Drilling system and method
10920507 ยท 2021-02-16
Assignee
Inventors
Cpc classification
E21B21/082
FIXED CONSTRUCTIONS
E21B21/08
FIXED CONSTRUCTIONS
International classification
E21B21/10
FIXED CONSTRUCTIONS
E21B21/08
FIXED CONSTRUCTIONS
Abstract
A method for managed pressure drilling comprising: extending a drilling riser with a drill string from a floating installation to a subsea blow-out preventer stack; providing a first fluid in the drilling riser annulus and a second fluid in a fluid conduit extending from the floating installation, where the first fluid has a higher density than the second fluid; circulating the second fluid through a control valve which is fluidly connected to the fluid conduit and operating the control valve to apply a surface back-pressure so as to obtain a pre-determined, desired combined hydrostatic and frictional circulation pressure below the subsea blow-out preventer stack.
Claims
1. A method for managed pressure drilling, comprising the steps of: extending a drilling riser having a drill string therein from a floating installation to a location on a seafloor, the drilling riser being fluidly connected to a subsea blow-out preventer stack and equipped with: a first fluid conduit extending from the floating installation to a lower region of the drilling riser proximate to but above the subsea blow-out preventer stack, the first fluid conduit being fluidly connected with a drilling riser annulus residing between the drill string and the surrounding drilling riser, and a second fluid conduit extending from the floating installation and fluidly connected to the drilling riser annulus through the subsea blow-out preventer stack; providing a first fluid in the drilling riser annulus via the first fluid conduit; providing a second fluid in the second fluid conduit and inside the drilling riser annulus below the first fluid, with the second fluid extending below the subsea blow-out preventer stack, wherein the first fluid has a higher density than the second fluid; circulating the second fluid through a control valve residing at the floating installation, which is fluidly connected to the second fluid conduit; and using a controller, operating the control valve to apply a surface back-pressure so as to obtain a pre-determined, combined hydrostatic and frictional circulation pressure for the second fluid below the subsea blow-out preventer stack; and wherein the first fluid conduit is a drilling riser booster line, and the second fluid conduit is a kill line and/or a choke line.
2. The method of claim 1, further comprising: using a pump, circulating the first fluid down the first fluid conduit and up the drilling riser annulus.
3. The method of claim 1, wherein the second fluid density is set such that the hydrostatic pressure acting on an open wellbore section below the subsea blow-out preventer stack is lower than or equal to a lowest formation pore pressure in the open wellbore section.
4. The method of claim 1, further comprising: providing a one-way valve in a lower part of the drill string.
5. The method of claim 1, wherein operating the control valve to apply a surface back-pressure produces a hydrostatic pressure acting on an open wellbore section below the subsea blow-out preventer stack which is higher than a formation pore pressure in the open wellbore section.
6. The method of claim 1, wherein: the second fluid is a sacrificial fluid, and the method further comprises pumping the sacrificial fluid through the drill string and/or through the second fluid conduit and into a weak formation zone along an open wellbore section below the subsea blow-out preventer stack.
7. The method of claim 6, further comprising: controlling the flow rate of the sacrificial fluid such that a hydraulic pressure acting on the open wellbore section is higher than a formation pore pressure in the open wellbore section.
8. The method of claim 7, further comprising: connecting a section of drill pipe to the drill string at the floating installation while pumping the second fluid down through the second fluid conduit and through the control valve at the floating installation.
9. The method of claim 1, further comprising: pumping the second fluid through the drill string and up the second fluid conduit, and through the control valve at the floating installation.
10. The method of claim 1, wherein operating the control valve to apply a surface back-pressure produces a pre-determined, substantially constant pressure at the subsea blow-out preventer stack to maintain a level of the second fluid.
11. The method of claim 1, further comprising: arranging a sealing element between the subsea blow-out preventer stack and the drilling riser, the sealing element being configured to seal the drilling riser annulus above the sealing element and below the sealing element around the drill string, and the sealing element residing along the lower region of the drilling riser proximate the subsea blow-out preventer stack; and providing the first fluid above the sealing element and the second fluid below the sealing element.
12. A managed pressure drilling system, comprising: a drilling riser having a drill string therein, extending from a floating installation to a location on a seafloor, the drilling riser being fluidly connected to a subsea blow-out preventer stack and equipped with: a first fluid conduit extending from the floating installation to a lower region of the drilling riser proximate to but above the subsea blow-out preventer stack, the first fluid conduit being fluidly connected with an annulus space around the drill string, a second fluid conduit extending from the floating installation to the subsea blow-out preventer stack and fluidly connected to the annulus space; a sealing element arranged within the drilling riser above and proximate to the subsea blow-out preventer stack, the sealing element being configured to seal the annulus space around the drill string; a first fluid provided in the annulus space above the sealing element via the first fluid conduit, and a second fluid provided in the second fluid conduit and in the annulus space below the sealing element, wherein the first fluid has a higher density than the second fluid; a control valve fluidly connected to the first fluid conduit and/or the second fluid conduit; and a controller configured to operate the control valve at the floating installation to apply a surface back-pressure so as to obtain a pre-determined, combined hydrostatic and frictional circulation pressure for the second fluid in the annulus space below the sealing element.
13. The system according to claim 12, further comprising: a third fluid conduit extending from the floating installation to a position below the sealing element, the third fluid conduit being fluidly connected with the annulus space and fluidly connected with the control valve.
14. The system of claim 13, wherein a tubular defining the annulus space below the sealing element, the third fluid conduit and the control valve is designed with a higher maximum allowable operating pressure than the drilling riser.
15. The system of claim 12, wherein the first fluid is configured such that a hydrostatic pressure from the first fluid acting on the sealing element from above is higher than or equal to the pre-determined, combined hydrostatic and frictional circulation pressure provided by the control valve and the second fluid acting on the said sealing element from below.
16. The system of claim 12, further comprising: a combined fluid injection and back-pressure pump fluidly connected to the control valve and to at least one of the first fluid conduit, the second fluid conduit and third fluid conduit.
17. The system of claim 16, wherein the combined fluid injection and back-pressure pump is a high pressure mud pump.
18. The system of claim 12, further comprising: a one-way valve arranged in a lower part of the drill string.
19. The system of claim 12, wherein the combined hydrostatic pressure from the first fluid provided in the annulus space around the drill string above the sealing element and the second fluid provided below the sealing element and acting on an open wellbore section is higher than a formation pore pressure.
20. The system of claim 12, further comprising: a fluid conduit fluidly arranged between a diverter housing and a tank and fluidly connected to a pump configured to circulate the first fluid between the diverter housing and the tank and to maintain a fluid level in the annulus space around the drill string.
21. The system of claim 20, further comprising: a level transmitter configured to monitor the fluid level in the riser and to identify any potential loss of fluid through the sealing element.
22. The system of claim 20, wherein: the tank is a trip tank, the first fluid conduit is a drilling riser booster line and the second fluid conduit is a choke line and/or a kill line.
23. A method for dynamically operating a managed pressure drilling system, the system comprising: a control valve on a drilling platform, a tubular extending from the drilling platform down to an earth surface; a blow-out preventer stack below the drilling platform, the tubular being fluidly connected to the blow-out preventer stack, a drill string within the tubular also extending from the drilling platform and down through the blow-out preventer stack, a sealing element residing above the blow-out preventer stack and arranged to seal an annulus space between the drill string and the surrounding tubular, a fluid conduit also extending from the drilling platform and fluidly connected to the annulus space below the sealing element, and a managed pressure drilling choke manifold containing the control valve and fluidly connected to the fluid conduit at the drilling platform, and the method comprising: operating a fluid pump to inject a fluid into the fluid conduit and to circulate the fluid through the control valve from the fluid conduit; and operating a controller to apply an increased surface back-pressure via the control valve and/or the fluid pump if a loss of circulation is detected simultaneously with a drop in drilling fluid circulation pressure so as to force the fluid down the fluid conduit and down the annulus space below the sealing element to maintain a pre-determined pressure for the fluid below the blow-out preventer stack.
24. The method of claim 23, further comprising: operating a pump to pump a drilling fluid through the drill string and into the wellbore.
25. The method of claim 23, wherein: the drilling platform is a floating offshore platform; the tubular is a low pressure marine drilling riser; the earth surface is a seabed; and the blow-out preventer stack is a subsea blow-out preventer stack.
26. The method of claim 23, wherein: the earth surface is a seabed or onshore dry land; the drilling platform is a fixed installation offshore, a drilling unit supported from the seabed or an onshore drilling facility; the tubular is a high pressure tubular designed for full shut-in pressure; and the blow-out preventer stack is located at the surface above the sea level or dry land.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) Illustrative embodiments, given as a non-restrictive examples, will now be described with reference to the attached drawings wherein:
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DETAILED DESCRIPTION OF CERTAIN EMBODIMENTS
(9) In an embodiment, there is provided a method and apparatus for managed pressure drilling (MPD) that can be used in deep or ultra-deep water when drilling with a floater with a subsea BOP stack, utilizing the marine drilling riser and the riser auxiliary tubulars commonly named booster line (fluidly connected to the riser) and kill & choke line (fluidly connected to the subsea BOP stack). The basic principle may be the same as for MPD carried out onshore with a rotating control device (RCD) installed above the BOP with one important difference that the RCD is replaced with a column of a first fluid in the riser annulus that is heavier than the second fluid used for drilling.
(10) In one embodiment, the system is used for pressurized mud cap drilling (PMCD). A first fluid, typically a viscous mud heavier than seawater, is circulated down the booster line and up the riser annulus back to the mud system at a substantially constant pump rate. The circulation of the first fluid (the heavier mud) may also be circulated from the top of the riser through the trip tank and riser fill-up line (not shown on the drawing) after the entire riser has been displaced with the heavier mud but through the booster line. In this way, the viscous heavy mud may intentionally be left stagnant in order to gel up in the riser annulus. Alternatively, it is also possible to locate a high viscous fluid between the booster line inlet and the kill or choke line outlet.
(11) A second fluid, typically seawater, is pumped down the drill pipe and injected together with drilled cuttings into the loss zone. A check valve or float (or, typically, two in series) is used in the bottom hole assembly (BHA) to avoid fluid flowing back during connection. Seawater is also pumped down the kill and choke line, part of that seawater is also circulated back to the mud system via a pressure control valve (PCV) to apply surface back-pressure in order to keep a safe and constant combined hydrostatic and frictional circulation pressure below the subsea BOP stack. The PCV is also used to adjust the amount of seawater that is pumped down the wellbore annulus and into the loss zone typically in the lower part of the well. If the pore pressure gradient in the loss zone is lower than the pore pressure gradient higher up in the same open wellbore, seawater can be pumped down the wellbore annulus at a sufficient flow rate to create a frictional pressure drop in the annulus to enable the entire wellbore to have an equivalent circulation density (ECD) higher than the highest pore pressure gradient in the open wellbore. By continuous circulating and injecting seawater through the kill and choke line, a constant combined hydrostatic and frictional circulation pressure below the subsea BOP stack can be maintained also during connection. During tripping, it can be desirable to close the BOP when the drilling bit is above the subsea BOP to avoid mud being lost to the formation in case the frictional pressure drop in the open wellbore is not high enough to maintain a safe and constant combined hydrostatic and frictional circulation pressure below the subsea BOP stack.
(12) Sometimes when total loss is experienced and drilling is continued using the above mentioned PMCD technique, the loss rate may decrease. The system can then also be used for managed pressure drilling (MPD) and obtain a safe minimum annulus pressure higher than the highest pore pressure gradient in the open wellbore, even if partial loss is experienced. A first fluid, typically heavy mud, is circulated down the booster line and up the riser annulus back to the mud system at a constant pump rate. A second drilling fluid, typically mud with a lower density than the first fluid, is pumped down the drill pipe and circulated back to the mud system via the kill and choke lines and a pressure control valve (PCV) used to apply surface back-pressure. A check valve or float (typically two in series) is used in the bottom hole assembly (BHA) to avoid fluid coming back during connection. A dedicated back-pressure pump or one of the HP mud pumps can be used to apply back-pressure during connection by circulating the drilling fluid through the PCV in the same way as used for conventional MPD with RCD.
(13) Referring now to
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(20) According to certain embodiments described herein, new systems and methods for managed pressure drilling (MPD) for a floater with subsea BOP stack, enabling drilled gas and inadvertent influx of gas under pressure to be treated in a high pressure system through a high pressure dedicated return line, a booster line, and a choke and/or kill line connected to the subsea BOP stack. Embodiments also include a dynamic pressure control (DPC) method that can be applied to any drilling system, although it will be most effective for an MPD system that enables rapid change of downhole pressure.
(21) Some advantages that can be realized with embodiments according to the presented invention can be summarized as follow: No drilled gas or inadvertent influx of gas is handled in the marine drilling riser. Gas influx can be handled by the MPD system in a high pressure system either through a dedicated high pressure return line, the high pressure booster line or the K&C lines. Utilizing the existing booster line and hose for cuttings and fluid returning to the MPD system may also reduce the CapEx and/or OpEx associated with current MPD systems and methods for a floater with a subsea BOP stack. Locating the RCD above the subsea BOP stack with a filled riser annulus with heavier mud above leaves the RCD out of the primary barrier envelope. The MPD system can still be operated even with a leaking RCD since fluid will leak down and not up and into the riser. The DPC method can avoid or reduce influx caused by partial or total loss. The DPC method can avoid or reduce influx caused by potential crossflow events. The DPC method can avoid or reduce influx and gas migration during PMCD. The DPC method can avoid or reduce further influx caused by gas hydrates forming in the wellbore after a gas influx event. The DPC method can avoid or reduce potential wellbore stability issues, such as wellbore collapse and stuck pipe caused by an influx event. The DPC method can avoid or reduce the problems of downhole pressure fluctuations due to surge and swap associated with drilling with a floater in harsh environment and narrow drilling window.
(22) The invention has been described in non-limiting embodiments. It is clear that the person skilled in the art may make a number of alterations and modifications to the described method without diverging from the scope of the invention as defined in the attached claims.