Managed Pressure Drilling: Fundamentals, Methods and Applications

Dr. Eric van Oort became Professor in Petroleum Engineering and Richard B. Curran Chair in Engineering at the University of Texas at Austin in 2012, after a 20-year industry career with Shell (Shell Research/KSEPL, Shell BTC & Shell Oil Company USA). He holds a PhD degree in Chemical Physics from the University of Amsterdam. He has (co-)authored more than 250 technical papers, holds 22 patents, is a former SPE Distinguished Lecturer, a SPE Distinguished Member, and the 2017 winner of the prestigious international SPE Drilling Engineering Award. He is the director of the RAPID industry consortium at UT Austin with 15-20 industry members annually, dedicated to drilling automation and optimization, data analytics, modeling and digital twinning, robotics, and sustainability issues such as geothermal & CCS well construction, well integrity, zonal isolation and permanent well P&A. He is also a co-founder of SPYDR Automation Inc. and Ultradeep Energy Co. LLC, and owns his own consulting company, EVO Energy Consulting.

• PrefaceA Note on NotationChapter 1 – Introduction1.1. What is MPD?1.2. MPD Variants, Terminology & Classification1.3. Brief History and Overview of MPD Variants1.3.1. General Introduction1.3.2. Continuous Circulation1.3.3. Surface Back Pressure MPD1.3.4. Riserless and Dual-Gradient Drilling1.3.5. Mud Cap Drilling1.3.6. Managed Pressure Cementing and Completions1.4. Main Benefits & Advantages of MPD1.5. The Stakeholder Case for Action – Why Adopt MPD?2. Fundamentals & Essential Background2.1. Introduction2.2. Hydraulics2.2.1. Hydraulics Introduction2.2.2. Hydrostatics2.2.2.1. Definitions2.2.2.2. Density – Ideal and Non-Ideal Mixing2.2.2.3. Incompressible Fluids2.2.2.4. Compressible Fluids2.2.2.5. Effect of Hole Cleaning and Barite Sag on Density2.2.2.6. Multiple Fluid Gradients & Unbalanced U-Tube Effects2.2.3. Hydrodynamics2.2.3.1. Pump Pressure, Frictional Pressure Loss & ECD2.2.3.2. Hydraulics Models2.2.3.3. Hydraulic Modeling: Calculating Frictional Pressure Losses during Circulation2.2.3.4. Transient Effects: Surge & Swab2.2.3.5. Transient Effects: Mud Gelation and Pump Startups2.2.3.6. Hole Cleaning2.2.3.7. Bit Pressure Drop2.2.3.8. Other Hydraulic Pressure Losses2.2.3.9. Uncertainty in Hydraulic Modeling2.3. Rock Mechanics and the Drilling Margin2.3.1. Drilling Margin Introduction2.3.2. Pore Pressure2.3.2.1. Pore Pressure Introduction2.3.2.2. Pore Pressure Regimes2.3.2.3. Deepwater Pore Pressure – Effect of Water Depth2.3.2.4. Pore Pressure Indicators2.3.2.5. Pore Pressure Evaluation and Prediction2.3.3. Fracture Gradient2.3.3.1 Fracture Gradient Introduction2.3.3.2. Formation Integrity & Leak-Off Testing, Dynamic MPD Testing2.3.3.3. Fracture Gradient Considerations2.3.3.4. Ballooning / Losses & Gains / Wellbore Breathing2.3.3.5. Fracture Gradient Evaluation and Prediction2.3.4. Effect of Depletion on Pore Pressure and Fracture Gradient2.3.5. Borehole Stability2.3.5.1. Borehole Stability Introduction2.3.5.2. Stress Tensor & Subsurface Stress Regimes2.3.5.3. Subsurface Stress and Rock Failure2.3.5.4. Near-Wellbore Stresses & Failure Orientation2.3.5.5. Mud Weight for Borehole Stability – Avoiding Shear Failure2.3.5.6. Mud Weight to Prevent Tensile Failure & Induced Fracturing2.3.5.7. Wellbore Trajectory and the Drilling Margin2.3.5.8. Obtaining Borehole Stability Modeling Input Variables2.3.5.9. Borehole Stability Modeling Recommendations2.3.6. Extending the Drilling Margin: Artificial Wellbore Strengthening2.4. Well Control2.4.1. Well Control Introduction2.4.2. Definitions2.4.3. Conventional Kick Detection2.4.4. Wellbore Breathing Detection & Flowback Fingerprinting2.4.5. Conventional Well Shut-In, SIDPP & SICP2.4.6. MAASP/MASP & MAWP2.4.7. Kick Intensity (KI) & Kick Tolerance (KT)2.4.8. Casing Point Selection2.4.9. Phase-Behavior of Gases2.4.10. Gas Solubility2.4.11. Conventional Well Control Methods2.4.11.1. Driller’s Method2.4.11.2. Wait & Weight Method2.4.11.3. Bullheading / Annular Injection2.4.11.4. Subsea Well Control2.4.11.5. Riser Margin and Emergency Riser Disconnects2.4.12. Mud Gas Separator (MGS) Sizing2.4.12.1. Gas Separation Capacity2.4.12.2. Maximum Allowable Internal Pressure and Gas Flow Rate2.5. Speed of Sound2.6. Temperature Effects2.6.1. Introduction2.6.2. Temperature Regimes, HPHT Classification2.6.3. Temperature Modeling2.6.4. Effect of Temperature on Fluid Properties2.6.5. Effect of Temperature on Wellbore Stability and Lost Circulation2.6.6. Effect of Temperature on MAASP and Kick Tolerance2.6.7. Effect of Temperature during Non-Circulatory Periods / Connections2.7. Pipe Light Conditions2.8. Recommended Reading3. MPD Benefits and Risks3.1. Introduction – How MPD Changes the Game and Adds Value3.2. Improved Safety3.2.1. Early Kick Detection (EKD), Early Kick & Loss Detection (EKLD)3.2.2. Improved Pressure Control and Influx Management3.2.3. Dynamic Pore Pressure, Formation Integrity and Leak Off Testing (DPPT, DFIT, DLOT)3.3. Well Design Optimization3.4. NPT Avoidance3.4.1. Lost Circulation and Wellbore Breathing Prevention and Mitigation3.4.2. Wellbore Instability and Stuck Pipe Prevention3.4.3. Differential Sticking and Stuck Pipe Prevention3.4.4. Remedial Cementing Avoidance through Managed Pressure Cementing3.4.5. Optimized Completions3.5. Invisible Lost Time (ILT) Avoidance & ROP Enhancement3.6. Reduced Reservoir Damage and Production Optimization3.7. Reduced Carbon Footprint of Well Construction Operations3.9. Risks and Drawbacks of MPD3.10. Techno-Economical Justification of MPD4. MPD Equipment, Software and Operational Implementation4.1. Introduction4.2. MPD Equipment4.2.1. Rotating / Non-Rotating Control Devices (RCD/ACD)4.2.1.1. Passive RCD Systems4.2.1.2. Active RCD Systems4.2.1.3. Active Closing Device (ACD) Systems4.2.1.4. Hybrid RCD Systems4.2.1.5. Integrated Pressure Management Device (PMD)4.2.1.6. RCD Sealing Element Life4.2.2. Chokes & Choke Manifolds4.2.3. Flow Metering4.2.4. Non-Return Valves (NRV)4.2.5. Pressure Relief Valves (PRV), Pressure Relief Chokes (PRC), Pressure Control Valves (PCV)4.2.6. Junk / Debris Catchers4.2.7. Distribution / Buffer Manifolds4.2.8. Piping, Hoses and Flowlines4.2.9. Special Downhole Valves4.2.9.1. Casing Isolation Valve (CIV) / Downhole Isolation Valve (DIV)4.2.9.2. Drill String Valve (DSV) / Hydrostatic Control Valve (HCV)4.2.10. Back-Pressure Pumps4.2.11. Mud Gas Separator (MGS)4.2.12. Riser Equipment & Configurations, Integrated Riser Joint (IRJ)4.2.13. Downhole Measurements & Telemetry4.2.14. Programmable Logic Controllers4.3. MPD Operational Implementation4.3.1. Piping and Instrumentation Diagrams (P&ID), Process Flow Diagrams (PFD)4.3.2. MPD Certification, Commissioning and Classification4.3.3. MPD Fingerprinting4.3.4. MPD Rig Integration4.3.4.1. General Considerations4.3.4.2. Land Rigs4.3.4.2. Offshore Rigs – Jack-Ups & Platform Rigs4.3.4.3. Offshore Rigs – Deepwater MODUs4.3.5. Pressure Operations Directive4.4. MPD Software and Data-Acquisition4.5. Recommended Reading5. Continuous Circulation (CC)5.1. Introduction5.2. Unique Systems, Equipment and Methods5.2.1. Continuous Circulation System (CCS)5.2.2. Continuous Circulation Valves (CCV)5.2.2.1. Eni Circulation Device (e-cdTM)5.2.2.2. Non-Stop Driller (NSDTM)5.2.2.3. Continuous Flow System (CFSTM)5.2.2.4. Rotating Continuous Circulation Tool (RCCT)5.3. Kick Detection and Well Control5.4. Tripping5.5. Case Histories5.5.1. CCS5.5.2. CCV5.6. Recommended Reading6. Surface Back Pressure (SBP)6.1. Introduction6.2. Drilling Margin Management6.2.1. Adding Back-Pressure to Control Annulus / Bottom-Hole Pressures6.2.2. Anchor Point Selection & Management6.2.3. Basis of Design (BOD)6.2.4. Dynamic Pore Pressure, Formation Integrity and Leak Off Testing (DPPT, DFIT, DLOT) 4046.2.5. Tripping, Compensating for Swab & Surge Pressures6.2.6. Heave Compensation6.3. Pressure Control & Influx Management6.3.1. Introduction6.3.2. Early Kick & Loss Detection (EKLD)6.3.3. Influx Management6.3.3.1. Primary & Secondary Barrier Operations6.3.3.2. MPD Operations Matrix6.3.3.3. MPD Influx Management Envelope (IME)6.3.3.4. MPD Influx Management Decision Tree (IMDT)6.3.4. SMAASP & DMAASP6.3.5. Mud Weight and SBP Selection using SMAASP & DMAASP6.3.6. Kick Tolerance and Well Design / Casing Point Optimization6.3.7. Riser Gas Handling (RGH) to Prevent Riser Gas Unloading (RGU) Events6.3.7.1. Introduction6.3.7.2. RGH / RGU Experimentation, Riser Gas Migration Monitoring6.3.7.3. RGH / RGU Modeling6.3.7.4. Gas Hydrates6.3.7.5. IADC Riser Gas Handling Guidelines6.3.7.6. Riser Gas Handling Equipment6.3.7.7. Influx Management Envelope (IME) for Riser Gas Handling Events6.3.7.8. Handling Gas-in-Riser with Back-Pressure and Dilution Control6.4. SBP Methods and Systems6.4.1. Manual Approach with Trapped Back-Pressure6.4.2. Automated Approach with Trapped Back-Pressure6.4.3. Automated Approach with Added Back-Pressure6.5. SBP-MPD for Challenging Wells6.5.1. (Ultra-)Deepwater Wells6.5.2. High Pressure High Temperature (HPHT) Wells6.5.3. Extended Reach Drilling (ERD) Wells6.6. SBP Case Histories6.7. Recommended Reading7. Dual Gradient Drilling (DGD)7.1. General Introduction7.2. Riserless Drilling (RD) – Weighted Mud Discharge at the Seafloor7.2.1. RD Introduction7.2.2. RD Systems, Equipment and Operation7.2.3. RD Case HistoriesIntermezzo – Road to RMR: Cuttings Transport System (CTS)7.3. Riserless Mud Recovery (RMR)7.3.1. RMR Introduction7.3.2. RMR Systems and Equipment7.3.3. RMR Operation7.3.3. RMR Case HistoriesIntermezzo – Road to CML7.4. Controlled (Annular) Mud Level (CML / CAML)7.4.1. CML IntroductionIntermezzo – ECD Management Toolbox7.4.2. CML Systems, Equipment and Operation7.4.3. CML Operation7.4.4. CML Kick Detection & Well Control7.4.4.1. CML Kick DetectionIntermezzo – CMP Well Control Trials Using the CML System7.4.4.2. CML Well Control7.4.5. CML+SBP7.4.6. CML Case Histories7.5. Inactive Systems7.5.1. Seabed Pumping7.5.1.1. Subsea Mudlift Drilling (SMD)7.5.1.2. DeepVision7.5.1.3. Shell Subsea Pumping System (SSPS)7.5.2. Riser Dilution7.5.2.1. Dilution with Gas7.5.2.2. Dilution with Hollow Spheres – Maurer JIP7.5.2.3. Dilution with Light Fluid - Continuous Annular Pressure Management (CAPM)7.5.3. Mid-Level Riser Pumping7.5.3.1. Low Riser Return System (LRRS)7.5.3.2. DeltaVision / Pumped Riser System (PRS)7.5.4. Miscellaneous DGD Methods7.5.4.1. Dual Drillstring - Reelwell7.5.4.2. E-duct Return (EdR)7.6. Recommended Reading8. Mud Cap Drilling (MCD)8.1. Introduction8.2. MCD Subvariants8.2.1. Floating Mud Cap Drilling (FMCD)8.2.2. Pressurized Mud Cap Drilling (PMCD)8.2.3. Dynamic Mud Cap Drilling (DMCD)8.2.4. Controlled Mud Cap Drilling (CMCD)8.2.5. Variant Selection and Comparison: FMCD vs. PMCD8.3. Gas Migration in MCD Operations8.4. Planning and Executing PMCD Operations8.4.1. Planning and Preparation8.4.2. Equipment8.4.3. Pit layout & fluid management8.4.4. Transitioning between MCD and Conventional or SBP-MPD Operations8.4.5. Well control8.4.6. Drilling8.4.7. Tripping8.5. PMCD Wireline and Coring Operations8.6. Case Histories8.6.1. FMCD Field Cases8.6.2. PMCD & DMCD Field Cases8.7. Recommended Reading9. Managed Pressure Cementing (MPC), Managed Pressure Completions (MPComp), Managed Pressure Casing/Liner/Completion Running9.1. General Introduction9.2. Managed Pressure Cementing (MPC)9.2.1. MPC Introduction9.2.2. MPC with SBP9.2.2.1. Equipment9.2.2.2. Workflow – Planning & Execution9.2.2.3. Casing vs. Liner MPC Considerations9.2.2.4. Risks9.2.3. MPC with RMR & CML9.2.4. MPC Modeling & Control9.2.5. MPC Case Histories9.3. Managed Pressure Completions (MPComp)9.4. Downhole Measurements during MPC & MP Completions9.5. Recommended Reading10. Miscellaneous Methods: RMD, Multi-Phase MPD, Reelwell10.1. Introduction10.2. RMD / RCD-Only / HSE Method10.3. Multi-Phase MPD10.3.1. Equipment & Preparation10.3.2. Modeling & Simulation10.3.3. Direct Injection vs. Concentric Injection10.3.4. Well Control, Connections and Tripping10.3.5. Case Histories10.4. Reelwell Pipe-in-Pipe Technology10.5. Recommended Reading11. MPD Event Detection, Automation and Control11.1. General Introduction11.2. Introduction to Drilling and MPD Automation11.2.1. Drivers for Automation11.2.2. Levels of Automation (LOA)11.2.3. Current State of Drilling Automation & MPD Automation11.2.3.1. Drilling Automation11.2.3.2. MPD Automation11.2.4. Human Factors (HF) & Situational Awareness (SA)11.3. Event Detection11.3.1. Artificial Intelligence (AI) and Machine Learning (ML) Introduction11.3.2. AI & ML Methods Overview11.3.3. Simple Rule-Based Event Detection11.3.4. AI & ML-Based Event Detection11.3.5. AI & ML-Based MPD Risk and Reliability Assessment11.3.6. AI & ML-Based Advisory at the Rigsite11.4. Automated MPD Control11.4.1. Closed-Loop vs. Open-Loop Control11.4.2. Process and Control Variables, Disturbances11.4.3. Manual and Automated Control11.4.3.1. Manual Control11.4.3.2. Two-Position On/Off Control11.4.3.3. Proportional (P), Integral (I) and Derivative (D) Control11.4.3.4. Model-Predictive Control (MPC)11.4.3.5. Other Control Approaches11.4.4. Models for Estimation and Control11.4.4.1. Introduction11.4.4.2. Simple ODE Control Approach11.4.4.3. RDFM Control Approach11.4.4.4. Control Switching: Pressure, Flow and Solubility Control11.4.5. Automated Tripping Advisory and Control11.4.6. Automated Heave Control11.4.7. Automated Fluid Monitoring11.4.8. Automated Well Control11.5. Digital Twinning & Hybrid Modeling11.5.1. Digital Twinning11.5.2. Hybrid Modeling: Combining Physics-Based and Data-Driven Modeling11.6. Recommended Reading12. MPD Planning, Implementation and Risk Management12.1. Well Construction Process (WCP)12.1.1. WCP Phases and Structure12.1.2. WCP Risk Register12.1.3. WCP Roles and Responsibilities12.1.4. WCP Value Creation, Erosion or Missed Opportunity12.1.5. WCP Cost Estimating12.1.6. WCP Key Performance Indicators (KPIs) & Benchmarking12.1.6.1. Safety12.1.6.2. Drilling Time & Cost12.1.6.3. Trouble and Inefficiency Time and Cost: NPT & ILT12.1.6.4. Production Added12.1.6.5. Sustainability Indicators12.1.6.6. Staffing12.1.6.7. Performance Benchmarking12.2. MPD Project Management12.2.1. Introduction.12.2.2. Project Scoping12.2.2.1. MPD Candidate Selection12.2.2.2. Technical Feasibility12.2.2.3. Economic Feasibility12.2.3. Front End Engineering & Design (FEED)12.2.4. Implementation12.2.7.3. Knowledge Management: After Action Review (AAR)12.2.7.4. Management of Change (MOC)12.3. MPD Risk Assessment12.3.1. Introduction12.3.2. IADC Well Classification System12.3.3. HAZID/HAZOP12.3.4. FMEA/FMECA12.3.5. LOPA/SIL12.3.6. HSE Risk Matrix12.3.7. HSE Risk Register12.3.7. Cause and Effect Diagram and Table12.3.8. Bow-Tie Analysis and Diagrams12.3.9. Fault Tree Analysis (FTA) 12.3.10 Event Tree Analysis (ETA)12.3.11 Linkage between Risk Assessment Approaches and HSE Management System12.4. Training & Competency Assessment12.5. Regulatory Approval12.6. Summary: Key Documents, Events and Success Measures12.7. Recommended Reading13. Future Outlook13.1. Introduction – MPD Projected Growth13.2. Talent Attraction, Retention & Training13.3. Technology Maturation & Continuous Improvement13.4. Collaborative Regulatory Environment13.5. Managed Pressure Engineering (MPE)13.6. Rig Integration and Standardization13.7. Riser Gas Handling & Riser Well Control13.8. Automation, Data-Analysis, ML & AI, Digital Twinning, Hybrid Models, Remote Operations13.9. Data Sharing and Collaboration13.10. Environmental Benefits13.11. Future Applications13.12. ConclusionAppendix A – Drift Flux Model (DFM) and Reduced Drift Flux Model (RDFM)A.1. DFM FormulationA.2. RDFM FormulationA.3. Numerical SimulationAppendix B – Hydraulics & Hole Cleaning AddendumB.1 Estimation of Pressure Losses in Annuli using the Finite Difference MethodB.2. Modeling Thixotropic Fluid Behavior and Estimating Pressure Transients During Flow InitiationB.3. Modeling Cuttings Transport using Local Fluid VelocitiesB.3.1. Calculation of Velocity Profile in the Annulus using the Narrow Slot ApproximationB.3.2. Calculation of Local Critical VelocityAppendix C – Rock Mechanics AddendumC.1. Modified Lade, Modified Wiebols-Cook and Mogi-Coulomb CriteriaC.2. Physico-Chemical Effects on Wellbore StabilityC.3. Rock Strength Anisotropy EffectsAppendix D – Kick Tolerance CalculationsD.1. KT Formula Derivation – Conventional DrillingD.2. KT Formula Derivation – SBP-MPDAppendix E - Gas Solubility ExampleList of AcronymsNomenclatureVariablesGreek lettersSubscripts & SuperscriptsReferences