WO2002050398A1 - Cloded loop fluid-handing system for well drilling - Google Patents
Cloded loop fluid-handing system for well drilling Download PDFInfo
- Publication number
- WO2002050398A1 WO2002050398A1 PCT/GB2001/005593 GB0105593W WO0250398A1 WO 2002050398 A1 WO2002050398 A1 WO 2002050398A1 GB 0105593 W GB0105593 W GB 0105593W WO 0250398 A1 WO0250398 A1 WO 0250398A1
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- Prior art keywords
- pressure
- flow
- fluid
- well
- drilling
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Classifications
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- E—FIXED CONSTRUCTIONS
- E21—EARTH DRILLING; MINING
- E21B—EARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B44/00—Automatic control systems specially adapted for drilling operations, i.e. self-operating systems which function to carry out or modify a drilling operation without intervention of a human operator, e.g. computer-controlled drilling systems; Systems specially adapted for monitoring a plurality of drilling variables or conditions
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH DRILLING; MINING
- E21B—EARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B21/00—Methods or apparatus for flushing boreholes, e.g. by use of exhaust air from motor
- E21B21/08—Controlling or monitoring pressure or flow of drilling fluid, e.g. automatic filling of boreholes, automatic control of bottom pressure
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH DRILLING; MINING
- E21B—EARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B21/00—Methods or apparatus for flushing boreholes, e.g. by use of exhaust air from motor
- E21B21/08—Controlling or monitoring pressure or flow of drilling fluid, e.g. automatic filling of boreholes, automatic control of bottom pressure
- E21B21/085—Underbalanced techniques, i.e. where borehole fluid pressure is below formation pressure
Definitions
- the present invention deals with a closed-loop system for drilling wells where a series of equipment, for the monitoring of the flow rates in and out of the well, as well as for adjusting the back pressure, allows the regulation of the out flow so that the out flow is constantly adjusted -to the expected value at all times.
- a pressure containment device keeps the well closed at all times. Since this provides a much safer operation, its application for exploratory wells will greatly reduce the risk of blow-outs. In environments with narrow margin between the pore and fracture pressure, it will create a step change compared to conventional drilling practice. In this context, applications in deep and ultra-deep water are included.
- a method for drilling, using said system is also disclosed. The drilling system and method are suited for all types of wells, onshore and offshore, using a conventional drilling fluid or a lightweight drilling fluid.
- Drilling oil/gas/geothermal wells has been done in a similar way for decades. Basically, a drilling fluid with a density high enough to counter balance the pressure of the fluids in the reservoir rock, is used inside the wellbore to avoid uncontrolled production of such fluids. However, in many situations, it can happen that the bottomhole pressure is reduced below the reservoir fluid pressure. At this moment, an influx of gas, oil, or water occurs, named a kick. If the kick is detected in the early stages, it is relatively simple and safe to circulate the invaded fluid out of the well. After the original situation is restored, the drilling activity can proceed. However, if, by any means, the detection of such a kick takes a long time, the situation can become out of control leading to a blowout.
- the well In the traditional drilling practice, the well is open to the atmosphere, and the drilling fluid pressure (static pressure plus dynamic pressure when the fluid is circulating) at the bottom of the hole is the sole factor for preventing the formation fluids from entering the well.
- This induced well pressure which by default, is greater than the reservoir pressure causes a lot of damage, i.e., reduction of near wellbore permeability, through fluid loss to the formation, reducing the productivity of the reservoir in the majority of cases.
- UBD underbalanced drilling
- This technique implies a concomitant production of the reservoir fluids while drilling the well.
- Special equipment has been developed to keep the well closed at all times, as the wellhead pressure in this case is not atmospheric, as in the traditional drilling method.
- special separation equipment must be provided to properly separate the drilling fluid from the gas, and/or oil, and/or water and drilled cuttings.
- the UBD technique has been developed initially to overcome severe problems faced while drilling, such as massive loss of circulation, stuck pipe due to differential pressure when drilling depleted reservoirs, as well as to increase the rate of penetration.
- BOP blow-out preventer equipment
- US patent 4,867,254 teaches a method of real time control of fluid influxes into an oil well from an underground formation during drilling.
- the injection pressure p,- and return pressure p r and the flow rate Q of the drilling mud circulating in the well are measured.
- the value of the mass of gas M s in the annulus is determined, and the changes in this value monitored in order to determine either a fresh gas entry into the annulus or a drilling mud loss into the formation being drilled.
- US patent 5,080,182 teaches a method of real time analysis and control of a fluid influx from an underground formation into a wellbore being drilled with a drill string while drilling and circulating from the surface down to the bottom of the hole into the drill string and flowing back to the surface in the annulus defined between the wall of the wellbore and the drill string, the method comprising the steps of shutting-in the well, when the influx is detected; measuring the inlet pressure P,- or outlet pressure P 0 of the drilling mud as a function of time at the surface; determining from the increase of the mud pressure measurement, the time t c corresponding to the minimum gradient in the increase of the mud pressure and controlling the well from the time t c .
- the kicks are merely controlled.
- the present application relates to a new concept of drilling whereby a method and corresponding instrumentation allows that kicks may be detected early and controlled much quicker and safer or even eliminated/mitigated than in state-of-the-art methods.
- a collapse pressure (pressure that causes the wellbore wall to fall into the well) curve is the lower limit, rather than the pore pressure curve. But, for the sake of simplicity, just the two curves should be considered, the pore pressure and fracture pressure one.
- a phase of the well is defined by the maximum and minimum possible mud weight, considering the curves mentioned previously and some design criteria that varies among the operators, such as kick tolerance and tripping margin.
- kick tolerance is the change in this bottomhole pressure for a certain volume of gas kick taken.
- Tripping margin is the value that the operators use to allow for pressure swab when tripping out of the hole, to change a bit, for example. In this situation, a reduction in bottomhole pressure, caused by the upward movement of the drill string can lead to an influx.
- a margin of 0.3 pound per gallon (ppg) is added to the pore pressure to allow a safety factor when stopping circulation of the fluid and subtracted from the fracture pressure, reducing even more the narrow margin, as shown by the dotted lines. Since the plot shown in Figure 1 is always referenced to the static mud pressure, the compensation of 0.3 ppg allows for the dynamic effect while drilling also. The compensation varies from scenario to scenario but typically lies between 0.2 and 0.5 ppg.
- a safety requirement for offshore drilling with a floating drilling unit is to have inside the well, below the mud line, a drilling fluid having sufficient weight to balance the highest pore pressure of an exposed drilled section of the well. This requirement stems from the fact that an emergency disconnection might happen, and all of a sudden, the hydrostatic column provided by the mud inside the marine riser is abruptly lost. The pressure provided by the mud weight is suddenly replaced by seawater. If the weight of the fluid remaining inside the well after the disconnection of the riser is not high enough to balance the pore pressure of the exposed formations, a blowout might occur.
- This safety guard is called Riser Margin, and currently there are several wells being drilled without this Riser Margin, since there is no dual-density method commercially available so far.
- underbalanced flow drilling which involves flowing fluids from the reservoir continuously into the wellbore is described and documented in the literature
- mud-cap drilling which involves continuous loss of drilling fluid to the formation, in which fluid can be overbalanced, balanced or underbalanced is also documented
- air drilling where air or other gas phase is used as the drilling fluid.
- underbalanced and air drilling are limited to formations with stable wellbores, and there are significant equipment and procedural limitations in handling produced effluent from the wellbore.
- the underbalanced method is used for limited sections of the wellbore, typically the reservoir section. This limited application makes it a specialist alternative to conventional drilling under the right conditions and design criteria. Air drilling is limited to dry formations due to its limited capability to handle fluid influxes. Similarly Mud-Cap drilling is limited to specific reservoir sections
- the present method and system 'employing back pressures can also be used with lightweight fluids so that the equivalent drilling fluid weight above the mud line can be set lower than the equivalent fluid weight inside the wellbore, with increasing safety and low cost relative to drilling with conventional fluids.
- the present invention is directed to a system for operating a well having a drilling fluid circulating therethrough comprising means for monitoring the flow rates in and out and means to predict a calculated value of flow out at any given time to obtain real time information on discrepancy between predicted and monitored flow out, thereby producing an early detection of influx or loss of drilling fluid, the well being closed with a pressure containment device at all times.
- the pressure/containment device may be a rotating blow out preventer (BOP) or a rotating control head, but is not limited to it.
- BOP rotating blow out preventer
- the location of the device is not critical. It may be located at the surface or at some point further down e.g. on the sea floor, inside the wellbore, or at any other suitable location.
- the type and design of device is not critical and depends on each well being drilled. It may be standard equipment that is commercially available or readily adapted from existing designs.
- the function of the rotating pressure containment device is to allow the drill string to pass through it and rotate, if a rotating drilling activity is carried on, with the device closed, thereby creating a back pressure in the well.
- the drill string is stripped through the rotating pressure containment device which closes the annulus between the outside of the drill pipe and the inside of the wellbore/casing/riser.
- a simplified pressure containment device may be a BOP designed to allow continuous passage of non-jointed pipe such as the stripper(s) on coiled tubing operations.
- the well preferably comprises a pressure containment device which is closed at all times, and a reserve BOP which can be closed as a safety measure in case of any uncontrolled event occurring.
- Reference herein to a well is to an oil, gas or geothermal well which may be onshore, offshore, deepwater or ultra-deepwater or the like.
- Reference herein to circulating drilling fluid is to what is commonly termed the mud circuit, the circulation of the drilling fluid down the wellbore may be through a drill string and the return through an annulus, as in state-of-the-art methods, but not limited to it.
- any way of circulation of the drilling fluid may be successfully employed in the practice of the present system and method, no matter where the fluids are injected or returned.
- conventional drilling fluids may be used, selected typically from oil and/or water liquid phase fluids, and optionally additionally gas phase fluid.
- the liquid phase is oil
- the oil can be diesel, synthetic, mineral, or vegetable oil, the advantage being the reduced density of oil compared to water, and the disadvantage being the strong negative effect on the environment.
- Means for monitoring of flow rates may be for monitoring of mass and/or volume flow.
- the system and method of the invention comprises monitoring the mass flow in and out of the well, optionally together with other parameters that produce an early detection of influx or loss independent of the mass flow in and out at that point in time.
- monitoring means are operated continuously throughout a given operation.
- monitoring is with commercially available mass and flow meters, which may be standard or multiphase. Meters are located on lines in and out.
- the system may be for actively drilling a well or for related inactive operation, for example the real time determination of the pore pressure or fracture pressure of a well by means of a direct reading of parameters relating to a fluid influx or loss respectively; alternatively or additionally the system is for detecting an influx and sampling to analyse the nature of the fluid which can be produced by the well.
- a system for operating a well having a drilling fluid circulating therethrough comprising in response to detection of an influx or loss of drilling fluid, means for pre-emptively adjusting back pressure in the wellbore based on influx or loss indication before surface system detection, the well being closed with a pressure containment device at all times.
- an influx may be detected by means as hereinbefore defined comprising detecting a real time discrepancy between predicted and monitored flow out as hereinbefore defined, or by means such as downhole temperature sensors, downhole hydrocarbon sensors, -pressure change sensors and pressure pulse sensors or by any other real time means.
- the well comprises additionally one or more pressure/flow control devices and means for adjustment thereof to regulate fluid out flow to the predicted ideal value at all times, or to preemptively adjust the backpressure to change the ECD (Equivalent Circulating Density) instantaneously in response to an early detection of influx or fluid loss.
- ECD Equivalent Circulating Density
- Means for adjustment ofthe pressure/flow control device suitably comprises means for closing or opening thereof, to the extent required to increase or reduce respectively the backpressure, adjusting the ECD.
- pressure/flow control devices are located anywhere suited for the purpose of creating or maintaining a backpressure on the well, for example on a return line for recovering fluid from the well.
- ECD is to the hydrostatic pressure plus friction losses occurring while circulating fluid, converted to equivalent mud density at the bottom of the well.
- adjustment is instantaneous and may be manual or automatic.
- Pressure/flow control devices The level of adjustment may be estimated, calculated or simply a trial adjustment to observe the response and may comprise opening or closing the control device for a given period, aperture and intervals.
- adjustment is calculated based on assumptions relating to the nature of the fluid influx or loss.
- the pressure/flow control device may be any suitable devices for the purpose such as restrictions, chokes and the like having means for regulation thereof and may be commercially available or may be specifically designed for the required purpose and chosen or designed according to the well parameters such as diameter of the return line, pressure and flow requirements.
- the system and method of the invention comprises adjusting the wellbore pressure with the aid of a pressure/flow control device to correct the bottomhole pressure to prevent fluid influx or losses in a pro-active as opposed to the state-of-the-art reactive manner.
- Closing or opening the pressure/flow control device restores the balance of flow and the predicted value, the bottomhole pressure regaining a value that avoids any further influx or loss, whereafter the fluid that has entered the well is circulated out or lost fluid is replaced.
- the one or more pressure/flow control devices are controlled by a central means which calculates adjustment.
- Adjustment of the pressure/flow control device is suitably by closing or opening to the extent required to increase or reduce respectively the backpressure, adjusting the ECD.
- the system may be used as a -system for controlling the ECD in any desired operation and continuously or intermittently drilling a gas, oil or geothermal well wherein drilling is carried out with bottom hole pressure controlled between the pore pressure and the fracture pressure of the well, being able to directly determine both values if desired, or drilling with the exact bottom hole pressure needed, with a direct determination of the pore pressure, or drilling with bottom hole pressure regulated to be just less than the pore pressure thus generating a controlled influx, which may be momentary in order to sample the well fluid in controlled manner, or may be continuous in order to produce well fluid in controlled manner.
- the system of the present invention is for drilling a well while injecting a drilling fluid through an injection line of said well and recovering through a return line of said well where the well is closed at all times, and comprises a pressure containment device and pressure/flow control device to a wellbore to establish and/or maintain a back pressure on the well, means to monitor the fluid flow in and out, means to monitor flow of any other material in and out, means to monitor parameters affecting the monitored flow value and means to predict a calculated value of flow out at any given time and to obtain real time information on discrepancy between predicted and monitored flow out and converting to a value for adjusting the pressure/flow control device and restoring the predicted flow value.
- the system and corresponding method of drilling oil, gas and geothermal wells according to the present invention is based on the principle of mass conservation, a universal law. Measurements are effected under the same dynamic conditions as those when the actual events occur.
- mass flow means the total mass flow being injected and returned, comprised of liquid, solids, and possibly gas.
- the flow rates in and out of the well are also monitored at all times. This way, the calculation of the predicted, ideal return flow of the well can be done with a certain redundancy and the detection of any discrepancy can be made with reduced risks.
- the present system envisages the addition of an accurate mass flow metering means that allows the present drilling method to be much safer than state-of-the-art drilling methods.
- the speed of adjustment is much greater in the present method, as opposed to the conventional situation, where increasing the mud density (weighting up) or decreasing the mud density (cutting back) is a very time consuming process.
- the ECD is the actual pressure that needs to overcome the formation pressure to avoid influx while drilling.
- the friction loss is zero and thus the ECD reduces to the hydrostatic value of the mud weight.
- the margin can be as low as 0.2 ppg. In these cases, it is common to observe influxes when circulation is interrupted, increasing substantially the risks of drilling with the conventional drilling system.
- the back pressure adjustment can be applied by pumping fluid, independent of the normal circulating flow path, into the wellbore, to compensate for the loss in friction head, and effecting a continuous flow that allows easy control of the back pressure by adjustment of the pressure/flow control device.
- This fluid flow may be achieved completely independent of the normal circulating path by means of a mud pump and injection line.
- the system therefore comprises additional means to pressurize the wellbore, more preferably through the annulus, independently of the cu ⁇ ent fluid injection path.
- This system enables changing temperature and fluid densities at any time whilst drilling or otherwise, and enables injecting fluid into the annulus while not drilling, keeping a desired bottom hole pressure during circulation stops, and continuously detecting and changes indicative of an influx or fluid loss.
- the system may comprise at least one circulation bypass comprised of a pump and a dedicated fluid injection line for injecting fluid direct to the annulus or a zone thereof, and optionally a dedicated return line, together with dedicated flow meters and additional means such as pressure/flow control devices, pressure and temperature sensors and the like.
- a circulation bypass comprised of a pump and a dedicated fluid injection line for injecting fluid direct to the annulus or a zone thereof, and optionally a dedicated return line, together with dedicated flow meters and additional means such as pressure/flow control devices, pressure and temperature sensors and the like.
- the system for drilling a well while injecting a drilling fluid through an injection line of said well and recovering through a return line of said well where the well being drilled is closed at all times comprises: a) a pressure containment device; b) a pressure/flow control device for the outlet stream, on the return line; c) means for measuring mass and/or volumetric flow and flow rate for the inlet and outlet streams on the injection and return lines to obtain real time mass and/or volumetric flow signals; d) means for measuring mass and/or volumetric flow and flow rate of any other materials in and out; e) means for directing all the flow and pressure signals so obtained to a central data acquisition and control system; and g) a central data acquisition and control system programmed with a software that can determine a real time predicted out flow and compare it to the actual out flow estimated from the mass and volumetric flow rate values and other relevant parameters.
- the means c) for measuring mass flow comprises a volume flow meter and at least one pressure sensor to obtain pressure signals and optionally at least one temperature sensor to obtain temperature signals; and may be a mass flow meter comprising integral pressure and optional temperature sensors to compensate for changes in density and temperature; and the means c) for measuring flow rate comprises means for assessing the volume of the hole at any given time, as a dynamic value having regard to the continuous drilling of the hole. At least one additional pressure and optional temperature sensor may be provided to monitor other parameters that produce an early detection of influx or loss independent of the mass flow in and out at that point in time.
- Means d) comprises means for measuring flow rate of all materials in and out.
- the mass flow metering principle is extended to include other subcomponents of the system where accuracy can be improved, such as, but not limited to means for measuring solids and gas volume/mass out, in particular for measuring the mass flux of cuttings.
- the system comprises additionally providing a means of measurement of drill cuttings rate, mass or volume, when required, to measure the rate of cuttings being produced from the well.
- Means d) for measuring cuttings volume/mass out is any commercially available or other equipment to verify that the mass of cuttings being received back at the surface is correlated with the rate of penetration and wellbore geometry. This data allows correction of the mass flow data and allows identification of trouble events.
- a shale shaker preferably in combination with a degasser.
- a closed 3-phase separator liquid, solid and gas
- a fully closed system is achieved. This may be desirable when dealing with hostile fluids or fluids posing environmentally risks.
- the central data acquisition and control system is provided with a software designed to predict an expected, ideal value for the outflow, said value being based on calculations taking into account several parameters including but not restricted to rate of penetration, rock and drilling fluid density, well diameter, in and out flow rates, cuttings return rate, bottomhole and wellhead pressures and temperatures, also rotary torque and rpm, top drive torque and rpm, rotation of drill string, mud-pit volumes, drilling depth, pipe velocity, mud temperature, mud weight, hookload, weight on bit, pump pressure, pumpstrokes, mud flows, calculated gallons/minute, gas detection and analysis, resistivity and conductivity.
- the system comprises: a) a pressure containment device; b) a pressure/flow control device on the outlet stream; c) means for measuring mass flow rate on the inlet and outlet streams; d) means for measuring volumetric flow rate on the inlet and outlet streams; e) at least one pressure sensor to obtain pressure data; f) optionally at least one temperature sensor to obtain temperature data; g) a central data acquisition and control system that sets a value for an expected out flow and compares it to the actual out flow estimated from data gathered by the mass and volumetric flow rate meters as well as from pressure and temperature data, and in case of a discrepancy between the expected and actual flow values, adjusting the said pressure/flow control device to restore the outflow to the expected value.
- the at least one pressure sensor may be located at any convenient location such as at the wellhead and/or at the bottom hole.
- the system may comprise two or more pressure containment devices in series throughout the wellbore whereby a pressure profile may be established throughout the well and two or more pressure control devices in series or parallel.
- the pressure profile is established in independent pressure zones created throughout the length of the well, wherein restrictions or pressure/flow control devices define the interfaces of each zone.
- each zone is provided with a circulation bypass comprising a pump, dedicated injection line and optional return lines.
- This system is preferably used in combination with a conventional or a lightweight fluid, as hereinbefore defined.
- Preferably lightweight drilling fluids are employed whenever a scenario of dual density drilling is considered.
- Using a light fluid with the applied back pressures enables the equivalent drilling fluid weight above the mud line to be set lower than the equivalent fluid weight inside the wellbore.
- a lightweight drilling fluid it may be one of the well-known lightweight fluids, that is, the drilling fluid is made up of a liquid phase, either water or oil, plus the addition of gas, hollow spheres, plastic spheres, or any other light material that can be added to the liquid phase to reduce the overall weight.
- lightweight drilling fluids may be advantageously employed even in the absence of a dual- density drilling system.
- the system comprises the said central data acquisition and control system which is provided with a time-based software to allow for lag time between in and out flux.
- the software is preferably provided with detection filters and/or processing filters to eliminate/reduce false indications on the received mass and fluid flow data, and any other measured or detected parameters.
- the system is a closed loop system, whereby monitoring means continuously provide data to the central data acquisition and control system whereby predicted flow out is continuously revised in response to any adjustment of pressure/flow control, adjusting ECD.
- the system of the invention comprises three safety barriers, the drilling fluid, the blow-out preventer (BOP) equipment and the pressure containment device.
- the corresponding method for operating a well having a drilling fluid circulating therethrough comprising monitoring the flow rates of fluid in and out and predicting a calculated value of flow out at any given time to obtain real time information on discrepancy between predicted and monitored flow out, thereby producing an early detection of influx or loss of drilling fluid, the well being closed with a pressure containment device at all times.
- monitoring is of mass and/or volume flow.
- monitoring is continuous throughout a given operation.
- the method may be for actively drilling a well or for related inactive operation, for example the real time determination of the pore pressure or fracture pressure of a well by means of a direct reading of parameters relating to a fluid influx or loss respectively; alternatively or additionally the system is for detecting a controlled influx and sampling to analyse the nature of fluid which can be produced by the well.
- a method for operating a well having a drilling fluid circulating therethrough comprising detecting an influx or loss of drilling fluid and pre-emptively adjusting back pressure in the wellbore based on influx or loss indication before surface system detection, the well being closed with a pressure containment device at all times.
- An influx may be detected by any known or novel methods, particularly by novel methods selected from the method as hereinbefore defined or by downhole temperature detection, downhole hydrocarbon detection, detecting pressure changes and pressure pulses.
- the method comprises adjusting pressure/flow to regulate fluid outflow to the expected value at all times and control ECD at all times or to pre-emptively adjust the back pressure to change the equivalent circulating density (ECD) instantaneously in response to an early detection of influx or fluid loss.
- ECD equivalent circulating density
- the ECD is the actual pressure that needs to overcome the formation pressure to avoid influx while drilling.
- the friction loss is zero and thus the ECD reduces to the hydrostatic value of the mud weight.
- the adjustment is instantaneous and may be manual or automatic.
- Level of adjustment may be estimated, calculated or simply a trial adjustment to observe the response, and may be staged, prolonged, intermittent, rapid or finite.
- adjustment is calculated based on assumptions relating to the nature of the influx or loss.
- adjustment is controlled by a central control device.
- the adjustment comprises increasing fluid flow to the extent required to reduce backpressure and counteract fluid loss; or where the discrepancy between actual and predicted out flows is a fluid gain, the adjustment comprises reducing fluid flow to the extent required to increase backpressure and counteract fluid gain to the extent required to reduce or increase respectively the backpressure, adjusting the ECD.
- the method may be for controlling the ECD in any desired operation and continuously or intermittently drilling a gas, oil or geothermal well wherein drilling is carried out with bottom hole pressure controlled between the pore pressure and the fracture pressure of the well, or drilling with the exact bottom hole pressure needed, with a direct determination of the pore pressure, or drilling with bottom hole pressure regulated to be just less than the pore pressure thus generating a controlled influx, which may be momentary in order to sample the well fluid in controlled manner, or may be continuous in order to produce well fluid in controlled manner.
- the corresponding method of the present invention comprises, in relation to the system of the invention- as hereinbefore defined, the following steps of injecting drilling fluid through said injection line through which said fluid is made to contact said means for monitoring flow and recovering drilling fluid through said return line; collecting any other material at the surface; measuring the flow in and out of the well and collecting flow and flow rate signals; measuring parameters affecting the monitored flow value and means; directing all the collected flow, correction and flow rate signals to the said central data acquisition and control system; monitoring parameters affecting the monitored flow value and means to predict a calculated value of flow out at any given time and to obtain real time information on discrepancy between predicted and monitored flow out and converting to a value for adjusting the pressure/flow control device and restoring the predicted flow value.
- the method comprises a step wherein fluid may be additionally injected directly to the annulus or a pressure zone thereof, and optionally returned from the annulus, thereby pressurising the wellbore through the annulus, independently of the current fluid injection path, and monitoring flow, pressure and optionally temperature.
- n the fluid (mud) density at a value slightly lower than that required to control the formation pressure and adjust backpressure on the well by means of the flow to exert an extremely controllable ECD at the bottomhole that has the flexibility to be adjusted up or down.
- the method includes monitoring values such as rate of penetration, rock and drilling fluid density, well diameter, in and out flow rates, cuttings return rate, bottomhole and wellhead pressures and temperatures, torque and drag, among other parameters and calculates the predicted ideal value for the outflow.
- the present invention provides a safe method for drilling wells, since not only is the well being drilled closed at all times, but also any fluid loss or influx that occurs is more accurately and faster determined and subsequently controlled than in state-of-the-art methods.
- One advantage of the present method over state-of-the-art methods is that it is able to instantly change the ECD (Equivalent Circulating Density) by adjusting the backpressure on the wellbore by closing or opening the pressure/flow control device.
- the method herein described and claimed incorporates early detection methods of influx/loss that are existing or yet to be developed as part of the method herein described and claimed, e.g., tools under development or that may be developed that can detect trace hydrocarbon influx, small temperature variations, pressure pulses etc.
- the output of these tools or technology that indicates a kick or fluid loss can be used as a feedback parameter to yield an instant reaction to the detected kick or fluid loss, thus controlling the drilling operation at all times.
- the method of the invention allows that drilling operations be carried out in a continuous manner, while in state-of-the-art methods drilling is stopped and mud weight is corrected in a lengthy, time-consuming step, before drilling can be resumed, after a kick or fluid loss is detected.
- system and method of the invention provide additional advantages in terms of allowing operation with a reduced reservoir, by virtue of closed operation under back pressure. Moreover the system and method can be operated efficiently, without the need for repeated balancing of the system after any operational pause in drilling.
- the method for drilling a well while injecting a drilling fluid through an injection line of said well and recovering through a return line of said well where the well being drilled is closed at all times comprising the following steps: a) providing a pressure containment device, suitably of a type that allows passage of pipe under pressure, to a wellbore; b) providing a pressure/flow control device to control the flow out of the well and to keep a back pressure on the well; c) providing a central data acquisition and control system and related software; d) providing mass flow meters in both injection and return lines; e) providing flow rate meters in both injection and return lines; f) providing at least one pressure sensor; g) providing at least one temperature sensor; h) injecting drilling fluid through said injection line through which said fluid is made to contact said mass flow meters, said fluid flow meters and said pressure and temperature sensors, and recovering drilling fluid through said return line; i) collecting drill cuttings at the surface; j) measuring the mass flow in and out of the well and collecting mass flow signals; k) measuring
- the mass flow metering according to the method comprises any subcomponents designed to improve accuracy of the measurement, preferably comprises measuring the mass flux of cuttings, produced at shaker(s) and mass outflow of gas, from degasser(s), and comprise measuring the mass flow and fluid flow into the well bore through the annulus, independently of the cu ⁇ ent fluid injection path.
- the method comprises additionally at i), measuring drill cuttings rate, mass or volume, when required, to measure the rate of cuttings being produced from the well.
- the method comprises measuring pressure at least at the well head and/or at the bottom hole.
- the invention contemplates also the use of more than one location for pressure/flow control device at different locations inside the well to apply back pressure.
- the method may include containing pressure at two or more locations in series, and controlling pressure/flow at two or more locations in series or parallel inside the well, to apply back pressure.
- the method comprises controlling pressure/flow at two or more locations in the well in series, whereby a pressure profile is established throughout the well.
- controlling pressure/flow at more than two locations in the well enable independent zones to be created throughout the length of the well, wherein the locations for the pressure/flow control define zone interfaces.
- fluid is additionally injected directly to each pressure zone of the annulus, and optionally returned from each pressure zone thereof.
- the drilling fluid may be selected from water, gas, oil and combinations thereof or their lightweight fluids.
- a lightweight fluid comprises added hollow glass spheres or other weight reducing material.
- a lightweight fluid is used.
- the main advantage of using a lightweight fluid is the possibility of starting drilling with a fluid weight less than water. This is especially important in zones with normal or below normal pressure, normal pore pressure being the pressure exerted by a column of water. In these cases, if a conventional drilling fluid is used, the initial bottomhole pressure might be already high enough to fracture the formation and cause mud losses. By starting with a lightweight fluid, the back pressure can be applied to achieve the balance required to avoid an influx, but being controlled at all times as to avoid an excessive value to cause the losses.
- the present invention provides also a method of drilling where the bottomhole pressure can be very close to the pore pressure, thus reducing the overbalanced pressure usually applied on the reservoir,- and consequently reducing the risk of fluid losses and subsequent contamination of the wellbore causing damage, the overall effect being that the well productivity is increased. Drilling with the bottomhole pressure close to the pore pressure also increases the rate of penetration, reducing the overall time needed to drill the well, incurring in substantial savings.
- the present invention provides further a method to drill with the exact bottomhole pressure needed, with a direct determination of the pore pressure.
- the present invention provides also a method for the direct determination of the fracture pressure if needed.
- a method for the real time determination of the fracture pressure of a well being drilled with a drill string and drilling fluid circulated therethrough, while the well is kept closed at all times comprising the steps of:
- a method for the real-time determination of the pore pressure of a well being drilled with a drill string and drilling fluid circulated therethrough, while the well is kept closed at all times comprising the steps of:
- the present invention allows a significant reduction of risk by determining either the pore pressure or the fracture pressure, or, in more critical situations, both the pore and fracture pressure curves in a very accurate mode while drilling the well. Therefore by eliminating uncertainties from pore and fracture pressures and being able to quickly react to correct any undesired event, the present method is consequently much safer than state-of-the-art drilling methods.
- the present invention provides further a drilling method where the elimination of the kick tolerance and tripping margin on the design of the well is made possible, since the pore and fracture pressure will be determined in real time while drilling the well, and, therefore, no safety margin or only a small one is necessary when designing the well.
- the kick tolerance is not needed since there will be no interruption in the drilling operation to circulate out any gas that might have entered into the well.
- the tripping margin is not necessary because it will be replaced by the back pressure on the well, adjusted automatically when stopping circulation.
- the invention provides a drilling method where a closed-loop system allowing the balance of the in and out flows may be used with a lightweight fluid as the drilling fluid.
- the invention provides further a drilling method where the use of a lightweight fluid together with the closed-loop system renders the drilling safer and cheaper, besides other technical advantages in deepwater scenarios where the pore pressure is normal, below normal, or slightly above normal, being normal the pore pressure equivalent to the sea water column.
- the invention provides still a drilling method of high flexibility in zones of normal or below normal pore pressure, by creating either a dual density gradient drilling in deepwater or just a single variable density gradient drilling, in zones of normal or below normal pore pressure.
- the invention provides still a drilling method which combines the generation of a dual density gradient drilling and a lightweight drilling fluid, this allowing it to be applied to pressure profiles where the fracture gradients are low and there are na ⁇ ow margins between pore and fracture pressure.
- the invention provides further a drilling method which combines the generation of a dual density gradient drilling and a lightweight drilling fluid, this allowing the density of the light fluid to be changed to optimize each pressure scenario, since the back pressure to be applied will also be continuously adjusted.
- the present invention allows the well control procedure to be much simpler, faster, and safer, since no time is wasted in checking the flow, closing the well, measuring the pressure, changing the mud weight if needed, and circulating the kick out ofthe well.
- a method for designing a system as hereinbefore defined having regard to the intended location geology and the like comprising designing parameters relating to a wellbore, sealing means, drill string, drill casing, fluid injection means at the surface and annulus evacuation means in manner to determine mass and dynamic flow by means of designing the location and nature of means to monitor fluid flow and flow rate and designing location and nature of means to adjust fluid flow, close the well, and acquire all the relevant parameters that might be available while drilling the well, and direct the acquired parameters to any means of predicting the ideal outflow to adjust the actual outflow to the predicted value.
- control software for a system or method as hereinbefore defined, designed to predict an expected, ideal value for outflow, based on calculations taking into account several parameters, and compare the predicted ideal value with the actual, return value as measured by flow meters, said comparison yielding any discrepancies, said software also receiving as input any early detection parameters, which input triggers a chain of investigation of probable scenarios, checking of actual other parameters and other means to ascertain that an influx/loss event has occurred.
- the said software utilizes all parameters being acquired during the drilling operation to enhance the prediction of the predicted flow.
- the software determines that, in the case that the fluid volume from the well is increasing or decreasing, after compensating for all possible factors, it is a sign that an influx or loss is happening.
- the software is provided with detection filters and/or processing filters to eliminate/reduce false indications on the received mass and fluid flow data, and any other measured or detected parameters.
- the software preferably provides a predicted ideal value of the outflow based on calculations taking into account among others rate of penetration, rock and drilling fluid density, well diameter, in and out flow rates, cuttings return rate, bottomhole and wellhead pressures and temperatures, torque and drag, weight on bit, hook load, and injection pressures.
- the software as hereinbefore defined acts on the principle of mass conservation, to determine the difference in mass being injected and returned from the well, compensates for increase in hole volume, additional mass of rock returning and other factors as an indication of the nature ofthe fluid event occurring downhole.
- the software compensates for relevant factors such as thermal expansion/contraction and compressibility changes, solubility effects, blend and mixture effects as an indication ofthe nature of fluid in a fluid influx event.
- detection of an influx or loss by means of the System or Method of the invention as hereinbefore defined or by any conventional system or method triggers a chain of investigation of probable influx events, starting with an assumption of fluid phase, comparing to the observation of discrepancy to check for behavioural agreement and in the event of disagreement repeating the assumption for different phases until agreement is reached.
- the software of the invention after identification of influx event, calculates the amount, location and timing of the influx or influxes and calculates an adjusted return flow rate required to circulate the fluid out and prevent further influx.
- the software as hereinbefore defined includes all the necessary algorithms, empirical calculations or other method to allow accurate estimation of the hydrostatic head and friction losses including any transient effects such as changing temperature profile along the well.
- the software as hereinbefore defined on identifying an influx or loss event automatically sends a command to a pressure/flow control device designed to adjust the return flow rate so as to restore the said return flow to the predicted ideal value, thereby preemptively adjusting backpressure to immediately control the event.
- the software as hereinbefore defined generates a command relating to an adjustment to the back pressure to compensate for dynamic friction losses when mud circulation is interrupted, avoiding influx of reservoir fluids.
- the software as hereinbefore defined is coupled with a feedback loop to constantly monitor the reaction to each action, as well as the necessary software design, and any necessary decision system to ensure consistent operation.
- a module for use in association with a conventional system for operating a well which provides the essential components ofthe system as hereinbefore defined.
- the module is for use in a return line of a system as hereinbefore defined comprising one or more return line segments in parallel each comprising a pressure/flow control device, optional sensors for flow out, and a degasser which is suited for insertion in a return line to operate in a desired pressure range.
- the module may be for location at the ground surface or at the seabed.
- a module is for -use in an injection line of a system as hereinbefore defined comprising a pump and optional sensors for fluid flow, and means for sealingly engaging with the well for injection into the annulus thereof.
- any improvements in mass/flow rate measurements or any other measuring device can be incorporated into the method. Also comprised within the scope of the application are any improvements in the accuracy and time lag to detect influx or fluid losses as well as any improvements in the system to manipulate the data and make decisions related to restore the predicted flow value.
- FIGURE 1 attached is a state-of-the-art log of pore and fracture pressure curves indicated hereinbefore. Included in this figure are the kick tolerance and tripping margin, used for designing the casing setting points, in this case taken as 0.3 ppg below the fracture pressure and above the pore pressure, respectively. This value is commonly used in the industry.
- the kick tolerance and tripping margin used for designing the casing setting points, in this case taken as 0.3 ppg below the fracture pressure and above the pore pressure, respectively. This value is commonly used in the industry.
- the number and diameter of the casing strings required to safely drill this well using the current conventional drilling method is shown. As pointed out before, the two curves shown are estimated before drilling. Actual values might never be determined by the current conventional drilling method.
- FIGURE 2 attached is a log of the same curves according to the invention, without the kick tolerance and tripping margin of 0.3 ppg included. On the right hand side the number of casing strings required can be seen.
- the drilling method described in the present application the elimination of the kick tolerance and tripping margin on the design of the well is made possible, since the pore and fracture pressure will be determined in real time while drilling the well, with the well being drilled closed at all times, and, therefore, no safety margin is necessary when designing the well.
- FIGURE 3 attached is a state-of-the-art schematics of the circulating system of a standard rig, with the return flow open to the atmosphere.
- FIGURES 4 to 6 attached are schematics of the circulating system of a rig with the drilling method described in the application.
- a pressure containment device located at the wellhead, fluid flow meters on the inlet and outlet streams, and other pieces of equipment have been added to the standard drilling rig configuration.
- Means is illustrated which receives all the data gathered and identifies a fluid influx or loss.
- fluid flow meters include mass flow and fluid flow rate meters, also pressure and temperature sensors, cuttings mass/volume measurement device and pressure/flow control device have been added to the standard drilling rig configuration and a control system has been added to receive data gathered and actuate the pressure/flow control device on the outlet stream.
- FIGURE 7 attached is a general block diagram of the method described in the present invention for the early detection of influx or loss of fluid, direct determination of pore and fracture pressure and regulating ECD instantaneously.
- FIGURE 8 attached is a flowsheet that schematically illustrates the method of the invention.
- the present system and method of drilling wells is based on a closed-loop system.
- the inventive method and system is applied to oil and gas wells, as well as to geothermal wells.
- a pressure/flow control device as a pro-active method for adjusting ECD based on early detection of influx/loss events; or 6. Defined the use of more than one pressure/flow control device combined to a lightweight drilling fluid to make that the equivalent drilling fluid weight above the mud line is lower than the equivalent fluid weight inside the wellbore.
- FIGURE 3 illustrates a drilling method according to state-of-the-art techniques.
- a drilling fluid is injected through the drill string (1), down the wellbore through the bit (2) and up the annulus (3).
- the fluid that is under atmospheric pressure is directed to the shale shaker (4) for solid/liquid separation.
- the liquid is directed to the mud tank (5) from where the mud pumps (6) suck the fluid to inject it through the drill string (1) and close the circuit.
- the BOP (8) In case of a kick, normally detected by mud tank volume variation indicated by level sensors (7), the BOP (8) must be closed to allow kick control. At this point the drilling operation is stopped to check pressure and adjust the mud weight to avoid further influxes.
- Improvements in state-of-the- art drilling methods are generally directed to, for example, improve the measurement of volume increase or decrease in tank (5). However, such improvements bring only minor changes to the kick detection procedure; furthermore, no fundamental modifications are known directed to the improvement of safety and/or to keeping the drilling method continuous, this modification being only brought about by the present invention.
- FIGURE 4 that illustrates the system of the invention
- the drilling fluid is injected through the drill string (1), going down towards the bottom hole through the bit (2) and up the annulus (3) and is diverted by a pressure containment device (26) through a closed return line (27) under pressure.
- BOP (8) remains open during drilling.
- the fluid is made to contact flow meter (11) and degasser (13) then to the shale shaker (4).
- the shale shaker (4) separates the cuttings (drill solids) from the liquid.
- the mass/volume of gas separated in degasser (13) is measured by a device (25).
- the drilling fluid is injected with the aid of pump (6) through an injection line (14) through which said fluid is made to contact flow meter (15).
- Devices (7), (11), (15) and (25) all acquire data which is directed to a central data point (18) and used to obtain real time values for flow rates, and compared with predicted values and identify any discrepancy.
- a discrepancy is evaluated initially as any event other than influx or fluid loss which might cause the observed discrepancy and a determination is made whether the discrepancy indicates a malfunctioning or other system event or is an early detection of influx or loss of drilling fluid.
- This early detection is important to a number of subsequent operations which may be performed in relation to the well, since the detection may be as much as several hours in advance of the consequence of such an influx or loss being apparent at the surface in the form of a kick.
- Operations include direct determination of pore or fracture pressure, controlling ECD to restore predicted values etc.
- Safety features present in the system and method include closing BOP (8) thereby closing the well to contain a kick.
- FIGURE 5 An embodiment of the system of FIGURE 4 is shown in FIGURE 5.
- the fluid is made to contact pressure and temperature sensors (9), fluid flow meter (10), mass flow meter (11) and flow/pressure control device (12) then degasser (13) and then to the shale shaker (4) .
- the shale shaker (4) separates the cuttings (drill solids) from the liquid and the solids have their mass/volume determined (19) while the liquid is directed to the mud tank (5) having the mass/volume determined as well (20). All standard drilling parameters are acquired by a device (21) normally called mud logging. Downhole parameters are acquired by a device (24) located close to the bit (2). The mass/volume of gas separated in degasser (13) is measured by a device (25).
- the drilling fluid is injected with the aid of pump (6) through an injection line (14) through which said fluid is made to contact mass flow meter (15), fluid flow meter (16), pressure and temperature sensors (17).
- System (18) sends a signal to the pressure/flow control device (12) to open or close it.
- a pump (23) may send fluid directly to the annulus (3) through a dedicated injection line (22) via a mass flow meter (28), fluid flow meter (28) and pressure and temperature sensors (28). For figure simplification these three devices are shown in just one piece of equipment.
- This injection line may be inco ⁇ orated as part of the standard circulation system, or embodied in other ways, the purpose being to provide an independent, of normal drilling circulation, means of flow into wellbore.
- the central data acquisition and control system (18) acquires data from device (28).
- FIGURE 6 A further embodiment of the system of FIGURE 4 is shown in FIGURE 6.
- the devices (12) may be placed, one at the bottom of the ocean and the other at the surface, or at any other convenient location.
- a lightweight fluid On using a lightweight fluid, it is injected and returned the same way as the conventional fluid, that is, injected through the drillstring and returned through the annulus.
- more than one dedicated injection line (22) may be used each with a pump (23) to send fluid directly to the annulus (3) through a mass flow meter (28), fluid flow meter (28) and pressure and temperature sensors (28).
- a pressure containment device (26) diverts the drilling fluid and keeps it under pressure.
- Device (26) is a rotating BOP and is located at the surface or the sea floor. The drilling fluid is diverted to a closed pipe (27) and then to a surface system.
- the device (26) is a standard equipment that is commercially available or readily adapted from existing designs.
- the pressure/flow control device (12) opens or closes to allow decrease or increase of the backpressure at the well head so that the outflow can be restored to the predicted value determined by system (18).
- Two or more of these pressure/flow control devices (12) can be installed in parallel with isolation valves to allow redundant operation.
- Devices (12) can be positioned downstream of the pressure containment device (26) at any suitable point in the surface system. Some surface systems may incorporate two or more of such devices (12) at different nodes.
- the equipment used to carry out such measurement is mass flow meters (11,15) and fluid flow meters (10,16).
- the equipment is installed in the injected (14) and return (27) fluid lines. These meters may also be installed at the gas outlet (25) of the degasser (13) and somewhere (20) on the fluid line between shale shaker (4) and tank (5). Also they may be installed on the independent injection line (22).
- the mass and fluid flow meters are commercially available equipment. Multi-phase meters are also commercially available and may be used. The precision of this equipment, allows accurate measurement, subsequent control and safer drilling.
- the cuttings mass/volume rate can be measured by commercially available equipment (19) to verify that the mass of cuttings being received back at the surface is correlated with the rate of penetration and wellbore geometry. This data allows correction of the mass flow data and allows identification of trouble events.
- the measurements of mass and fluid flow rates provide data that are collected and directed to a central data acquisition and control system (18).
- the central data acquisition and control system (18) is provided with a software designed to predict an expected, ideal value for the outflow, said value being based on calculations taking into account several parameters including but not restricted to rate of penetration, rock and drilling fluid density, well diameter, in and out flow rates, cuttings return rate, bottomhole and wellhead pressures and temperatures.
- Said software compares the said predicted ideal value with the actual, return flow rate value as measured by the mass flow meters (11,15) and fluid flow meters (10,16). If the comparison yields any discrepancy, the software automatically sends a command to a pressure/flow control device (12) designed to adjust the return flow rate so as to restore the said return flow rate to the predicted, ideal value.
- Said software can also receive as input any early detection parameters available or being developed or capable of being developed. Such input will trigger a chain of investigation of probable scenarios, checking of actual other parameter and any other means (databased or software or mathematical) to ascertain that an influx/loss event has occurred. Said software will in such cases pre-emptively adjust backpressure to immediately control the event.
- Said software will allow for override of the standard detection (state-of-the-art) by the early detection system of the invention and will compensate and filter for any conflict in fluid/mass flow indication.
- Said software may have filters, databases, historical learning and/or any other mathematical methods, fuzzy logic or other software means to optimize control of the system.
- the pressure/flow control device (12) used to restore the ideal flow is standard, commercially available equipment or is specifically designed for the required purpose chosen according to the well parameters such as diameter of the return line, pressure and flow requirements.
- the flow rates in and out of the wellbore are controlled, and the pressure inside the wellbore is adjusted by the pressure/flow control device (12) installed on the return- line (27) or further downstream in the surface system.
- the surface pressure should be increased to restore the bottomhole pressure in such a way as to overcome the reservoir pressure.
- control system (18) will proactively adjust the backpressure by opening or closing pressure/flow control device (12) to suit the occurred event.
- the system acts in order to adjust the rate of return flow and/or pressure thus increasing or decreasing the backpressure, while creating the desired condition downhole of no inflow from the exposed formation or no loss of fluid to the same exposed formation.
- This is coupled with a feedback loop to constantly monitor the reaction to each action, as well as the necessary software design, and any necessary decision system including but not limited to databases and fuzzy logic filters to ensure consistent operation.
- Another very important device used in the method and system of this invention is the pressure containment equipment (26), to keep the well flowing under pressure at all times.
- the pressure containment equipment (26) By controlling the pressure inside the well with a pressure/flow control device (12) on the return line (27) the bottomhole pressure can be quickly adjusted to the desired value so as to eliminate the losses or gains being detected.
- the assessment of the pore and fracture pressures according to the method of the invention is carried out in the following way: if the central data acquisition and control system (18) detects any discrepancy and a decision to actuate the pressure/flow control device (12) is made, it is a sign that either a fluid loss or influx is occurring. The Applicant has thus ascertained that if there is a fluid loss this means that the bottomhole pressure being recorded is equivalent to the fracture pressure ofthe formation.
- the bottomhole pressure being recorded is equivalent to the pore pressure ofthe formation.
- the variables pore pressure and fracture pressure can be estimated.
- the bottomhole pressure is not one of the variables being recorded and only the wellhead or surface pressure is the pressure variable being acquired.
- the pore pressure and the fracture pressure can then be indirectly estimated by adding to the obtained value the hydrostatic head and friction losses within the wellbore.
- the software pertaining to the central data and control system (18) would include all the necessary algorithms, empirical correlations or other method to allow accurate estimation of the hydrostatic head and friction losses including any transient effects like, but not limited to, changing temperature profile along the wellbore.
- a circulation bypass composed of a pump (23) and a dedicated injection line (22) to the wellbore annulus allows keeping a constant pressure downhole during circulation stops and continuously detecting any changes in the mass balance indicative of an influx or loss during the circulation stop.
- the errors from estimating the required mud weight based on static conditions are avoided since the measurements are effected under the same dynamic conditions as those when the actual events occur.
- This method also renders possible to run the mud density at a value slightly lower than that required to balance the formation pressure and using the backpressure on the well to exert an extremely controllable ECD at the bottomhole that has the flexibility to be instantaneously adjusted up or down. This will be the preferred method in wells with very narrow pore pressure/fracture pressure margins as occur in some drilling scenarios.
- the method of the invention allows, by creating an instant control mud weight window, controlling the ECD by increasing or decreasing the backpressure, controlled by the positioning ofthe pressure/flow control device, to create the conditions for staying within the na ⁇ ow margin.
- BOP blow-out preventer
- the central data acquisition and control system (18) has a direct output for actuation of the pressure/flow control device(s) (12) downstream the wellhead opening or closing the flow out of the well to restore the expected value.
- the bottomhole pressure is recorded and associated to the pore or fracture pressure, if a gain or loss is being observed, respectively.
- the circulation of the gas out of the well is immediately effected.
- the pressure/flow control device ( 12) By closing the pressure/flow control device ( 12) to restore the balance of flow and the predicted value, the bottomhole pressure regains a value that avoids any further influx. At this point no more gas will enter the well and the problem is limited to circulating out the small amount of gas that might have entered the well.
- the function of the rotating pressure containment device (26) is to allow the drill string (1) to pass through it and rotate, if a rotating drilling activity is carried on.
- the drill string (1) is stripped through the rotating pressure containment device; the annulus between the outside of the drill pipe and the inside of the wellbore/casing/riser is closed by this equipment.
- the rotating pressure containment device (26) can be replaced by a simplified pressure containment device such as the stripper(s) (a type of BOP designed to allow continuous passage of non-jointed pipe) on coiled tubing operations.
- the return flow of drilling fluid is, therefore, diverted to a closed pipe (27) to the surface treatment package.
- This surface package should be composed of at least a degasser (13) and shale shaker (4) for solids separation. This way the influxes can be automatically handled.
- the central data acquisition and control system (18) receives all the signals of different drilling parameters, including but not limited to injection and return flow rates, injection and return mass flow rates, back-pressure at the surface, down- hole pressure, cuttings mass rates, rate of penetration, mud density, rock lithology, and wellbore diameter. It is not necessary to use all these parameters with the drilling method herein proposed. -
- the central data acquisition and control system (18) processes the signals received and looks for any deviation from expected behavior. If a deviation is detected, the central data acquisition and control system (18) activates the flow pressure/flow control device (12) to adjust the back-pressure on the return line (27). This is coupled with a feedback loop to constantly monitor the reaction to each action, as well as the necessary software design, and any necessary decision system including but not limited to databases and fuzzy logic filters to ensure consistent operation.
- an influx may be detected by other means including but not limited to downhole temperature effects, downhole hydrocarbon detection, pressure changes, pressure pulses; said system pre-emptively adjusting backpressure on the wellbore based on influx or loss indication before surface system detection.
- the drilling ofthe well is done with the rotating pressure containment device (26) closed against the drill string. If a deviation outside the predicted values of the return flow and mass flow rates is observed, the control system (18) sends a signal either to open the flow, reducing the back-pressure or restricting the flow, increasing the back-pressure.
- This deviation may also be a signal from an early detection device.
- the first option (flow opening) is applied in case a fluid loss is detected and the second one (flow restriction), if a fluid gain is observed.
- the changes in flow are done in steps previously defined. These step changes can be adjusted as the well is drilled and the effective pore and fracture pressures are determined.
- FIGURE 7 A block diagram of the method described in the present invention is shown in FIGURE 7.
- the present system and method implies many variations and modifications within its scope and as such it can be applied to all kinds of wells, onshore as well as offshore, and the equipment location and distribution can vary according to the well, risks, application and restrictions of each case.
- the pore and fracture pressure may be directly determined while drilling the well. This entails great savings as regards safety and time, two parameters of utmost importance in drilling operations.
- the bottomhole pressure is adjusted by increasing or reducing the mud weight.
- the increase or reduction in mud weight is most of the time effected based on quasi-empirical methods, which by definition implies inaccuracies, which are handled by an iterative process of: -adjusting mud weight, measuring mud weight- this process being repeated until the desired value is reached.
- the time lag caused by the circulation time (i.e., time for a full loop movement of a unit element of mud)
- the adjustments must be made in stages, e.g., in order to quickly contain an influx, a higher density mud is introduced into the system to produce an increase in ECD (Equivalent Circulating Density).
- the method and system of the invention allows for a precise adjustment of increase or reduction in bottomhole pressure.
- the pressure/flow control device (12) to restore the equilibrium and pressures inside the wellbore, the adjustment is much faster achieved, avoiding the hazardous situation of well-known methods.
- the equivalent drilling fluid weight above the mud line may be set lower than the equivalent fluid weight inside the wellbore, this creating a dual-density gradient, which in some situations is absolutely necessary to accomplish the objectives ofthe well.
- FIGURE 8 is a flowchart illustrating the drilling method of the invention in a schematic mode, with the decision-making process that identifies an influx or loss and/or leads to the restoration of the predicted flow as determined by the central data acquisition and control system.
- a further decision making loop is incorporated at "discrepancy" and applies scenarios to the observed discrepancy, such as sensor malfunction, fluid loss to the shaker with formation changes, ECD gain, fluid addition rate exceeding the programmed rate for a predicted fluid flow and the like. If the discrepancy is found to be caused by such a scenario, the system generates a sensor alert, or restore a malfunctioning or malcontrolled parameter or resets predicted values to the deviant parameter. If the discrepancy is found not to be caused by such a scenario, it is identified as an influx or fluid loss.
- a further decision making loop is then incorporated at "fluid loss” and "fluid gain” and applies loss or gain events to the observed discrepancy to identify the nature of fluid, whereupon by applying the principle of mass conservation, the influx or loss can be fully characterised by amount and location(s), and change in backpressure calculated to contain the influx or loss event.
- Table A shows such a decision making process applied after identifying an influx or fluid loss, either by conventional method such as downhole temperature effects, hydrocarbon detection, change in pressure, pressure pulse and the like, or by the method ofthe invention comparing predicted and actual flow out.
- FIG 9 is shown the predicted ECD with time against the actual value.
- a discrepancy is observed at A. which is contained at B. and circulated out at C.
- Containment of influx occurs after influx event analysis to identify nature of fluid, whereupon location and amount of influx is determined.
- the influx increase as it rises up the well, and circulation out is only complete as the solubility is identified in a second influx event analysis at D.
- a control loop continuously checks predicted and actual ECD values and revises adjustment required to restore the predicted ECD, or in the case of a change in formation or the like, sets a new predicted ECD.
- UBD underbalanced drilling
- mud-cap drilling mud-cap drilling
- air drilling air drilling
- TABLE 1 shows the key differences among the traditional drilling system (Conv.), compared with the underbalanced drilling system (UBD) and the present drilling method herein proposed. It can be seen that the key points addressed by the present application are not covered or considered by either the traditional conventional drilling system or by the underbalanced drilling method currently used by the industry.
- 1 - real time is the determination of the pore and fracture pressure at the moment the influx of fluid loss occurs, rather than by means of calculation after some period of time.
- the present method is applicable to the- whole wellbore from the first casing string with a BOP connection, and to any type of well (gas, oil or geothermal), and to any environment (land, offshore, deep offshore, ultra-deep offshore). It can be implemented and adopted to any rig or drilling installation that uses the conventional method with very few exceptions and limitations.
- the present method can be called INTELLIGENT SAFE DRILLING, since the response to influx or losses is nearly immediate and so smoothly done that the drilling can go on without any break in the normal course of action, this representing an unusual and unknown feature in the technique.
- the present system and method of drilling makes possible: i) accurate and fast determination of any difference between the in and out flow, detecting any fluid losses or influx; ii) easy and fast control ofthe influx or losses; iii) strong increase of drilling operations safety in challenging environments, such as when drilling in narrow margin between pore and fracture pressures; iv) strong increase of drilling operations safety when drilling in locations with pore pressure uncertainty, such as exploration wells; v) strong increase of drilling operations safety when drilling in locations with high pore pressure; vi) easy switch to underbalanced or conventional drilling modes; vii) drilling with minimum overbalance, increasing the productivity of the wells, increasing the rate of penetration and thus reducing the overall drilling time; viii) direct determination of both the pore and fracture pressures; ix) a large reduction in time and therefore cost spent weighting
- Skid comprising eg 3 parallel injection lines each having sensors, and a common degasser is designed for eg 5000 psi in 3 chokes, or greater pressure tolerance in 10 chokes etc. Skid can be simply installed in any conventional system.
- a further skid may comprise one or more chokes with a bypass for adjustment.
- a further skid may comprise a dedicated circulating system for injection direct into the annulus
Abstract
Description
Claims
Priority Applications (12)
Application Number | Priority Date | Filing Date | Title |
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AU1932202A AU1932202A (en) | 2000-12-18 | 2001-12-14 | Cloded loop fluid-handing system for well drilling |
DK01271487T DK1356186T3 (en) | 2000-12-18 | 2001-12-14 | Fluid treatment system with closed circuit for fire drilling |
EP01271487A EP1356186B1 (en) | 2000-12-18 | 2001-12-14 | Closed loop fluid-handing system for well drilling |
BRPI0116306-0A BR0116306B1 (en) | 2000-12-18 | 2001-12-14 | "SYSTEM AND METHOD FOR DRILLING A WELL". |
AU2002219322A AU2002219322B2 (en) | 2000-12-18 | 2001-12-14 | Closed loop fluid-handing system for well drilling |
DE60111781T DE60111781T2 (en) | 2000-12-18 | 2001-12-14 | FLUID PIPING SYSTEM WITH CLOSED CIRCUIT FOR USE IN DRILLING |
EA200300693A EA006054B1 (en) | 2000-12-18 | 2001-12-14 | Drilling system and method |
AT01271487T ATE298835T1 (en) | 2000-12-18 | 2001-12-14 | CLOSED CIRCUIT FLUID LINE SYSTEM FOR USE IN DEEP DRILLING |
MXPA03005396A MXPA03005396A (en) | 2000-12-18 | 2001-12-14 | Cloded loop fluid-handing system for well drilling. |
CA002432119A CA2432119C (en) | 2000-12-18 | 2001-12-14 | Drilling system and method |
NO20032655A NO326132B1 (en) | 2000-12-18 | 2003-06-12 | Drilling system and feed rate |
AU2006252289A AU2006252289B2 (en) | 2000-12-18 | 2006-12-29 | Closed loop fluid handling system for well drilling |
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US09/737,851 | 2000-12-18 | ||
US09/737,851 US20020112888A1 (en) | 2000-12-18 | 2000-12-18 | Drilling system and method |
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EP (1) | EP1356186B1 (en) |
AT (1) | ATE298835T1 (en) |
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NO20032655L (en) | 2003-08-11 |
US7650950B2 (en) | 2010-01-26 |
BR0116306A (en) | 2004-03-02 |
NO326132B1 (en) | 2008-10-06 |
WO2002050398B1 (en) | 2002-09-06 |
US7367411B2 (en) | 2008-05-06 |
US20020112888A1 (en) | 2002-08-22 |
NO20032655D0 (en) | 2003-06-12 |
AU2006252289A1 (en) | 2007-01-25 |
EP1356186A1 (en) | 2003-10-29 |
DE60111781D1 (en) | 2005-08-04 |
EA006054B1 (en) | 2005-08-25 |
AU2006252289B2 (en) | 2009-11-12 |
AU2002219322B2 (en) | 2006-10-05 |
ATE298835T1 (en) | 2005-07-15 |
CA2432119C (en) | 2009-07-28 |
US7278496B2 (en) | 2007-10-09 |
DK1356186T3 (en) | 2005-10-24 |
US20030079912A1 (en) | 2003-05-01 |
CA2432119A1 (en) | 2002-06-27 |
EP1356186B1 (en) | 2005-06-29 |
AU2009222591B2 (en) | 2012-01-19 |
US20060113110A1 (en) | 2006-06-01 |
BR0116306B1 (en) | 2014-04-22 |
US20060037781A1 (en) | 2006-02-23 |
US20080041149A1 (en) | 2008-02-21 |
MXPA03005396A (en) | 2004-10-14 |
DE60111781T2 (en) | 2006-05-18 |
AU2009222591A1 (en) | 2009-10-29 |
EA200300693A1 (en) | 2004-02-26 |
AU1932202A (en) | 2002-07-01 |
US7044237B2 (en) | 2006-05-16 |
ES2244554T3 (en) | 2005-12-16 |
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