Hollow Sphere Dual Gradient Drilling · PDF fileWeight: 350 kips ... 0 5,000 10,000 15,000 )...
Transcript of Hollow Sphere Dual Gradient Drilling · PDF fileWeight: 350 kips ... 0 5,000 10,000 15,000 )...
A Noble Drilling Corporation Subsidiary
TT01-43 1
Hollow Sphere Dual Gradient Drilling
System
JIP Kickoff Meeting
Dr. William C. Maurer September 27, 2001
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Lightweight Mud
LIGHT WEIGHT
MUD MUD HOLLOW SPHERES
5.84 ppg 8.5 ppg 3.17 ppg
0.70 S.G. 1.02 S.G. 0.38 S.G.
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Particle Sizes in Unweighted, Water-Based Mud
(After Bourgoyne Jr. et al, 1986)
.01 0.1 1 10 100 1000 10,000
SILT FINE SAND
COARSE SAND
GRAVEL
200
100
60
20
MESH
Solid
s Perc
enta
ge
MICRONS
Bentonite Small Hollow Spheres
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Oilfield Hydroclone (Moore et al., 1974)
Underflow Discharge (Cuttings)
Feed Chamber
Feed Inlet
Vortex Finder
Vortex
Overflow Opening (Hollow Spheres)
TT01-43 51
Hydrostatic Gradients for Conventional and Riserless Drilling
(Snyder, 1998)
Surface
Casing
Depth
Seawater (E) hydrostatic pressure
Mud hydrostatic pressure (C) (Conventional)
Mud hydrostatic pressure (D) ( Riserless )
Fracture (B) pressure
Pore pressure (A)
Pressure
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Riserless Drilling System (Peterman, 1998)
Mud Return and Pump
Return Line Riser
Mudlift Pump
BHA
Wellhead and BOP
Diverter
Drillpipe
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“DGD is estimated to save $9 million per well and increase the project value by $150 to $250 million at Crazy Horse”
Andy Frazelle, BP (Wellconnected, Dec, 2000)
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“In an ultra-deepwater well, the savings could range from $5 - 15 million in casing running alone”
Conoco, 2001 (Drilling Contractor, May/June)
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DEEPVISION Subsea Centrifugal Pump
Pressure & volume compensator
Strainer for compensator
Isolation valves for motor filters
Main filters
Pump suction
Pump discharge
Electrical connections
Motor cooling loop
Filter for bearing pack
Isolation valves for Bearing pack filters
6-Stage pump
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DEEPVISION Subsea Module
5-pump module station
Size: 15’ *17’ * 40’
Weight: 350 kips
Max. available hhp 4050
ANSI 2500 (6250 psi) rated
Standard riser joint connection
Independent of BOP MUX control system
Self contained power and control
10,000 ft. Pump Station
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DEEPVISION Drillstring Valve
VALVE SEAT & CONE
VALVE PLUNGER
DISC SPRING PACKAGE
4-3/4” Flow Stop Sub
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DGD Rock Removal Rates
Drilling Rates (ft/hr)
Rock
Rem
ova
l Rate
(to
ns/
hr)
100 50 0 150 200 0
4
8
12
12-1/4” Bit
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Shell SSPS DGD System (Offshore, June 2001)
Power Control Existing Rig Pumps From Rig Power
Water Depth
Pump Section
Motor & Seal Nitrogen Tank
Check Valve
Level Sensor For Process Control
Eductor Pump
Control Module
Element Optional For Fluid Sep.
Mud Processing
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SSPS Gumbo Slide & Mud/Gas Separation
Nitrogen Tank (Back-up)
Mud/Gas Separator
Flowline
Subsea BOP
Cuttings Eductor
Gumbo Slide
Nitrogen Tank Cut Away View
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Dual Gradient Project Participation
CONOCO*
HYDRIL*
BP
CHEVRON
MUDLIFT
TEXACO
DIAMOND OFFSHORE
GLOBAL MARINE
SCHLUMBERGER
BAKER HUGHES*
TRANSOCEAN SEDCO FOREX*
DEEPVISION
BP
CHEVRON
SHELL
SSPS
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Surface Hollow Sphere System
Riser
Mud Line
BHA
Wellhead and BOP
Drillpipe
Mud
Shale Shaker
Mud
Spheres
Spheres & Mud
Mud Pump (Spheres)
Mud Pump (Mud)
Swivel
Valve
Mud & Spheres
Drill Ship
Mud
Rock
Drill String Valve
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Sea Water Density Mud (50 % Spheres)
LIGHT WEIGHT
MUD MUD HOLLOW SPHERES
8.56 ppg 14 ppg 3.17 ppg
1.02 S.G. 1.68 S.G. 0.38 S.G.
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4
6
8
10
12
14
16
18
0 20 30 40 70
Sphere Concentration (Volume %)
Mix
ture
Density,
ppg
18 16 14 12 10
Sphere Sp. Gr. = 0.38
Mud Weight
ppg
Water Sea Water
Mixture Density vs. Sphere Volume
10 50 60
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Single Injection Point
Valve
Riser Flow Line
Mud & Spheres
Surface
Sea Floor
Mud & Spheres
Wellhead and BOP
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Multiple Injection Points
10,000’
7,500’
5,000’
2,500’
Valve
Riser Flow Line
Sea Water & Spheres
Surface
Sea Floor
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Particle Sizes in Unweighted, Water-Based Mud
(After Bourgoyne Jr. et al, 1986)
.01 0.1 1 10 100 1000 10,000
SILT FINE SAND
COARSE SAND
GRAVEL
200
100
60
20
MESH
Solid
s Perc
enta
ge
MICRONS
Large Hollow Spheres
Bentonite Small Hollow Spheres
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Relative Particle Size (Microns)
50 Small Hollow Spheres
147 100 Mesh
Screen
300 Large Hollow Spheres
1700 Frac Sand
(12 mesh)
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Composite Sphere Densities
Water Depth (ft) PVC
Thermoplastic Macrospheres
GRE Minispheres
Carbon Fibre Minispheres
Foam System Density (g/cc)
1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 11000 12000 13000 15000
0.25 0.36
0.28 0.34 0.36 0.39 0.43 0.44 0.48 0.53 0.53
0.40 0.41 0.45 0.48 0.51 0.55 0.60 0.62 0.65
0.43 0.45 0.46 0.48 0.50 0.53 0.56 0.59 0.61 0.66
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DGD Sphere Separation System 1
100 1000
MESH
MICRONS
100 20
Large Spheres
20 Mesh
Large Cuttings
Return Mud 2000 gpm 25% Spheres
Mud 1500 gpm
To Seafloor 1000 gpm
50% Spheres
Clean Mud
Shale Shaker
Shale Shaker Spheres
Spheres 500 gpm
Seawater
Medium Cuttings
Spheres 500 gpm
100 Mesh
Spheres
Conventional Mud
System
To Rig Pump 1000 gpm No Spheres
500 gpm
Fine Cuttings
Spheres 500 gpm
Mud 1500 gpm
+
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Hydrocyclone Separator
Barite (SG = 4.25)
Drill Cuttings (SG = 2.65)
Hollow Spheres (SG = 0.4)
Water (SG = 100)
Barite, Drill Cuttings
Mud & Spheres
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100 1000
MESH
MICRONS
100 20
Large Spheres
DGD Sphere Separation System 2 20 Mesh
Large Cuttings Return Mud 2000 gpm 25% Spheres
Mud 1000 gpm
To Seafloor 1000 gpm
50% Spheres
Clean Mud
Shale Shaker
Shale Shaker
Medium Cuttings (Few Spheres)
100 Mesh
Conventional Mud
System
To Rig Pump 1000 gpm No Spheres
Centrifugal Pump
Spheres 500 gpm
Mud 1000 gpm
Fine Cuttings
Mud 500 gpm
+
Special Hydrocyclone
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Effect of Spheres on Plastic Viscosity
12.5 12.0
22.5
0
5
10
15
20
25
Pla
sti
c V
isco
sit
y (
cp
)
No Spheres Large Spheres Standard
Spheres
Water 36% Spheres
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Mud Line
Wellhead and BOP
Drillstring Injection DGD System
Riser
BHA
Drillpipe
Mud
Sphere Mixing Tank
Mud Pump (Mud)
Swivel
Mud & Spheres
Drill Ship
Mud
Rock
Casing
Sphere Separator
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Drill String Sphere Separator
Sea Floor
Spheres
Spheres & Mud
Riser
Sphere Separator
Mud
Spheres & Mud
Casing Drill Bit
Drill Pipe
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Carrier Fluid Dual Gradient System
Riser
Mud Line
BHA
Wellhead and BOP
Drillpipe
Mud
Shale Shaker
Carrier Fluid
Spheres
Carrier Fluid & Spheres
Mud Pump (Spheres)
Mud Pump (Mud)
Swivel
Choke
Mud & Spheres
Drill Ship
Mud
Rock
Injector Pump Screen
Valve
Flow Controller
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Mud
Injector Pump (Moineau)
Carrier Fluid Plus Spheres
Screen
Return Line
Valve
Carrier Fluid
Carrier Fluid Dual Gradient System
Mud
Choke
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Seawater Transfer System
Mud
Seawater and Spheres
Seawater
Mud
Injector Pump (Moineau)
Mud and Spheres
Screen
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Spreading Pore Pressure/Frac Curves Apart
Surface
Depth
Fracture
pressure
Pore pressure
Pressure
Seafloor
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`
DRILLING FLUID
SPHERES
OR GAS PARASITE
INJECTION PORT
Fluid Injection Techniques
GAS OR SPHERES
`
Concentric Drill Pipe Parasite String
Tie-Back Casing
SPHERES
OR GAS
MUD
`
MUD
SPHERES
OR GAS
Jet Sub
`
MUD
SPHERES
OR GAS
Nozzle
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Seafloor Sphere Injection 0
6000
10000
15000
20000
15,000 10,000 5,000 0
We
ll D
ep
th (
ft)
Riser
Sea Water Density (8.6 ppg) (50%)
4470 psi Sea Floor
11,750 psi
8110 psi
Annulus Pressure (psi)
Casing
Seafloor Sphere Injection
14 ppg (0%)
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Sub Seafloor Sphere Injection 0
6000
10000
15000
20000
15,000 10,000 5,000 0
We
ll D
ep
th (
ft)
Riser
10.4 ppg (33%)
Sea Floor
14 ppg (0%)
11,750 psi
8110 psi
Annulus Pressure (psi)
Casing
Sub Sea Floor Sphere Injection
5410 psi 4470 psi
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Sub Seafloor Sphere Injection 0
6000
10000
15000
20000
15,000 10,000 5,000 0
We
ll D
ep
th (
ft)
Riser
11.3 ppg (25%)
Sea Floor
14 ppg (0%)
11,750 psi
8110 psi
Annulus Pressure (psi)
Casing
Sub Sea Floor Sphere Injection
5876 psi 4470 psi
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Lightweight Brine Drilling Fluid
Sea Water (8.56 ppg)
Salt Brine (12 ppg)
Salt Brine + 39% Spheres (8.56 ppg)
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Major Questions
• Will Hollow Spheres Survive?
• Can Spheres Be Pumped Reliably?
• Can Spheres Be Separated From Mud?
• Can Sphere Circulation Be Initiated after Shutdowns?
• Maximum Sphere Concentration Achievable?
• How to Detect and Handle Kicks?
• Can Constant Seafloor Pressure Be Maintained?
• System Cost and Reliability?