combined with smart visualization tools in decision support systems, helping to build confidence in the users, or even utilized to adjust the initial prediction for improved accuracy in control systems. The tool is independent of the internal calculations in the mathematical model, and it can therefore be utilized in combination with any model.
- North America > United States (0.28)
- Europe > Netherlands (0.28)
- Management > Risk Management and Decision-Making > Decision-making processes (1.00)
- Data Science & Engineering Analytics > Information Management and Systems (1.00)
- Well Drilling > Pressure Management > Managed pressure drilling (0.87)
- Information Technology > Decision Support Systems (1.00)
- Information Technology > Architecture > Real Time Systems (1.00)
- Information Technology > Data Science > Data Mining (0.92)
Abstract An experimental set-up is established, designed for recording the absorption rate of a liquid during gas influx and at rotational flow conditions in an annulus. Likewise, the set-up is designed for monitoring the degassing rate from the liquid during controlled depressurisation, resembling the pressure drop during vertical annulus flow. The set-up is designed for system conditions up to 400 bar, 150 °C, resembling downhole conditions. Annulus outer/inner diameters are 73/59 mm and the length of the main section is 1000 mm. A windowed section at the top allows monitoring of liquid volume changes and possible foaming behaviour during gas absorption/degassing. An inner cylinder can be rotated at speeds up to several hundred rpm, enough to produce Taylor-vortices and even turbulent flow in the annulus. For the reported test runs the system pressure is 100 bar, with temperatures 40 and 80 °C. Two different base oils are tested, one normal mineral oil and one linear paraffin oil. A number of tests are run, with varying rotational speed and depressurisation rate. For tests with lower rotational speeds the degassing is postponed, with a corresponding higher maximum degassing rate as system pressure decreases towards atmospheric conditions. The impact from drill string rotation and type of base oil is shown, demonstrating the importance of describing the kinetics of the gas bubble nucleation rather than assuming instant equilibrium of gas and drilling fluid during the depressurisation during the vertical annulus flow. Tests performed at experimental set-ups like the one presented will provide data for more advanced models of drilling fluid degassing behaviour. This will enable a more correct interpretation of data during well control events.
- Well Drilling > Pressure Management > Well control (1.00)
- Well Drilling > Drilling Fluids and Materials > Drilling fluid selection and formulation (chemistry, properties) (1.00)
- Well Drilling > Drilling Fluids and Materials > Drilling fluid management & disposal (1.00)
Abstract During a gas influx scenario in drilling and well operations, early detection is important in order to prevent harmful consequences to rig, personnel and environment. However, the influx of natural gas may be masked if the gas loading capability of the drilling fluid is considerable. This work aims to provide a methodology for predicting the gas loading capability of oil-based drilling fluids, such that precautions for early gas influx detection can be made also for HPHT-drilling with oil-based drilling fluids. In principle, the bubble-point curve; i.e. the transition from single liquid phase to two-phase, of the mixture of drilling fluid and natural gas determines the maximum loading capability of gas in the drilling fluid at the actual pressure and temperature. In overbalance situations the gas loading capability is decisive for the volumetric response and severity of gas influx. Thus, the gas loading capability needs to be accurately described for hydraulic models used for well control. This paper describes a methodology for gas loading capability prediction based on the bubble-point curve as determined from thermodynamical equations-of-state calculations. Different thermodynamical models have been evaluated and compared with experimental data for OBDF–methane systems. In particular, the features and requirements for the models are discussed. Strategies for tuning the models to experimental results are necessary regardless of the choice of equations. Both models and experimental data on gas loading capability versus pressure follow the linear Henry's law in the subcritical region, and deviate severely from this as the pressure is increased towards the dense phase region of the drilling fluid – natural gas mixture. The determination of the dense phase region is of particular interest, as for this region there exists no limit in terms of gas loading in the drilling fluid. The proposed methodology forms the basis of a promising tool for gas loading capability calculations that, if utilized in drilling simulation software, may improve understanding and help detecting gas kicks early, thus lowering the associated risks, in particular for HPHT-drilling.
- Europe > Netherlands (0.28)
- North America > United States (0.28)
- Well Drilling > Pressure Management > Well control (1.00)
- Well Drilling > Drilling Fluids and Materials > Drilling fluid selection and formulation (chemistry, properties) (1.00)
- Reservoir Description and Dynamics > Fluid Characterization > Phase behavior and PVT measurements (1.00)
Abstract In the continual search for Oil and Gas, more and more exploration wells are being drilled in High Pressure-High Temperature (HPHT) environments. Pore and Fracture pressure prediction and understanding the true drilling window in HPHT exploration wells poses significant challenges. Once the pressure profile is ascertained, then the next challenge is to drill and cement the well within those limits to avoid kicks, losses and maintain the integrity of the well. There are special challenges in cementing HPHT wells. These wells typically have a narrow drilling window which could make it very difficult to manage the bottom hole pressure correctly while cementing the open hole section. In any stage of cementing in this type of wells, hydrostatic, dynamic and circulating effects should be considered. These tight windows in HPHT wells, combined with the effect of temperature and pressure on mud density possess significant risks for cementing operation. Also physical and chemical behavior of cement changes in high pressure and temperature. This paper details the advantages of applying advanced Managed Pressure Drilling (MPD) technology during coiled tubing cementing operations in a case study HPHT well. This advanced technique not only allows for maintaining a Constant Bottom Hole Pressure (CBHP) but also reduces the additional costs associated with cement weight and additives. Furthermore, real time flow monitoring eliminates the down hole fluid losses which in conjunction with CBHP reduce formation damage. A precise managed pressure coiled tubing cementing program was analyzed and planned inclusive of operational procedures and risks management. The well was displaced to a lighter drilling fluid through coiled tubing, while keeping bottom hole pressure (BHP) constant slightly over the formation pressure by applying surface back pressure (SBP). Four different densities of cement slurries were pumped in the hole through coiled tubing and held bottom hole pressure constant during the entire cementing operation within 30 kg/m (0.25 ppg) pore pressure and fracture pressure window. Held annular pressure constant with the help of SBP during the eight hours of cement setting time to ensure that hydrostatic pressure would remain in place. This document demonstrates the successful application of managed pressure coiled tubing cementing operation. It also elaborates the recommended operational procedures, integrated MPD and Coiled tubing equipment setup, along with real-time graphs and data from the case study well.
- Europe > Netherlands (0.28)
- North America (0.28)
- Well Drilling > Pressure Management > Managed pressure drilling (1.00)
- Well Drilling > Drilling Operations (1.00)
- Well Drilling > Drilling Fluids and Materials (1.00)
- (4 more...)
Abstract Well barrier verification is having the confidence and being able to prove that "the folk on the rig will do the right thing and the equipment will function as intended when called upon to do so". This paper describes a method of achieving that aim by analyzing well control barrier systems in a logical and complete manner with regard to the technical, operational and organizational elements so that the results can be used as the basis for a straightforward means of barrier verification during operations. BowTie diagrams, while a useful illustrative starting point, are limited in their ability to depict well control barriers as systems consisting of individual elements that interact with each other. Portraying them as systems enables the processes, people and equipment required for effective well control to be analyzed in a way that is both logical and complete. Further examination of the elements reveals the critical aspects that must be checked to verify barrier effectiveness. Operationalising the verification process is done by extending and formalizing established practices of wellsite supervisor oversight and cross-checking complemented with periodic inspections. The analysis is resource intensive because each operational mode must be considered separately to ensure completeness. Once this work is done, general themes within critical aspects emerge that enable the verification tasks to be grouped into a set of logical activities that include: conversations with crew members to verify knowledge, criteria for drills to check on team capability and periodic inspections to ensure equipment integrity. Although difficult to achieve, the process must be carried out in a way that engages the crews in a sense of self-preservation to avoid becoming a box ticking exercise.
- Europe (1.00)
- North America > United States > Texas (0.46)
- Well Drilling > Pressure Management > Well control (1.00)
- Well Drilling > Drilling Operations (1.00)
- Health, Safety, Environment & Sustainability > Safety > Operational safety (1.00)
- Health, Safety, Environment & Sustainability > HSSE & Social Responsibility Management (1.00)
Abstract Wired Drillpipe (WDP) technology provides two-way and high speed measurements from bottom hole and along-string sensors. The data offered by WDP technology has maximum benefit when applied in an automation system or as a real-time advisory tool. Improved control is demonstrated for Managed Pressure Drilling (MPD) with the use of high-speed telemetry and physics-based models. Stabilizing and minimizing pressure within an acceptable bound leads to higher and more consistent Rate of Penetration (ROP). MPD control is challenging due to tight pressure windows and the nonlinearity of the choke and pump response on Bottom Hole Pressure (BHP). This work demonstrates a new Hammerstein-Wiener nonlinear model predictive controller for BHP regulation in drilling. Hammerstein-Wiener models employ input and output static nonlinear blocks before and after linear dynamics blocks and thereby simplify the controller design. The control performance is evaluated in scenarios such as drilling, pipe connections, and kick attenuation. A physics-based drilling simulator, WeMod, is used for model identification and control performance evaluation. The control performance of the new nonlinear controller is compared to conventional controllers in various scenarios. Because of the interconnected multivariable and nonlinear nature of the drilling operation, conventional controllers show severe limitations. In a first scenario, the performance of set point tracking during normal drilling operation is compared. By changing the set point of the BHP, the conventional controller manipulates only the choke valve opening while the nonlinear controller moves choke valve opening, mud pump, and back pressure pump simultaneously. In a second scenario, a pipe connection of a typical drillpipe stand is demonstrated. The conventional controller is not able to regulate the BHP by adjusting the choke valve only. Although a linear version of the controller is able to exploit multivariable relationships, absence of the nonlinear relationships results in severe oscillation when the operational range is shifted outside of the training region. The nonlinear controller maintains a BHP within ±1 bar of the requested set point. A third scenario investigates the kick attenuation performance of conventional and nonlinear control algorithms. The nonlinear controller attenuates the kick within well control conditions, without requiring a well shut-in procedure. Recent advances in drilling simulators and the reliability of the WDP data highway have enabled tighter BHP control. This study presents a robust method to control BHP by applying Hammerstein-Wiener models in an efficient model predictive controller. The proposed methods have been validated in the downstream industry, but are applied for the first time to drilling with nonlinear control functionality. The multivariable control adjusts three main manipulated variables in MPD simultaneously.
- North America (0.46)
- Oceania > Australia (0.28)
- Europe (0.28)
- Well Drilling > Pressure Management > Well control (1.00)
- Well Drilling > Drilling Operations (1.00)
- Well Drilling > Drilling Fluids and Materials > Drilling fluid management & disposal (1.00)
- (6 more...)