Managed Pressure Drilling: Fundamentals, Methods and Applications

Preface
A Note on Notation

Chapter 1 - Introduction
1.1. What is MPD?
1.2. MPD Variants, Terminology & Classification
1.3. Brief History and Overview of MPD Variants
1.3.1. General Introduction
1.3.2. Continuous Circulation
1.3.3. Surface Back Pressure MPD
1.3.4. Riserless and Dual-Gradient Drilling
1.3.5. Mud Cap Drilling
1.3.6. Managed Pressure Cementing and Completions
1.4. Main Benefits & Advantages of MPD
1.5. The Stakeholder Case for Action - Why Adopt MPD?
2. Fundamentals & Essential Background
2.1. Introduction
2.2. Hydraulics
2.2.1. Hydraulics Introduction
2.2.2. Hydrostatics
2.2.2.1. Definitions
2.2.2.2. Density - Ideal and Non-Ideal Mixing
2.2.2.3. Incompressible Fluids
2.2.2.4. Compressible Fluids
2.2.2.5. Effect of Hole Cleaning and Barite Sag on Density
2.2.2.6. Multiple Fluid Gradients & Unbalanced U-Tube Effects
2.2.3. Hydrodynamics
2.2.3.1. Pump Pressure, Frictional Pressure Loss & ECD
2.2.3.2. Hydraulics Models
2.2.3.3. Hydraulic Modeling: Calculating Frictional Pressure Losses during Circulation
2.2.3.4. Transient Effects: Surge & Swab
2.2.3.5. Transient Effects: Mud Gelation and Pump Startups
2.2.3.6. Hole Cleaning
2.2.3.7. Bit Pressure Drop
2.2.3.8. Other Hydraulic Pressure Losses
2.2.3.9. Uncertainty in Hydraulic Modeling
2.3. Rock Mechanics and the Drilling Margin
2.3.1. Drilling Margin Introduction
2.3.2. Pore Pressure
2.3.2.1. Pore Pressure Introduction
2.3.2.2. Pore Pressure Regimes
2.3.2.3. Deepwater Pore Pressure - Effect of Water Depth
2.3.2.4. Pore Pressure Indicators
2.3.2.5. Pore Pressure Evaluation and Prediction
2.3.3. Fracture Gradient
2.3.3.1 Fracture Gradient Introduction
2.3.3.2. Formation Integrity & Leak-Off Testing, Dynamic MPD Testing
2.3.3.3. Fracture Gradient Considerations
2.3.3.4. Ballooning / Losses & Gains / Wellbore Breathing
2.3.3.5. Fracture Gradient Evaluation and Prediction
2.3.4. Effect of Depletion on Pore Pressure and Fracture Gradient
2.3.5. Borehole Stability
2.3.5.1. Borehole Stability Introduction
2.3.5.2. Stress Tensor & Subsurface Stress Regimes
2.3.5.3. Subsurface Stress and Rock Failure
2.3.5.4. Near-Wellbore Stresses & Failure Orientation
2.3.5.5. Mud Weight for Borehole Stability - Avoiding Shear Failure
2.3.5.6. Mud Weight to Prevent Tensile Failure & Induced Fracturing
2.3.5.7. Wellbore Trajectory and the Drilling Margin
2.3.5.8. Obtaining Borehole Stability Modeling Input Variables
2.3.5.9. Borehole Stability Modeling Recommendations
2.3.6. Extending the Drilling Margin: Artificial Wellbore Strengthening
2.4. Well Control
2.4.1. Well Control Introduction
2.4.2. Definitions
2.4.3. Conventional Kick Detection
2.4.4. Wellbore Breathing Detection & Flowback Fingerprinting
2.4.5. Conventional Well Shut-In, SIDPP & SICP
2.4.6. MAASP/MASP & MAWP
2.4.7. Kick Intensity (KI) & Kick Tolerance (KT)
2.4.8. Casing Point Selection
2.4.9. Phase-Behavior of Gases
2.4.10. Gas Solubility
2.4.11. Conventional Well Control Methods
2.4.11.1. Driller's Method
2.4.11.2. Wait & Weight Method
2.4.11.3. Bullheading / Annular Injection
2.4.11.4. Subsea Well Control
2.4.11.5. Riser Margin and Emergency Riser Disconnects
2.4.12. Mud Gas Separator (MGS) Sizing
2.4.12.1. Gas Separation Capacity
2.4.12.2. Maximum Allowable Internal Pressure and Gas Flow Rate
2.5. Speed of Sound
2.6. Temperature Effects
2.6.1. Introduction
2.6.2. Temperature Regimes, HPHT Classification
2.6.3. Temperature Modeling
2.6.4. Effect of Temperature on Fluid Properties
2.6.5. Effect of Temperature on Wellbore Stability and Lost Circulation
2.6.6. Effect of Temperature on MAASP and Kick Tolerance
2.6.7. Effect of Temperature during Non-Circulatory Periods / Connections
2.7. Pipe Light Conditions
2.8. Recommended Reading
3. MPD Benefits and Risks
3.1. Introduction - How MPD Changes the Game and Adds Value
3.2. Improved Safety
3.2.1. Early Kick Detection (EKD), Early Kick & Loss Detection (EKLD)
3.2.2. Improved Pressure Control and Influx Management
3.2.3. Dynamic Pore Pressure, Formation Integrity and Leak Off Testing (DPPT, DFIT, DLOT)
3.3. Well Design Optimization
3.4. NPT Avoidance
3.4.1. Lost Circulation and Wellbore Breathing Prevention and Mitigation
3.4.2. Wellbore Instability and Stuck Pipe Prevention
3.4.3. Differential Sticking and Stuck Pipe Prevention
3.4.4. Remedial Cementing Avoidance through Managed Pressure Cementing
3.4.5. Optimized Completions
3.5. Invisible Lost Time (ILT) Avoidance & ROP Enhancement
3.6. Reduced Reservoir Damage and Production Optimization
3.7. Reduced Carbon Footprint of Well Construction Operations
3.9. Risks and Drawbacks of MPD
3.10. Techno-Economical Justification of MPD
4. MPD Equipment, Software and Operational Implementation
4.1. Introduction
4.2. MPD Equipment
4.2.1. Rotating / Non-Rotating Control Devices (RCD/ACD)
4.2.1.1. Passive RCD Systems
4.2.1.2. Active RCD Systems
4.2.1.3. Active Closing Device (ACD) Systems
4.2.1.4. Hybrid RCD Systems
4.2.1.5. Integrated Pressure Management Device (PMD)
4.2.1.6. RCD Sealing Element Life
4.2.2. Chokes & Choke Manifolds
4.2.3. Flow Metering
4.2.4. Non-Return Valves (NRV)
4.2.5. Pressure Relief Valves (PRV), Pressure Relief Chokes (PRC), Pressure Control Valves (PCV)
4.2.6. Junk / Debris Catchers
4.2.7. Distribution / Buffer Manifolds
4.2.8. Piping, Hoses and Flowlines
4.2.9. Special Downhole Valves
4.2.9.1. 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 Pumps
4.2.11. Mud Gas Separator (MGS)
4.2.12. Riser Equipment & Configurations, Integrated Riser Joint (IRJ)
4.2.13. Downhole Measurements & Telemetry
4.2.14. Programmable Logic Controllers
4.3. MPD Operational Implementation
4.3.1. Piping and Instrumentation Diagrams (P&ID), Process Flow Diagrams (PFD)
4.3.2. MPD Certification, Commissioning and Classification
4.3.3. MPD Fingerprinting
4.3.4. MPD Rig Integration
4.3.4.1. General Considerations
4.3.4.2. Land Rigs
4.3.4.2. Offshore Rigs - Jack-Ups & Platform Rigs
4.3.4.3. Offshore Rigs - Deepwater MODUs
4.3.5. Pressure Operations Directive
4.4. MPD Software and Data-Acquisition
4.5. Recommended Reading
5. Continuous Circulation (CC)
5.1. Introduction
5.2. Unique Systems, Equipment and Methods
5.2.1. 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 Control
5.4. Tripping
5.5. Case Histories
5.5.1. CCS
5.5.2. CCV
5.6. Recommended Reading
6. Surface Back Pressure (SBP)
6.1. Introduction
6.2. Drilling Margin Management
6.2.1. Adding Back-Pressure to Control Annulus / Bottom-Hole Pressures
6.2.2. Anchor Point Selection & Management
6.2.3. Basis of Design (BOD)
6.2.4. Dynamic Pore Pressure, Formation Integrity and Leak Off Testing (DPPT, DFIT, DLOT) 404
6.2.5. Tripping, Compensating for Swab & Surge Pressures
6.2.6. Heave Compensation
6.3. Pressure Control & Influx Management
6.3.1. Introduction
6.3.2. Early Kick & Loss Detection (EKLD)
6.3.3. Influx Management
6.3.3.1. Primary & Secondary Barrier Operations
6.3.3.2. MPD Operations Matrix
6.3.3.3. MPD Influx Management Envelope (IME)
6.3.3.4. MPD Influx Management Decision Tree (IMDT)
6.3.4. SMAASP & DMAASP
6.3.5. Mud Weight and SBP Selection using SMAASP & DMAASP
6.3.6. Kick Tolerance and Well Design / Casing Point Optimization
6.3.7. Riser Gas Handling (RGH) to Prevent Riser Gas Unloading (RGU) Events
6.3.7.1. Introduction
6.3.7.2. RGH / RGU Experimentation, Riser Gas Migration Monitoring
6.3.7.3. RGH / RGU Modeling
6.3.7.4. Gas Hydrates
6.3.7.5. IADC Riser Gas Handling Guidelines
6.3.7.6. Riser Gas Handling Equipment
6.3.7.7. Influx Management Envelope (IME) for Riser Gas Handling Events
6.3.7.8. Handling Gas-in-Riser with Back-Pressure and Dilution Control
6.4. SBP Methods and Systems
6.4.1. Manual Approach with Trapped Back-Pressure
6.4.2. Automated Approach with Trapped Back-Pressure
6.4.3. Automated Approach with Added Back-Pressure
6.5. SBP-MPD for Challenging Wells
6.5.1. (Ultra-)Deepwater Wells
6.5.2. High Pressure High Temperature (HPHT) Wells
6.5.3. Extended Reach Drilling (ERD) Wells
6.6. SBP Case Histories
6.7. Recommended Reading
7. Dual Gradient Drilling (DGD)
7.1. General Introduction
7.2. Riserless Drilling (RD) - Weighted Mud Discharge at the Seafloor
7.2.1. RD Introduction
7.2.2. RD Systems, Equipment and Operation
7.2.3. RD Case Histories
Intermezzo - Road to RMR: Cuttings Transport System (CTS)
7.3. Riserless Mud Recovery (RMR)
7.3.1. RMR Introduction
7.3.2. RMR Systems and Equipment
7.3.3. RMR Operation
7.3.3. RMR Case Histories
Intermezzo - Road to CML
7.4. Controlled (Annular) Mud Level (CML / CAML)
7.4.1. CML Introduction
Intermezzo - ECD Management Toolbox
7.4.2. CML Systems, Equipment and Operation
7.4.3. CML Operation
7.4.4. CML Kick Detection & Well Control
7.4.4.1. CML Kick Detection
Intermezzo - CMP Well Control Trials Using the CML System
7.4.4.2. CML Well Control
7.4.5. CML+SBP
7.4.6. CML Case Histories
7.5. Inactive Systems
7.5.1. Seabed Pumping
7.5.1.1. Subsea Mudlift Drilling (SMD)
7.5.1.2. DeepVision
7.5.1.3. Shell Subsea Pumping System (SSPS)
7.5.2. Riser Dilution
7.5.2.1. Dilution with Gas
7.5.2.2. Dilution with Hollow Spheres - Maurer JIP
7.5.2.3. Dilution with Light Fluid - Continuous Annular Pressure Management (CAPM)
7.5.3. Mid-Level Riser Pumping
7.5.3.1. Low Riser Return System (LRRS)
7.5.3.2. DeltaVision / Pumped Riser System (PRS)
7.5.4. Miscellaneous DGD Methods
7.5.4.1. Dual Drillstring - Reelwell
7.5.4.2. E-duct Return (EdR)
7.6. Recommended Reading
8. Mud Cap Drilling (MCD)
8.1. Introduction
8.2. MCD Subvariants
8.2.1. 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. PMCD
8.3. Gas Migration in MCD Operations
8.4. Planning and Executing PMCD Operations
8.4.1. Planning and Preparation
8.4.2. Equipment
8.4.3. Pit layout & fluid management
8.4.4. Transitioning between MCD and Conventional or SBP-MPD Operations
8.4.5. Well control
8.4.6. Drilling
8.4.7. Tripping
8.5. PMCD Wireline and Coring Operations
8.6. Case Histories
8.6.1. FMCD Field Cases
8.6.2. PMCD & DMCD Field Cases
8.7. Recommended Reading
9. Managed Pressure Cementing (MPC), Managed Pressure Completions (MPComp), Managed Pressure Casing/Liner/Completion Running
9.1. General Introduction
9.2. Managed Pressure Cementing (MPC)
9.2.1. MPC Introduction
9.2.2. MPC with SBP
9.2.2.1. Equipment
9.2.2.2. Workflow - Planning & Execution
9.2.2.3. Casing vs. Liner MPC Considerations
9.2.2.4. Risks
9.2.3. MPC with RMR & CML
9.2.4. MPC Modeling & Control
9.2.5. MPC Case Histories
9.3. Managed Pressure Completions (MPComp)
9.4. Downhole Measurements during MPC & MP Completions
9.5. Recommended Reading
10. Miscellaneous Methods: RMD, Multi-Phase MPD, Reelwell
10.1. Introduction
10.2. RMD / RCD-Only / HSE Method
10.3. Multi-Phase MPD
10.3.1. Equipment & Preparation
10.3.2. Modeling & Simulation
10.3.3. Direct Injection vs. Concentric Injection
10.3.4. Well Control, Connections and Tripping
10.3.5. Case Histories
10.4. Reelwell Pipe-in-Pipe Technology
10.5. Recommended Reading
11. MPD Event Detection, Automation and Control
11.1. General Introduction
11.2. Introduction to Drilling and MPD Automation
11.2.1. Drivers for Automation
11.2.2. Levels of Automation (LOA)
11.2.3. Current State of Drilling Automation & MPD Automation
11.2.3.1. Drilling Automation
11.2.3.2. MPD Automation
11.2.4. Human Factors (HF) & Situational Awareness (SA)
11.3. Event Detection
11.3.1. Artificial Intelligence (AI) and Machine Learning (ML) Introduction
11.3.2. AI & ML Methods Overview
11.3.3. Simple Rule-Based Event Detection
11.3.4. AI & ML-Based Event Detection
11.3.5. AI & ML-Based MPD Risk and Reliability Assessment
11.3.6. AI & ML-Based Advisory at the Rigsite
11.4. Automated MPD Control
11.4.1. Closed-Loop vs. Open-Loop Control
11.4.2. Process and Control Variables, Disturbances
11.4.3. Manual and Automated Control
11.4.3.1. Manual Control
11.4.3.2. Two-Position On/Off Control
11.4.3.3. Proportional (P), Integral (I) and Derivative (D) Control
11.4.3.4. Model-Predictive Control (MPC)
11.4.3.5. Other Control Approaches
11.4.4. Models for Estimation and Control
11.4.4.1. Introduction
11.4.4.2. Simple ODE Control Approach
11.4.4.3. RDFM Control Approach
11.4.4.4. Control Switching: Pressure, Flow and Solubility Control
11.4.5. Automated Tripping Advisory and Control
11.4.6. Automated Heave Control
11.4.7. Automated Fluid Monitoring
11.4.8. Automated Well Control
11.5. Digital Twinning & Hybrid Modeling
11.5.1. Digital Twinning
11.5.2. Hybrid Modeling: Combining Physics-Based and Data-Driven Modeling
11.6. Recommended Reading
12. MPD Planning, Implementation and Risk Management
12.1. Well Construction Process (WCP)
12.1.1. WCP Phases and Structure
12.1.2. WCP Risk Register
12.1.3. WCP Roles and Responsibilities
12.1.4. WCP Value Creation, Erosion or Missed Opportunity
12.1.5. WCP Cost Estimating
12.1.6. WCP Key Performance Indicators (KPIs) & Benchmarking
12.1.6.1. Safety
12.1.6.2. Drilling Time & Cost
12.1.6.3. Trouble and Inefficiency Time and Cost: NPT & ILT
12.1.6.4. Production Added
12.1.6.5. Sustainability Indicators
12.1.6.6. Staffing
12.1.6.7. Performance Benchmarking
12.2. MPD Project Management
12.2.1. Introduction.
12.2.2. Project Scoping
12.2.2.1. MPD Candidate Selection
12.2.2.2. Technical Feasibility
12.2.2.3. Economic Feasibility
12.2.3. Front End Engineering & Design (FEED)
12.2.4. Implementation
12.2.7.3. Knowledge Management: After Action Review (AAR)
12.2.7.4. Management of Change (MOC)
12.3. MPD Risk Assessment
12.3.1. Introduction
12.3.2. IADC Well Classification System
12.3.3. HAZID/HAZOP
12.3.4. FMEA/FMECA
12.3.5. LOPA/SIL
12.3.6. HSE Risk Matrix
12.3.7. HSE Risk Register
12.3.7. Cause and Effect Diagram and Table
12.3.8. Bow-Tie Analysis and Diagrams
12.3.9. Fault Tree Analysis (FTA)
12.3.10 Event Tree Analysis (ETA)
12.3.11 Linkage between Risk Assessment Approaches and HSE Management System
12.4. Training & Competency Assessment
12.5. Regulatory Approval
12.6. Summary: Key Documents, Events and Success Measures
12.7. Recommended Reading
13. Future Outlook
13.1. Introduction - MPD Projected Growth
13.2. Talent Attraction, Retention & Training
13.3. Technology Maturation & Continuous Improvement
13.4. Collaborative Regulatory Environment
13.5. Managed Pressure Engineering (MPE)
13.6. Rig Integration and Standardization
13.7. Riser Gas Handling & Riser Well Control
13.8. Automation, Data-Analysis, ML & AI, Digital Twinning, Hybrid Models, Remote Operations
13.9. Data Sharing and Collaboration
13.10. Environmental Benefits
13.11. Future Applications
13.12. Conclusion
Appendix A - Drift Flux Model (DFM) and Reduced Drift Flux Model (RDFM)
A.1. DFM Formulation
A.2. RDFM Formulation
A.3. Numerical Simulation
Appendix B - Hydraulics & Hole Cleaning Addendum
B.1 Estimation of Pressure Losses in Annuli using the Finite Difference Method
B.2. Modeling Thixotropic Fluid Behavior and Estimating Pressure Transients During Flow Initiation
B.3. Modeling Cuttings Transport using Local Fluid Velocities
B.3.1. Calculation of Velocity Profile in the Annulus using the Narrow Slot Approximation
B.3.2. Calculation of Local Critical Velocity
Appendix C - Rock Mechanics Addendum
C.1. Modified Lade, Modified Wiebols-Cook and Mogi-Coulomb Criteria
C.2. Physico-Chemical Effects on Wellbore Stability
C.3. Rock Strength Anisotropy Effects
Appendix D - Kick Tolerance Calculations
D.1. KT Formula Derivation - Conventional Drilling
D.2. KT Formula Derivation - SBP-MPD
Appendix E - Gas Solubility Example
List of Acronyms
Nomenclature
Variables
Greek letters
Subscripts & Superscripts
References

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drilling; MPD; back pressure; micro-flux; geobalance; lost circulation; NPT; nonproductive time; continuous circulation systems; MPO; mud cap drilling; dual-gradient drilling; well control; rock mechanics; IADC; underbalanced drilling; gulf