AU2008201481B2

AU2008201481B2 - Underbalanced well drilling and production

Info

Publication number: AU2008201481B2
Application number: AU2008201481A
Authority: AU
Inventors: Gavin Humphreys
Original assignee: Stena Drilling Ltd
Current assignee: Stena Drilling Ltd
Priority date: 2003-10-30
Filing date: 2008-04-01
Publication date: 2009-04-23
Anticipated expiration: 2024-10-25
Also published as: AU2008201481A1

Description

Australian Patents Act 1990 - Regulation 3.2 ORIGINAL COMPLETE SPECIFICATION STANDARD PATENT Invention Title ""Underbalanced well drilling and production"" The following statement is a full description of this invention, including the best method of performing it known to us: 0 \0PER\MRF\2008\305I 1074 87.doc PQOPER\MRF\10M I1074 1spa doc-31/0)3/209 -2 Underbalanced Well Drilling And Production Field of the Invention This invention relates generally to drilling of wells and production from wells. Background 5 Generally, wells are drilled in a slightly over-balanced condition where the weight of the drilling fluid used is only slightly over the pore pressure of the rocks being drilled. Drilling mud is pumped down the drill string to a drill bit and used to lubricate and cool the drill bit and remove drilled cuttings from the hole while it is being drilled. The viscous drilling mud carries the drilled cuttings upwardly on the outside and around the 10 drill string. In a balanced situation, the density of the mud going downwardly to the drill bit and the mud passing upwardly from the drill bit is substantially the same. This has the benefit of reducing the likelihood of a so-called kick. In a kick situation, the downward pressure of the drilling mud column is not sufficient to balance the pore pressure in the 15 rocks being drilled, for example of gas or other fluid, which is encountered in a formation. As a result, the well may blowout (if an effective blowout preventer (BOP) is not fitted to the well) which is an extremely dangerous condition. In underbalanced drilling, the aim is to deliberately create the situation described above. Namely, the density or equivalent circulating density of the upwardly returning 20 mud is below the pore pressure of the rock being drilled, causing gas, oil, or water in the rock to enter the well-bore from the rock being drilled. This may also result in increased drilling rates but also the well to flow if the rock permeability and porosity allowed sufficient fluids to enter the well-bore. In this drilling environment it is general practice to provide a variety of blowout 25 preventers to control any loss of control incidents or blowouts that may occur. A variety of techniques have been utilized for underbalanced or dual gradient drilling. Generally, they involve providing a density lowering component to the returning drilling mud. Gases, seawater, and glass beads have been injected into the returning mud flow to reduce its density. 30 In deep subsea applications, a number of problems may arise. Because of the pressures involved, everything becomes significantly more complicated. The pressure that bears down on the formation includes the weight of the drilling mud, whereas the pressure P3OPERMRf\Spcictions\2UO8 DIVSIONAL305|1074 divisionaldc-/4/20 -3 in the shallow formations is dictated by the weight of seawater above the formation. Because of the higher pressures involved, the drilling mud may actually be injected into the formation, fracture it and may even clog or otherwise foul the formation itself, severely impairing potential hydrocarbon production. 5 The reference in this specification to any prior publication (or information derived from it), or to any matter which is known, is not, and should not be taken as an acknowledgment or admission or any form of suggestion that that prior publication (or information derived from it) or known matter forms part of the common general knowledge in the field of endeavour to which this specification relates. 10 Summary of the Invention According to a first aspect of the present invention, there is provided a method comprising: coupling a surface blow out preventer to a wellhead using casing; 15 providing a remotely operable subsurface latch to sever the connection between said wellhead and said surface blow out preventer; and producing hydrocarbons from a subsea well in an underbalanced condition using a rotating head mounted on the surface blow out preventer. According to a second aspect of the present invention, there is provided a drilling 20 rig comprising: a rotating head; a surface blow out preventer mounted under said rotating head on said rig; and an apparatus to pump fluid to a subsea location to lower the density of drilling mud returning to said rig. 25 According to a third aspect of the present invention, there is provided a subsea shutoff assembly comprising: a pair of shear blow out preventers; and a device coupling said blow out preventers, said device having an inlet to receive a density lowering fluid to lower the density of drilling mud moving upwardly through said 30 device. According to a fourth aspect of the present invention, there is provided a method P.\OPER\M\0511074 IsP d-31/03/200 -4 comprising: providing a rotating head that transfers rotational energy to said drill string through a packer; and producing hydrocarbons from a subsea well in an underbalanced condition using 5 the rotating head mounted on the surface blow out preventer. Brief Description of the Drawings The present invention will now be described, by way of non-limiting example only, with reference to the accompanying drawings, in which: 10 Figure 1 is a schematic depiction of one embodiment of the present invention; Figure 2 is an enlarged schematic depiction of the subsea shut-off assembly shown in Figure 1 in accordance with one embodiment of the present invention; Figure 3 is an enlarged, schematic, cross-sectional view of the spool 34 shown in Figure 2 in accordance with one embodiment of the present invention; and 15 Figure 4 is a schematic cross-sectional view of the rotating head shown in Figure 1 in accordance with one embodiment of the present invention. Detailed Description In some embodiments of the present invention, both drilling and production of 20 fluids from a formation may occur in an underbalanced condition. As used herein, "underbalanced" means that the weight of the drilling mud is less than the pore pressure of the formation. As used herein, "dual gradient "refers to the fact that the density of fluid, at some point along its course, moving away from a drill bit, is lower than the density of the fluid moving towards the drill bit. Dual gradient techniques may be used to implement 25 underbalanced drilling. The creation of a dual-gradient or underbalanced condition may be implemented using any known techniques, including the injection of gases, seawater, and glass beads, to mention a few examples. Referring to Figure 1, a drilling and production apparatus 11 may include a rotating head 10 which rotates a string for purposes of drilling a well in a subsea formation SF. The 30 rotating head 10 rotates the string through a surface blowout preventer (BOP) stack 12. The surface blowout preventer stack 12 may include annular blowout preventers that P OPERWRFSpecificaio2()\DIV SIONALS30 1074 divisional doc- IA4/2008 -5 control the flow of fluid moving upwardly from the wellhead to the overlying floating rig 14. The rig 14 may be tensioned using ring tensioners 16, coupled by a pulleys 54 to hydraulic cylinders 56 to create a tensioning system 50. The tensioning system 50 allows 5 the upper portion of the apparatus 11 to move relative to the lower portion, for example in response to sea conditions. The system 50 allows this relative movement and adjustment of relative positioning while maintaining tension on the casing 22, which extends from the floating rig 14 downwardly to a subsea shutoff assembly 24. The surface portion of the apparatus 11 is coupled by a connector 20 to the 10 casing 22. The casing 22 is connected to the lower section of the apparatus 11 via a disconnectable latch 72 located below the sea level WL. The latch 72 may be hydraulically operated from the surface to disconnect the upper portion of the apparatus I1 from the lower portion including the subsea shutoff assembly 24. Also provided on the rig 14 is a source of fluid that is of a lower density than the 15 density of mud pumped downwardly through the casing 22 from the surface in one embodiment of the present invention. The lower density fluid may be provided through the tubing 60. A hanger system 58 includes a tensioner58 that rests on a support 56. The hanger system 58 tensions the tensioned tubing 26 that extends all the way down to a 20 disconnectable subsea latch 74 above the subsea shutoff assembly 24. Like the latch 72, the latch 74 may be remotely or surface operated to sever the tubing 26 from the subsea shutoff assembly 24. In one embodiment, the support 56 may include hydraulic ram devices that move like shear ram blowout preventers to grip the tubing 26. The rate of lower density fluid flow through the tubing 26 from the surface may be 25 controlled from the surface by remotely controllable valving in the subsea shutoff assembly 24, in one embodiment. It is advantageous to provide this lower density fluid from the surface as opposed to attempting to provide it from a subsea location, such as within the subsea shutoff assembly 24, because it is much easier to control and operate large pumps from the rig 14. 30 The subsea shutoff assembly 24 operates with the surface blowout preventer stack 12 to prevent blowouts. While the surface blowout preventer stack 12 controls fluid P \OPER\MF\Specncation\ \DIVISIONAA10511074 divis-Iol doc- I0412008 -6 flow, the subsea shutoff assembly 24 is responsible for cutting off or severing the wellhead from the portions of the apparatus 11 thereabove, using shear rams 30a and 30b as shown in Figure 2. Thus, the casing 22 may be coupled by connector 28a to the shear ram 30a. The shear ram 30a is coupled by a spool 34 with flanges 32a and 32b to the shear ram30b. 5 The shear ram 30b may be coupled through the flange 38 to a wellhead connector 28b, in turn connected to the wellhead. As shown in Figure 2, the tubing 26 connects to a remotely controlled valve 36 that controls the rate of lower density fluid flow through the tubing 26 to the interior of the spool 34. The inlet from the tubing 26 to the spool 34 is between the two shear rams 30a 10 and 30b. The injection of lower density fluid, as shown in Figure 3, makes use of the remotely controlled valve 36 on a spool 34. The spool 34 may have drilling mud, indicated as M[, moving downwardly through the casing 22. The returning mud, indicated as MOUT, extends upwardly in the annulus 46 surrounding the string 40 and annulus 44. Thus, lower 15 density fluid may be injected, when the valve 36 is opened, into the returning mud/hydrocarbon flow to lower its density. An underbalanced situation may be created as a result of the dual densities of mud in one embodiment. Namely, mud above the valve 36 may be at a lower density than the density of the mud below the valve 36, as well as the density of the mud moving 20 downwardly to the formation. The valve 36 may include a rotating element 37 that allows the valve 36 to be opened or controlled. As an additional example, the valve 36 may be a pivoted gate valve with a hydraulic fail safe that automatically closes the valve in the event of a loss of hydraulics. The valve 36 may enable the extent of underbalanced drilling to be surface or remotely controlled depending on sensed conditions, including the upward 25 pressure supplied by the formation. For example, the valve 36 may be controlled acoustically from the surface. Thus, in some embodiments of the present invention, flow control may be done most effectively at the surface, whereas shutoff control is done on the seafloor bed. The pumping of the lower density fluid is also done on the surface, but its injection may be 30 done at the subsea shutoff assembly 24, in one embodiment between the shear rams 30a and 30b.

P 3OPER\MRF\Spctfi4ions\2008\DIVISIONAL\30511074 division doc-l04/2008 -7 The rotating head 10, shown in more detail in Figure 4, is coupled to the surface blowout preventer stack 12 at a joint 70. Returning fluid, indicated as MOUT, is passed through a valve 68 to an appropriate collection area. The collection area may collect both mud with entrained debris, as well as production fluids such as hydrocarbons. The 5 production fluids may be separated using well known techniques. The upward flow of the fluid MOUT is constrained by a packer 62. In one embodiment, the packer 62 is a rubber or resilient ring that seals the annulus around the string 40 and prevents the further upward flow of the fluids. At the same time, the packer 62 enables the application of a rotating force in the direction of the circular arrow 10 from the rotating head 66 to the string 40 for purposes of drilling. Seals 65 may be provided between a telescoping joint 64 and the rotating head 66 as both drilling and production may be accomplished in an underbalanced situation. Thus, in some embodiments of the present invention, a subsea shutoff assembly 24 may be provided to cut off the string in the event of a failure, such as a blowout. At the 15 same time, surface annular blowout preventers control fluid flow. Dual gradient drilling may be achieved through the provision of fluid from the surface through a side inlet into the region between the upper and lower ram type shear blowout preventers 30. Through the provision of the separate tubing 26 with a remotely operable latch 74, appropriate volumes of fluid can be achieved that would not be available with conventional kill and choke lines. 20 The tubing 26 for providing the density control fluid may be both tensioned and latched. As a result, dual gradient production and drilling may be achieved in some embodiments of the present invention. While the present invention has been described with respect to a limited number of embodiments, those skilled in the art will appreciate numerous modifications and 25 variations therefrom. It is intended that the appended claims cover all such modifications and variations as fall within the true spirit and scope of this present invention. Throughout this specification and the claims which follow, unless the context requires otherwise, the word "comprise", and variations such as "comprises" and "comprising", will be understood to imply the inclusion of a stated integer or step or group 30 of integers or steps but not the exclusion of any other integer or step or group of integers or steps.

Claims

1. A method comprising: coupling a surface blow out preventer to a wellhead using casing; 5 providing a remotely operable subsurface latch to sever the connection between said wellhead and said surface blow out preventer; and producing hydrocarbons from a subsea well in an underbalanced condition using a rotating head mounted on the surface blow out preventer. 10

2. The method of claim 1 including using the surface blow out preventer to provide surface flow control.

3. The method of claim 2 including providing a subsurface blow out preventer in addition to said surface blow out preventer. 15

4. The method of claim 3 including providing subsurface shear blow out preventers.

5. The method of claim I including tensioning said casing. 20

6. The method of claim 1 including providing a flow of mud through a casing to a drill bit.

7. The method of claim 6 including lowering the density of mud returning from said drill bit through said casing. 25

8. The method of claim 7 including providing a separate line to enable fluid to be pumped from the surface to a subsurface location to lower the density of the returning mud. 30

9. The method of claim 8 including providing a tensioned line to provide said fluid from said surface. P:\OPERWRFSpcfications\2008\DIVISIONA L\05 1074 divisionaldoc-.I4/2005 -9

10. The method of claim 9 including providing a disconnectable latch to disconnect the line from the wellhead. 5

11. The method of claim 10 including providing a subsurface blow out preventer and providing said line to said subsurface blow out preventer.

12. The method of claim 11 including providing a pair of shear ram subsurface blow out preventers and pumping said fluid between said shear blow out preventers. 10

13. The method of claim 12 including providing a remotely operable valve to control the flow of said fluid and positioning said valve at a subsea location.

14. The method of claim 1 including providing a rotating head that transfers rotational 15 energy to said drill string through a packer.

15. The method of claim 14 including providing said rotational energy through a resilient packer. 20

16. A drilling rig comprising: a rotating head; a surface blow out preventer mounted under said rotating head on said rig; and an apparatus to pump fluid to a subsea location to lower the density of drilling mud returning to said rig. 25

17. The rig of claim 16 including a casing coupled from said surface blow out preventer to a subsea subsurface blow out preventer.

18. The rig of claim 17 wherein said subsea blow out preventer includes a pair of shear 30 blow out preventers. P \OPER\MRF\Spcificaiont200BDIVISIONAL\30511074 divuina doc-/04/2008 -10

19. The rig of claim 18 including a remotely operable latch to sever said casing from said subsea blow out preventer.

20. The rig of claim 19 wherein said casing is tensioned. 5

21. The rig of claim 16 including a separate line to supply lower density fluid to a subsea location to lower the density of drilling mud to be returned to said rig.

22. The rig of claim 21 wherein said line is tensioned. 10

23. The rig of claim 22 wherein a disconnectable latch is provided to disconnect the line at a subsea location.

24. The rig of claim 16 including a subsurface blow out preventer and a coupling to 15 receive said line.

25. The rig of claim 24 wherein said subsurface blow out preventer includes a pair of shear ram subsurface blow out preventers and said coupling is arranged between said pair of shear ram subsurface blow out preventers. 20

26. The rig of claim 25 including a valve in said line to control the flow of fluid to lower the density of said drilling mud.

27. The rig of claim 16 wherein said rotating head includes a resilient packer and a drill 25 string and tubing, said resilient packer to seal the region between said drill string and said tubing and to transfer rotational energy from said tubing to said drill string.

28. A subsea shutoff assembly comprising: a pair of shear blow out preventers; and 30 a device coupling said blow out preventers, said device having an inlet to receive a density lowering fluid to lower the density of drilling mud moving upwardly through said P %OPER\MARF\Spec~ificaionsU\8\VISIONAL\31O1 I074fd i dc-II04/I2(00 device.

29. The assembly of claim 28 including a line for supplying density lowering fluid, said line including a remotely actuatable valve. 5

30. The assembly of claim 29 wherein said valve automatically closes upon loss of control.

31. A method comprising: 10 providing a rotating head that transfers rotational energy to said drill string through a packer; and producing hydrocarbons from a subsea well in an underbalanced condition using the rotating head mounted on the surface blow out preventer. 15

32. The method of claim 31 including providing said rotational energy through a resilient packer.

33. A method according to any one of claims I to 15, substantially as hereinbefore described with reference to the drawings and/or Examples. 20

34. A drilling rig substantially as hereinbefore described with reference to the drawings and/or Examples.

35. A subsea shutoff assembly substantially as hereinbefore described with reference to 25 the drawings and/or Examples.

36. A method according to either one of claims 31 and 32, substantially as hereinbefore described with reference to the drawings and/or Examples.