Drilling System and Method

Abstract

A method for managed pressure drilling comprising: extending a drilling riser (2) with a drill string (20) from a floating installation (52) to a subsea blow-out preventer stack (1); providing a first fluid in the drilling riser annulus (12) and a second fluid in a fluid conduit (6,7) extending from the floating installation (52), where the first fluid has a higher density than the second fluid; circulating the second fluid through a control valve (31) which is fluidly connected to the fluid conduit (6,7) and operating the control valve (31) 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 (1).

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, the first fluid conduit being fluidly connected with a drilling riser annulus, a second fluid conduit and a third fluid conduit extending from the floating installation and fluidly connected to the subsea blow-out preventer stack; providing a first fluid in the drilling riser annulus and a second fluid in the second fluid conduit and/or the third fluid conduit, wherein 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 second fluid conduit and/or third fluid conduit; and operating the control valve to apply a surface back-pressure so as to obtain a pre-determined, combined hydrostatic and frictional circulation pressure below the subsea blow-out preventer stack.

2. The method of claim 1, further comprising: circulating the first fluid down the first fluid conduit and up the drilling riser annulus.

3. The method of claim 2, wherein the second fluid density is set such that the hydrostatic pressure acting on an open wellbore section is lower than or equal to a lowest formation pore pressure in the open wellbore section.

4. The method of claim 2, further comprising: providing a one-way valve in a lower part of the drill string.

5. The method of claim 2, wherein operating the control valve to apply a surface back-pressure produces a hydrostatic pressure acting on an open wellbore section which is higher than a formation pore pressure in the open wellbore section.

6. The method of claim 2, 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/or through the third fluid conduit and into a weak formation zone along an open wellbore section.

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 while pumping the second fluid through the second fluid conduit and/or third fluid conduit.

9. The method of claim 7, further comprising: pumping the second fluid through the drill string and up the second fluid conduit and/or the third fluid conduit.

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 a location below the subsea blow-out preventer stack.

11. The method of claim 1, wherein: the first fluid conduit is a drilling riser booster line, and the second fluid conduit and the third fluid conduit each comprise a choke or kill line that is fluidly connected to the subsea blow-out preventer stack.

12. The method of claim 1, further comprising: arranging a sealing element in the lower region of the drilling riser or between the subsea blow-out preventer stack and the drilling riser, the sealing element being configured to seal an annulus space around the drill string, and providing the first fluid above the sealing element and the second fluid below the sealing element.

13. 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, the first fluid conduit being fluidly connected with an annulus space around the drill string, a second fluid conduit and a third 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 in the lower region of the drilling riser or between the subsea blow-out preventer stack and the drilling riser, 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 and a second fluid provided in the annulus space below the sealing element, wherein the first fluid has a higher density than the second fluid; and a control valve fluidly connected to the first fluid conduit, second fluid conduit and/or the third fluid conduit and configured to apply a surface back-pressure so as to obtain a pre-determined, combined hydrostatic and frictional circulation pressure in the annulus space below the sealing element.

14. The system according to claim 13, further comprising: a fourth fluid conduit extending from the floating installation to a position below the sealing element, the fourth fluid conduit being fluidly connected with the annulus space and fluidly connected with the control valve.

15. The system of claim 14, wherein a tubular defining the annulus space below the sealing element, the fourth fluid conduit and the control valve is designed with a higher maximum allowable operating pressure than the drilling riser.

16. The system of claim 13, 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.

17. The system of claim 13, 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 fourth fluid conduit, the second fluid conduit and third fluid conduit.

18. The system of claim 17, wherein the combined fluid injection and back-pressure pump is a high pressure mud pump.

19. The system of claim 13, further comprising: a one-way valve arranged in a lower part of the drill string.

20. The system of claim 13, wherein the combined hydrostatic pressure from the first fluid provided in the drilling riser annulus above the sealing element and a second fluid provided below the sealing element and acting on an open wellbore section is higher than a formation pore pressure along an open wellbore section.

21. The system of claim 13, 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 riser annulus.

22. The system of claim 21, 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.

23. The system of claim 22, wherein: the tank is a trip tank, the first fluid conduit is a drilling riser booster line and the second fluid conduit and the third fluid conduit are a choke or a kill line.

24. A method for operating a managed pressure drilling system, the system comprising a sealing element arranged above a blow-out preventer stack and arranged to seal an annulus space around a drill string within a tubular, a fluid conduit fluidly connected to the annulus space below the sealing element, and a managed pressure drilling choke manifold containing a control valve fluidly connected to the fluid conduit, and the method comprising: operating a fluid pump to inject fluids into the fluid conduit and circulate fluid through the control valve; and operating a controller to apply an increased surface back-pressure via the control valve and/or the fluid pump if a partial or total loss of circulation is detected simultaneously with a drop in drilling fluid circulation pressure such as to force fluid down the fluid conduit to maintain a pre-determined pressure below the subsea blow-out preventer stack.

25. A method for drilling, comprising: extending a drill string into a wellbore; operating a pump to pump a drilling fluid through the drill string and into the wellbore; and operating a controller to increase a flowrate of the pump if a partial or total loss of circulation is detected simultaneously with a drop in drilling fluid circulation pressure such as to maintain a pre-determined, desired pressure below a subsea blow-out preventer stack.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0021] Illustrative embodiments, given as a non-restrictive examples, will now be described with reference to the attached drawings wherein:

[0022] FIG. 1 shows a floating drilling rig arrangement;

[0023] FIG. 2 is a simplified schematic showing an embodiment used for pressurized mud cap drilling (PMCD);

[0024] FIG. 3 is a simplified schematic showing an embodiment used for managed pressure drilling (MPD) with partial loss or when PMCD with total loss cannot any longer be achieved;

[0025] FIG. 4a is a simplified schematic showing an embodiment for a MPD system with a subsea installed blow-out preventer (BOP) stack, an annulus sealing element below the low pressure marine drilling riser and a high pressure cuttings and fluid return line on the outside of the marine drilling riser;

[0026] FIG. 4b is a simplified schematic showing an embodiment for a MPD system with a subsea installed blow-out preventer stack utilizing the booster line for cuttings and fluid return back to the MPD choke;

[0027] FIG. 5 is a simplified schematic showing an embodiment for MPD with a surface installed blow-out preventer stack; and

[0028] FIG. 6 is a simplified schematic showing an embodiment used in conjunction with conventional drilling.

DETAILED DESCRIPTION OF CERTAIN EMBODIMENTS

[0029] 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.

[0030] In one embodiment the system is used for pressurized mud cap drilling (PMCD). A first fluid, typically 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 (heavier mud) may also be circulated from the top of the riser trough the trip tank and riser fill-up line (not shown on the drawing) after the entire riser has been displaced with heavier 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 booster line inlet and kill or choke line outlet.

[0031] 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 & choke line, part of that seawater is also circulated back to the mud system via a pressure control valve (PCV) to apply surface backpressure 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 an 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 & 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.

[0032] 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 lower density than the first fluid, is pumped down the drill pipe and circulated back to the mud system via the kill & choke lines and a pressure control valve (PCV) used to apply surface backpressure. 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 backpressure pump or one of the HP mud pumps can be used to apply backpressure during connection by circulation the drilling fluid through the PCV in the same way as used for conventional MPD with RCD.

[0033] Referring now to FIG. 1, a floating drilling rig 52 floating on a sea surface 50 comprises a marine drilling riser 2 extending from the rig 52 to a subsea BOP stack 1 arranged on the sea bed 51. The riser 2 is connected to a subterranean wellbore 53 extending into the underground formation and, at some point during the drilling process, into a petroleum reservoir 54. As can be seen in FIGS. 2-4, the system further comprises a slip-joint 3, a diverter housing 4 and a flowline 5 fluidly connected to a mud system. In addition to the equipment normally available on a floating drilling unit the present invention is also equipped with a managed pressure drilling (MPD) choke manifold 30. The MPD choke manifold 30 may consist of one or several pressure control valves (PCV) 31, a pressure relief device 32, a pressure transmitter (PT) 33, a flow transmitter (FT) 34 and programmable logic controller (PLC) 35. The MPD choke manifold 30 is fluidly connected to a choke line 6 and a kill line 7, either directly through a buffer manifold (not shown) or via a kill & choke manifold 8. Downstream the PCV 31 the MPD choke manifold 30 is fluidly connected to a mud gas separator (MGS) 9 and to a mud return system. Either a 3-way selector valve (not shown) or an isolation valve 36 and an isolation valve 37 are installed to return the fluid either directly to the mud return system 57 or via the MGS 9.

[0034] FIG. 2 is a simplified schematic showing a preferential form of embodiment of the present invention, when the invention is used for pressurized mud cap drilling (PMCD). PMCD is typically used when a total loss zone 16 is intersected and can also be associated with gas influx higher up in the same open wellbore 17. A high pressure mud pump 10 circulate a first fluid (typically mud), down the booster line 11 and up the riser annulus 12 and back to the mud return system via the flowline 5. The first fluid (mud) circulated in the riser annulus 12 has a higher density than a second fluid that is called a sacrificial fluid (typically seawater). The sacrificial fluid is being pumped down the choke line 6 and/or kill line 7 with a second high pressure mud pump 14, down the wellbore annulus 15 and into the total loss zone 16. The arrows in the figure illustrate the flows of the first fluid and the sacrificial fluid. The sacrificial fluid is being pumped down the wellbore annulus 15 in sufficient amount also during connection to ensure the entire open wellbore 17 stays overbalanced and by that preventing gas entering the wellbore. The sacrificial fluid is also being pumped by a high pressure mud pump 18 through an internal blow-out preventer (IBOP) 19 located in a top drive (not shown) and down a drill string 20. The drilling string 20 is also equipped with minimum one, one-way directional flow device (float) 21, to prevent reversed flow during connection. The PCV 31 is used to balance the amount of sacrificial fluid that is pumped down the choke line 6 and kill line 7 in order to maintain a safe overbalanced pressure in the entire wellbore 17. The PCV 31 is automatically controlled by a controller 35 taking input from either calculated or measured total flow into the system, i.e. high pressure mud pumps 10, 14, 18, pressure 22 in the subsea BOP stack 1 (if available), flowrate 23 in the flowline 5, flowrate 34 through the PCV 31 and upstream pressure 33, in order to maintain a safe overbalanced pressure in top of the open wellbore 17 below the last cemented liner or casing string 24.

[0035] FIG. 3 is a simplified schematic showing a preferential form of embodiment of the present invention, when the invention is used for managed pressure drilling (MPD), to maintain a safe overbalanced pressure in top of the open wellbore 17 below the last cemented liner or casing string 24. A high pressure mud pump 10 circulate a first fluid (heavy annular mud), down the booster line 11 and up the riser annulus 12 and back to the mud return system via a flowline 5. The first fluid circulated in the riser annulus 12 has a higher density than a second fluid that is for drilling (typically light drilling mud). The light drilling mud is pumped by at least one high pressure mud pump 18 through an internal blow-out preventer (IBOP) 19 located in a top drive (not shown) and down a drill string 20. The drilling string 20 is also equipped with minimum one, one-way directional flow device (float) 21, to prevent reversed flow during connection. A dedicated backpressure pump or high pressure mud pump 14 is used to apply surface backpressure by circulating through the PCV 31. The PCV 31 is automatically controlled by a control system 35 taking input from either calculated or measured total flow into the system, i.e. high pressure mud pumps 10, 14, 18, pressure 22 in the subsea BOP stack 1 (if available), flowrate 23 in the flowline 5, flowrate 34 through the PCV 31 and upstream pressure 33, in order to maintain a safe overbalanced pressure in top of the open wellbore 17 below last cemented liner or casing string 24 or a constant bottom hole pressure 25.

[0036] FIG. 4a is a simplified schematic showing a preferential form of embodiment of the present invention, when the invention is used for managed pressure drilling (MPD) with a sealing element 56 also commonly named a rotating control device (RCD), located in the lower region 55 of the drilling riser 2 typically below the inlet of the booster line 11. The injection of mud into the riser annulus 12 by means of a high pressure mud pump 10 also commonly named the booster pump, and a booster line 11 is no longer used to transport drilling cuttings up the riser, but to circulate heavy gas free mud without cuttings and drilled gas up the riser. The heavier mud returning from the diverter housing 4 is taken back by the mud return line to the mud system 57 and to a separate mud tank (not shown) and back to the booster pump 10, and down the booster line 11 to complete the circulation of the heavier mud returning from the diverter housing 4. The light drilling mud is pumped by at least one high pressure mud pump 18 through an internal blow-out preventer (IBOP) 19 located in a top drive (not shown) and down a drill string 20. The drill string 20 is also equipped with a one-way directional flow device (float) 21, to prevent reversed flow during connection. A dedicated return line 58 for drilled gas, cuttings and drilling fluid may be provided or either the kill 6 and/or choke line 7 may be used as return lines. A dedicated backpressure pump or high pressure mud pump 63 is used to apply surface backpressure by circulating through the PCV 31. The PCV 31 is automatically controlled by a controller 35 taking input from either calculated or measured total flow into the system, i.e. high pressure mud pumps 10, 14, 18, pressure 22 in the subsea BOP stack 1 (if available), flowrate 34 through the PCV 31 and upstream pressure 33, in order to maintain a safe overbalanced pressure in top of the open wellbore 17 below the sealing element 56. In the case of partial or total loss scenarios, the drilling fluid is injected down the dedicated return line 58, the kill line 6 and/or choke line 7, during connection and if necessary also during drilling. It should be noted that injecting down the return line 58, 6, 7 during drilling is only relevant during sudden loss scenarios and PMCD to maintain a safe overbalanced pressure also in top of the open wellbore 17 and to mitigate gas influx from the top fractures in the open wellbore. This method to immediately fill any fracture that may be intersected during drilling can informally be denoted dynamic pressure control (DPC). If the standpipe pressure 66 shows an abnormal drop in pressure in combination with a flow return transmitter 34 showing that a partial or total loss of drilling fluid event has occurred, this is a strong indication that the formation fracture gradient has been exceeded or a natural fracture has been intersected. Rather than reducing the applied surface backpressure by opening the PCV 31 to prevent severe losses, the DPC method will increase applied surface backpressure by closing the PCV 31. The purpose of increasing the applied surface backpressure is to be able to force fluid down the return line 58, 6, 7, supplied by the backpressure pump 63. The fluid injected will compress the fluid in the fracture and fill the fracture with drilling fluid as quick as possible in order to avoid a temporary drop in the open wellbore 17 annulus 15 pressure. The purpose of the DPC method is to to maintain a safe overbalanced pressure also in top of the open wellbore 17 and to mitigate gas influx from the top fractures or higher pressured reservoirs in the open wellbore even during loss events and crossflow events.

[0037] FIG. 4b is a simplified schematic showing a preferential form of embodiment of the present invention used for managed pressure drilling (MPD). The main difference between FIGS. 4a and 4b is that the first fluid conduit 11 also called booster line is used as a return line for drilled gas, cuttings and drilling fluid. The booster line is no longer connected to the annulus space 12 above the RCD 56 but connected to the annulus space 15 below the RCD 56. A high pressure mud pump 10 also commonly named the booster pump, is used to apply surface backpressure by circulating drilling fluid through the PCV 31. The common fluid conduit 68 will take both cuttings and fluid returning from the wellbore through the booster line 11 and the fluid being circulated through the high pressure mud pump 10. The high pressure mud mup 10 and the booster line 11 may also be used to change or circulate the heavier first fluid in the riser annulus 12, by means of closing a subsea BOP 1 and open the sealing element 56. However, when the system is in drilling mode the subsea BOP 1 is open and the sealing element 56 is closed. To ensure the riser annulus 12 is filled at all time with the heavier first fluid, a tank 70 normally a trip tank, will be filled up and the first fluid circulated by means of the a circulation pump 71 normally the trip tank pump, up to the diverting housing 4 where excess fluid is drained back by means of a fluid conduit 69. Potential loss of the heavier fluid in the riser annulus 12 due to leaking RCD 56 will be monitored by a level transmitter 72 and the riser annulus 12 will be continuously filled by means of the circulation pump 71.

[0038] FIG. 5 is a simplified schematic showing an MPD system with a surface installed BOP stack 62, located above the sea level 50. The figure shows a typical installation offshore with a subsea wellhead 60 located on the seabed 51 and with a high pressure riser or a tubular 61 fluidly connecting the wellhead 60 with the surface BOP stack 62. The MPD system shown typically further consist of an RCD 56 located above the BOP stack 62, and a short flow spool 65 fluidly connected with fluid return line 58 connected to a MPD choke manifold 30. The system shown is typically used for fixed installation offshore and drilling units supported from the seabed (jack-ups). However, a similar system may also be used for MPD systems onshore, where the surface BOP stack 62 typically is installed directly on the wellhead 60. The purpose with this FIG. 5 is to show that the dynamic pressure control (DPC) method described under FIG. 4a may also be used for any MPD systems where rapid change of downhole pressure can be achieved.

[0039] FIG. 6 is a simplified schematic showing a typical conventional drilling application with no MPD system provided. The figure shows a typical offshore installation with a subsea BOP stack 1 and a low pressure riser 2, however the same dynamic pressure control (DPC) method is also valid for other conventional installation onshore and offshore with a surface installed BOP stack. In this case since it takes time to close the BOP and since in this case there is no MPD systems installed, the DPC method will be obtained by instantly increasing the flowrate down the drillstring 20. If the standpipe pressure 66 shows an abnormal drop in pressure in combination with a flow return transmitter 23 showing that a partial or total loss of drilling fluid event has occurred, this is a strong indication that the formation fracture gradient has been exceeded or a natural fracture has been intersected. Rather than reducing the flowrate from the high pressure mud pumps 18 to prevent severe losses, the DPC method will automatically increase the high pressure pump 18 speed by a controller 67. The purpose of the DPC method is to reduce the potential influx of gas caused by a sudden loss or crossflow event, due to a temporary drop in the open wellbore 17 annulus 15 pressure.

[0040] 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, booster line, 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 effect for MPD system that enables rapid change of downhole pressure.

[0041] Some advantages that can be realized with embodiments according to the presented invention can be summarized as follow: [0042] No drilled gas or inadvertent influx of gas is handled in the marine drilling riser. [0043] 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. [0044] 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. [0045] 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. [0046] The MPD system can still be operated even with a leaking RCD since fluid will leak down and not up and into the riser. [0047] The DPC method can avoid or reduce influx caused by partial or total loss. [0048] The DPC method can avoid or reduce influx caused by potential crossflow events. [0049] The DPC method can avoid or reduce influx and gas migration during PMCD. [0050] The DPC method can avoid or reduce further influx caused by gas hydrates forming in the wellbore after a gas influx event. [0051] The DPC method can avoid or reduce potential wellbore stability issues, such as wellbore collapse and stuck pipe caused by an influx event. [0052] 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.

[0053] 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.