A Noble Drilling Corporation Subsidiary TT01-431 Hollow Sphere Dual Gradient Drilling System JIP...
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Transcript of A Noble Drilling Corporation Subsidiary TT01-431 Hollow Sphere Dual Gradient Drilling System JIP...
1
A Noble DrillingCorporation Subsidiary
TT01-43
Hollow SphereDual Gradient Drilling
System
Hollow SphereDual Gradient Drilling
System
JIP Kickoff Meeting
Dr. William C. MaurerSeptember 27, 2001
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DOE Hollow SphereUnderbalanced Drilling
Project
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Types of Flow Regimes
MISTFOAMLIQUID GASAERATEDLIQUID
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Lightweight MudLightweight Mud
LIGHT WEIGHTMUDMUD HOLLOW SPHERES
5.84 ppg8.5 ppg 3.17 ppg0.70 S.G.1.02 S.G. 0.38 S.G.
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Glass BeadsGlass Beads
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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
Drilled Solids
SILT FINESAND
COARSESAND
GRAVEL
200
100
60 20
MESH
Solid
s Pe
rcen
tag
e
MICRONS
BentoniteSmallHollow
Spheres
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Centrifuge TestCentrifuge Test
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Desilter Tests
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Oilfield Hydroclone(Moore et al., 1974)
Underflow Discharge(Cuttings)
Feed Chamber
Feed Inlet
Vortex Finder
Vortex
Overflow Opening(Hollow Spheres)
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Golden State Drilling Rig Mud System
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Mud ReturnsMud Returns
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Dual Gradient Drilling Systems
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Hydrostatic Gradients for Conventional
and Riserless Drilling(Snyder, 1998)
Surface
Casing
Depth
Seawater (E)hydrostaticpressure
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 Returnand Pump
Return LineRiser
MudliftPump
BHA
Wellheadand 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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Mudlift System
(Conoco/Hydril)
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Mudlift PumpingSystem
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Mudlift Subsea Diaphragm Pumps
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Mudlift Subfloor Module
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Mudlift Subsea Diverter
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Mudlift Drillstring Valve
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(Baker Hughes/Transocean)
DEEPVISION System
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DEEPVISION Subsea Centrifugal Pump
Pressure & volumecompensator
Strainer forcompensator
Isolation valves formotor filters
Main filters
Pump suction
Pump discharge
Electrical connections
Motor cooling loop
Filter for bearing pack
Isolation valves forBearing 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
VALVEPLUNGER
DISC SPRINGPACKAGE
4-3/4” Flow Stop Sub
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DGD Rock Removal Rates
Drilling Rates (ft/hr)
Rock
Rem
oval R
ate
(to
ns/
hr)
100500 150 2000
4
8
12
12-1/4” Bit
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Shell SSPS System
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Shell SSPS DGD System(Offshore, June 2001)
Power Control Existing Rig PumpsFrom RigPower
Water Depth
Pump Section
Motor & Seal
6 - Pumps Total
NitrogenTank
Check Valve
Level SensorFor Process Control
EductorPump
ControlModule
Element OptionalFor Fluid Sep.
Mud Processing
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SSPS Gumbo Slide & Mud/Gas Separation
Nitrogen Tank
(Back-up)
Mud/GasSeparator
Flowline
Subsea BOP
Cuttings
Eductor
GumboSlide
Nitrogen TankCut Away View
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Dual Gradient Project Participation
CONOCO* HYDRIL* BP CHEVRON
MUDLIFTMUDLIFT TEXACO DIAMOND OFFSHORE GLOBAL MARINE SCHLUMBERGER
BAKER HUGHES* TRANSOCEAN SEDCO
FOREX*
DEEPVISIONDEEPVISION BP CHEVRON
SHELLSSPSSSPS
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Hollow SphereDual Gradient System
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Surface Hollow Sphere System
Riser
Mud Line
BHA
Wellheadand 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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Hollow Glass Sphere Technique
Mixture
Mud
Slurry
HollowGlass Spheres
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New Seafloor Equipment
DeepVision Mudlift
Shell SSPS Maurer
Nothing
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Sea Water Density Mud(50 % Spheres)
LIGHT WEIGHTMUDMUD HOLLOW SPHERES
8.56 ppg14 ppg 3.17 ppg1.02 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
Den
sity
, ppg
181614 12 10
Sphere Sp. Gr. = 0.38
Mud Weightppg
WaterSea Water
Mixture Density vs. Sphere Volume
10 50 60
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Sea Floor
Fracture GradientPore Pressure
Safe Zone
10
12
1416
18
Mud weight (ppg)
Dual Gradient Mud Weights
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Single Injection Point
Valve
Riser Flow Line
Mud& Spheres
Surface
Sea Floor
Mud& Spheres
Wellheadand 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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Surface Sphere Separation
ShaleShak
erSeawater
HollowSpheres
Drill CuttingsMud
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Large and Small Hollow Glass Spheres
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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
Drilled Solids
SILT FINESAND
COARSESAND
GRAVEL
200
100
60 20
MESH
Solid
s Pe
rcen
tag
e
MICRONS
LargeHollowSpheres
BentoniteSmallHollow
Spheres
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Relative Particle Size (Microns)
50SmallHollow
Spheres
147100 Mesh
Screen
300LargeHollow
Spheres
1700FracSand
(12 mesh)
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Composite Hollow Spheres
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Composite Sphere Densities
WaterDepth (ft) PVC
ThermoplasticMacrospheres
GREMinispheres
Carbon FibreMinispheres
Foam System Density (g/cc)
100020003000400050006000700080009000
1000011000120001300015000
0.250.36
0.280.340.360.390.430.440.480.530.53
0.400.410.450.480.510.550.600.620.65
0.430.450.460.480.500.530.560.590.610.66
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Riser Buoyancy Modules
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Solids Separation
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DGD Sphere Separation System 1100 1000
MESH
MICRONS
100 20
LargeSpheres
20 Mesh
Large CuttingsReturn Mud2000 gpm25% Spheres
Mud 1500 gpm
To Seafloor1000 gpm
50% Spheres
Clean Mud
ShaleShake
r
ShaleShake
rSpheres
Spheres500 gpm
Seawater
Medium Cuttings
Spheres500 gpm
100 Mesh
Spheres
ConventionalMud
System
To Rig Pump1000 gpm
No Spheres
500 gpm
Fine Cuttings
Spheres500 gpm
Mud1500 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
LargeSpheres
DGD Sphere Separation System 220 Mesh
Large CuttingsReturn Mud2000 gpm25% Spheres
Mud 1000 gpm
To Seafloor1000 gpm
50% Spheres
Clean Mud
ShaleShake
r
ShaleShake
r
Medium Cuttings(Few Spheres)
100 Mesh
ConventionalMud
System
To Rig Pump1000 gpm
No Spheres
CentrifugalPump
Spheres500 gpm
Mud 1000 gpm
Fine Cuttings
Mud500 gpm
+
SpecialHydrocyclone
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Effect of Spheres on Plastic Viscosity
12.5 12.0
22.5
0
5
10
15
20
25
Pla
stic
Vis
cosi
ty (
cp)
No Spheres Large Spheres StandardSpheres
Water36% Spheres
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Alternative Hollow Sphere
Injection Systems
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Mud Line
Wellheadand 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
SphereSeparator
Mud
Spheres& Mud
Casing Drill Bit
Drill Pipe
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Carrier Fluid Dual Gradient System
Riser
Mud Line
BHA
Wellheadand BOP
Drillpipe
Mud
Shale Shaker
CarrierFluid
Spheres
Carrier Fluid& Spheres
Mud Pump(Spheres)
Mud Pump(Mud)
Swivel
Choke
Mud & Spheres
Drill Ship
Mud
Rock
InjectorPump Screen
Valve
Flow Controller
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Mud
Injector Pump(Moineau)
Carrier FluidPlus Spheres
Screen
Return Line
Valve
CarrierFluid
Carrier Fluid Dual Gradient System
Mud
Choke
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Seawater Transfer System
Mud
Seawater andSpheres
Seawater
Mud
Injector Pump(Moineau)
Mud andSpheres
Screen
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Spreading Pore Pressure/Frac Curves Apart
Surface
Depth
Fracturepressure
Pore pressure
Pressure
Increased Frac Pressure
Seafloor
Flow Drilling
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Curved Gradient Drilling
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Fracture Gradient
Riser
Pore PressureGradient
Sea Floor
Conventional Deep Water Drilling
Safe Zone
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Fracture Gradient
Riser
Pore PressureGradient
Sea Floor
Dual-Gradient Deep Water Drilling
Safe Zone
SubseaPumps
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Fracture Gradient
Riser
Pore PressureGradient
Sea Floor
Curved-Gradient Deep Water Drilling
Safe Zone
Gas or SphereInjection Points
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`
DRILLING FLUID
SPHERESOR GAS
PARASITE
INJECTIONPORT
Fluid Injection Techniques
GAS ORSPHERES
`
Concentric Drill Pipe Parasite String
Tie-Back Casing
SPHERESOR GAS
MUD
`
MUD
SPHERESOR GAS
Jet Sub
`
MUD
SPHERESOR GAS
Nozzle
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Seafloor Sphere Injection0
6000
10000
15000
2000015,00010,0005,0000
Well D
ep
th (
ft)
Riser
Sea Water Density (8.6 ppg) (50%)
4470 psiSea Floor
11,750 psi
8110 psi
Annulus Pressure (psi)
Casing
Seafloor Sphere Injection
14 ppg (0%)
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Sub Seafloor Sphere Injection0
6000
10000
15000
2000015,00010,0005,0000
Well 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 FloorSphere Injection
5410 psi4470 psi
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Sub Seafloor Sphere Injection0
6000
10000
15000
2000015,00010,0005,0000
Well 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 FloorSphere Injection
5876 psi4470 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?
164TT01-43