WO2005042911A2 - Systeme de forage de petrole et puits de gaz pourvus d'un train de forage surdimensionne permettant d'atteindre des vitesses de retour annulaires superieures - Google Patents

Systeme de forage de petrole et puits de gaz pourvus d'un train de forage surdimensionne permettant d'atteindre des vitesses de retour annulaires superieures Download PDF

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Publication number
WO2005042911A2
WO2005042911A2 PCT/US2004/036328 US2004036328W WO2005042911A2 WO 2005042911 A2 WO2005042911 A2 WO 2005042911A2 US 2004036328 W US2004036328 W US 2004036328W WO 2005042911 A2 WO2005042911 A2 WO 2005042911A2
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WIPO (PCT)
Prior art keywords
drilling
drilling fluid
wellbore
mud
surface location
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Application number
PCT/US2004/036328
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English (en)
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WO2005042911A3 (fr
Inventor
Luc De Boer
Original Assignee
Luc De Boer
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Publication date
Application filed by Luc De Boer filed Critical Luc De Boer
Publication of WO2005042911A2 publication Critical patent/WO2005042911A2/fr
Publication of WO2005042911A3 publication Critical patent/WO2005042911A3/fr

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Classifications

    • E—FIXED CONSTRUCTIONS
    • E21—EARTH OR ROCK DRILLING; MINING
    • E21B—EARTH OR ROCK 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 OR ROCK DRILLING; MINING
    • E21B—EARTH OR ROCK 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
    • E21B21/001—Methods or apparatus for flushing boreholes, e.g. by use of exhaust air from motor specially adapted for underwater drilling
    • E—FIXED CONSTRUCTIONS
    • E21—EARTH OR ROCK DRILLING; MINING
    • E21B—EARTH OR ROCK 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
    • E21B21/06—Arrangements for treating drilling fluids outside the borehole
    • E21B21/063—Arrangements for treating drilling fluids outside the borehole by separating components
    • E—FIXED CONSTRUCTIONS
    • E21—EARTH OR ROCK DRILLING; MINING
    • E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
    • E21B33/00—Sealing or packing boreholes or wells
    • E21B33/02—Surface sealing or packing
    • E21B33/03—Well heads; Setting-up thereof
    • E21B33/068—Well heads; Setting-up thereof having provision for introducing objects or fluids into, or removing objects from, wells
    • E21B33/076—Well heads; Setting-up thereof having provision for introducing objects or fluids into, or removing objects from, wells specially adapted for underwater installations
    • E—FIXED CONSTRUCTIONS
    • E21—EARTH OR ROCK DRILLING; MINING
    • E21B—EARTH OR ROCK 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 subject invention is generally related to systems for delivering drilling fluid (or "drilling mud") for oil and gas drilling applications. More particularly, the present invention is directed to a system for controlling the density and flow of drilling mud in offshore (deep and shallow water) and land-based oil and gas drilling applications. 2. Description of the Prior Art It is well known to use drilling mud to provide hydraulic horse power for operating drill bits, to maintain hydrostatic pressure, to cool the wellbore during drilling operations, and to carry away particulate matter when drilling for oil and gas in subterranean wells.
  • drilling mud is pumped down the drill pipe to provide the hydraulic horsepower necessary to operate the drill bit, and then it flows back up from the drill bit along the periphery of the drill pipe and inside the open borehole and casing.
  • the returning mud carries the particles loosed by the drill bit (i.e., "drill cuttings") to the surface.
  • the return mud is cleaned to remove the particles and then is recycled down into the hole.
  • the density of the drilling mud is monitored and controlled in order to maximize the efficiency of the drilling operation and to maintain hydrostatic pressure.
  • a well is drilled using a drill bit mounted on the end of a drill string.
  • the drilling mud is pumped down the drill pipe and through a series of jets in the drill bit to provide a hydraulic horsepower at the cutting bit face.
  • the mud passes through the drill bit and flows upwardly along the drill string inside the annulus formed between the open hole or cased hole and the drill string, carrying the loosened particles to the surface.
  • the velocity or rate of the return mud flow must also be monitored and controlled.
  • the rate at which the return mud flows upward through the annulus between the open/cased hole and the drill string is referred to as the "annular velocity.”
  • the annular velocity of the return mud is commonly expressed in units of feet per minute (FPM) and is a function of the cross-sectional area of the annular space between the hole and the drill string.
  • the annular velocity of trie return mud must be maintained to be greater than the rate at which the cuttings and debris being carried by the mud slip downward due to the effects of gravity. This is referred to as "critical velocity.” If the annular velocity of the return mud falls below the critical rate, then there will be a risk that the cuttings and debris particles will slip and settle thus forming bridges that may obstruct the wellbore . Furthermore, the annular velocity of the return mud must be maintained at a laminar level to avoid turbulent flow which could be damaging to the formation itself, and also increase the equivalent circulating density unnecessarily.
  • amud control system is shown and described inU.S. PatentNo.
  • blowout preventers are installed at the ocean floor or at the surface to contain the wellbore and to prevent a kick from becoming a "blowout" where the gases or fluids in the wellbore overcome the BOP and flow upward creating an out-of-balance well condition.
  • BOP's blowout preventers
  • the primary method for minimizing the risk of a blowout condition is the proper balancing of the drilling mud density to maintain the well in an overbalanced condition at all times.
  • the column of drilling mud in the annular space around the drill stem is of sufficient weight and density to produce a high enough pressure to limit risk to near-zero in normal drilling conditions. This is referred to as "overbalanced" drilling. In an overbalanced state, the hydrostatic pressure induced by the weight of the drilling fluid is greater than the actual pore pressure of the formation.
  • the drilling mud may penetrate the formation from the wellbore. Moreover, too much overbalanced drilling slows down the drilling process.
  • underbalanced drilling has been attempted in order to increase the drilling rate and to reduce drilling mud penetration into the formation.
  • the hydrostatic pressure induced by the weight of the drilling fluid in the well is less than the actual formation pressure within the pore spaces of the formation. Accordingly, during underbalanced drilling, the fluids within the pore spaces of the reservoir formation actually flow into the wellbore.
  • the present invention is directed at a system for controlling drilling mud density in land- based and offshore (shallow water, deep water or ultra deep water) drilling applications. It is an important aspect of the present invention that the drilling mud is diluted using a light fluid.
  • the light fluid may be of lesser density or greater density than the drilling mud required at the wellhead.
  • the light fluid and drilling mud are combined to yield a diluted mud.
  • the light fluid has a density less than seawater (or less than 8.6 PPG).
  • the light fluid is an oil base having a density of approximately between 6.5 - 8.5 PPG.
  • the mud may be pumped from the surface through the drill string and into the bottom of the wellbore at a density of 12.5 PPG, typically at a rate of around 800 gallons per minute in a 12-1/4 inch hole.
  • the fluid in the riser which is at this same density, is then diluted above the sea floor or alternatively below the sea floor with an equal amount or more of light fluid through the riser charging lines and annulus.
  • Mi 12.5 PPG
  • Mb 6.5 PPG
  • F I 800 gpm
  • F M b 1500 gpm.
  • the return flow in the riser is a mud having a density of 8.6 PPG (or the same as seawater) flowing at 2300gpm.
  • the density of the drilling fluid being circulated through the drill bit is less than the density of the fluid being inserted into the return mud.
  • the return mud In cases where it is necessary or advantageous to drill with a non-damaging, low density fluid (e.g., in the production zone) to achieve a near-balanced or slightly underbalanced state, the return mud must still be weighted down above the reservoir to maintain hydrostatic pressure and to take pressure off of the wellhead. Accordingly, a fluid having a greater density than the light drilling fluid is injected into the wellbore at a location below the wellhead to add weight to the return mud. It is another important aspect of the present invention that the return flow is treated at the surface in accordance with the mud treatment system of the present invention.
  • the mud is returned to the surface and the cuttings are separated from the mud using a shaker device. While the cuttings are transported in a chute to a dryer (or alternatively discarded overboard), the cleansed return mud falls into riser mud tanks or pits.
  • the return mud pumps are used to carry the drilling mud to a separation skid which is preferably located on the deck of the drilling rig.
  • the separation skid includes: (1) return mud pumps, (2) a centrifuge device to strip the light fluid having density Mb from the return mud to achieve a drilling fluid with density Mi, (3) a light fluid collection tank for gathering the lighter fluid stripped from the drilling mud, and (4) a drilling fluid collection tank to gather the heavier drilling mud having a density Mi.
  • Holding tanks e.g., hull tanks
  • a conditioning tank is located beneath the separation skid such that the stripped drilling fluid can flow from the drilling fluid collection tank into conditioning tanks.
  • the drilling fluid flows into active tanks located below the conditioning tanks.
  • the cleansed and stripped drilling fluid can be returned to the drill string via a mud manifold using the mud pumps, and the light fluid can be re-inserted into the riser stream via charging lines or choke and kill lines, or alternatively into a concentric riser using light fluid pumps.
  • the mud recirculation system includes a multi-purpose control unit for manipulating drilling fluid systems and displaying drilling and drilling fluid data. It is an object and feature of the subject invention to provide a system for diluting mud density in land-based and offshore (i.e., shallow water, deep water, and ultra deep water) drilling applications for both drilling units and floating drillmg unit configurations. It is another object and feature of the subject invention to provide a system for decreasing/increasing the density of mud in a riser by injecting low/high density fluids into the riser lines (typically the charging line or booster line or possibly the choke or kill line) or riser systems with surface BOP's.
  • the riser lines typically the charging line or booster line or possibly the choke or kill line
  • FIG. 1 is a schematic of a typical offshore drilling system modified to accommodate the teachings of the present invention depicting drilling mud being diluted with a light fluid at or above the seabed.
  • FIG. 2 is a schematic of a typical offshore drilling system modified to accommodate the teachings of the present invention depicting drilling mud being diluted with a light fluid below the seabed.
  • FIG. 3 is an enlarged sectional view of a below-seabed wellhead injection apparatus in accordance with the present invention for injecting a light fluid into drilling mud below the seabed.
  • FIG.4 is a schematic of an offshore drilling system depicting a vertical well being drilled by running a light mud through the drill bit and injecting a heavy mud over the column of light return mud.
  • FIG. 5 is a schematic of an offshore drillmg system depicting a horizontal section of a well being drilled by running a light mud through the drill bit and inj ecting a heavy mud over the column of light return mud.
  • FIG. 6 is a schematic of an offshore drilling system depicting a horizontal section of a well or a vertical section of a well being drilled by running a light mud through the drill bit and injecting a heavy mud over the column of light return mud and including a rotating head to control formation pressures to facilitate underbalanced drilling.
  • FIG. 5 is a schematic of an offshore drillmg system depicting a horizontal section of a well being drilled by running a light mud through the drill bit and inj ecting a heavy mud over the column of light return mud.
  • FIG. 7A is a schematic of an offshore drilling system depicting a prior art drill string comprising a string of drill pipes having an outer diameter range of 2 7 / 8 " to 6 5 / 8 ".
  • FIG. 7B is an enlarged cross-sectional view of a prior art drill string comprising a string of drill pipes having an outer diameter range of 2 7 / 8 " to 6 5 / 8 ".
  • FIG. 8 A is a schematic of an offshore drilling system depicting an oversized drill string in accordance with the present invention comprising a string of drill pipes having an outer diameter range of 6 3 / 4 " to 9 7 / 8 ".
  • FIG. 8B is an enlarged cross-sectional view of an oversized drill string in accordance with the present invention comprising a string of drill pipes having an outer diameter range of 6 3 / 4 " to 9 7 / 8 ".
  • FIG. 9A is a schematic of an offshore drilling system depicting a concentric drill string employed to inject drilling fluid in accordance with the present invention.
  • FIG. 9B is an enlarged cross-sectional view of a concentric drill string in accordance with the present invention.
  • FIG. 10 is a graph showing depth versus down hole pressures in a single gradient drilling mud application.
  • FIG. 11 is a graph showing depth versus down hole pressures and illustrates the advantages obtained using multiple density muds injected at the seabed versus a single gradient mud.
  • FIG. 9A is a schematic of an offshore drilling system depicting a concentric drill string employed to inject drilling fluid in accordance with the present invention.
  • FIG. 9B is an enlarged cross-sectional view of a concentric drill string in accordance with the
  • FIG. 12 is a graph showing depth versus down hole pressures and illustrates the advantages obtained using multiple density muds injected below the seabed versus a single gradient mud.
  • FIG. 13 is a graph showing depth versus down hole pressures and illustrates the advantages obtained by drilling with a light mud once the production zone is reached and injecting a heavy mud over the column of light return mud.
  • FIG. 14 is a diagram of the drilling mud treatment system in accordance with the present invention for stripping the light fluid from the drilling mud at or above the seabed.
  • FIG. 15 is a diagram of control system for monitoring and manipulating variables for the drilling mud treatment system of the present invention.
  • FIG. 16 is an enlarged elevation view of a conventional solid bowl centrifuge as used in the treatment system of the present invention to separate the low-density material from the high-density material in the return mud.
  • a mud recirculation system for use in deepwater (i.e., beyond the continental shelf) offshore drilling operations to pump drilling mud: (1) downward through a drill string to operate a drill bit thereby producing drill cuttings, (2) outward into the annular space between the drill string and the formation of the wellbore where the mud mixes with the cuttings, and (3) upward from the wellbore to the surface via a riser in accordance with the present invention is shown.
  • a drilling unit 10 is provided from which drilling operations are performed.
  • the drilling unit 10 may be an anchored floating platform or a drill ship or a semi-submersible drilling unit.
  • a series of concentric strings runs from the drilling unit 10 to the sea floor or seabed 20 and into a stack 30.
  • the stack 30 is positioned above a wellbore 40 and includes a series of control components, generally including one or more blowout preventers or BOP's 31.
  • the concentric strings include casing 50, a drill string 70, and a riser 80.
  • a drill bit 90 is mounted on the end of the drill string 70.
  • a riser charging line (or booster line) 100 runs from the surface to a switch valve 101.
  • the riser charging line 100 includes an above-seabed section 102 running from the switch valve 101 to the riser 80 and a below-seabed section 103 running from the switch valve 101 to a wellhead injection apparatus 32.
  • the above-seabed charging line section 102 is used to insert a light fluid into the riser 80 to mix with the upwardly returning drillmg mud at a location at or above the seabed 20.
  • the below-seabed charging line section 103 is used to insert a light fluid into the wellbore to mix with the upwardly returning drilling mud via a wellhead injection apparatus 32 at a location below the seabed 20.
  • the switch valve 101 is manipulated by a control unit to direct the flow of the light fluid into either the above-seabed charging line section 102 or the below-seabed charging line section 103.
  • the mud recirculation system of the present invention can also be employed for any offshore operation (shallow, deep, or ultra deep) and even land-based drilling operations.
  • FIG.3 the wellhead injection apparatus 32 for injecting a light fluid into the drilling mud at a location below the seabed is shown.
  • the injection apparatus 32 includes: (1) a wellhead connector 200 for connection with a wellhead 300 and having an axial bore therethrough and an inlet port 201 for providing communication between the riser charging line 100 (FIGS 1 and 2) and the wellbore; and (2) an annulus injection sleeve 400 having a diameter larger than the diameter of the axial bore of the wellhead connector 200 attached to the wellhead connector thereby creating an annulus injection channel 401 through which the light fluid is pumped downward.
  • the wellhead 300 is supported by a wellhead body 302 which is cemented in place to the seabed.
  • the wellhead housing 302 is a 36 inch diameter casing and the wellhead 300 is attached to the top of a 20 inch diameter casing.
  • the annulus injection sleeve 400 is attached to the top of a 13-3/8 inch to 16 inch diameter casing sleeve having a 2,000 foot length.
  • the light fluid is injected into the wellbore at a location approximately 2,000 feet below the seabed. While the preferred embodiment is described with casings and casing sleeves of a particular diameter and length, it is intended that the size and length of the casings and casing sleeves can vary depending on the particular drilling application.
  • drilling mud is pumped downward from the drilling unit 10 into the drill string 70 to turn the drill bit 90 via the tubing 60.
  • a riser charging line 100 is provided for charging (i.e., circulating) the light fluid in the riser 80.
  • a light fluid is mixed with the drilling mud either at (or immediately above) the seabed or below the seabed.
  • a reservoir contains a light fluid of lower density than the drilling mud and a set of pumps connected to the riser charging line (or booster charging line).
  • This light fluid is of a low enough density that when the proper ratio is mixed with the drilling mud a combined density equal to or close to that of seawater can be achieved.
  • the switch valve 101 is manipulated by a control unit to direct the flow of the light fluid from the drilling rig 10 to the riser 80 via the charging line 100 and above-seabed section 102 (FIG. 1).
  • the switch valve 101 is manipulated by a control unit to direct the flow of the light fluid from the drilling rig 10 to the riser 80 via the charging line 100 and below-seabed section 103 (FIG. 2).
  • the drilling mud is an oil based mud with a density of 12.5 PPG and the mud is pumped at a rate of 800 gallons per minute or "gpm".
  • the light fluid is an oil base fluid with a density of 6.5 to 7.5 PPG and can be pumped into the riser charging lines at a rate of 1500 gpm.
  • Mi 12.5 PPG
  • Mb 6.5 PPG
  • FM_ 800 gpm
  • F M b 1500 gpm.
  • the return flow in the riser above the light fluid injection point is a mud having a density of 8.6 PPG (or close to that of seawater) flowing at 2300 gpm.
  • the wellbore is drilled as described above (using a light fluid injected into the return mud stream) until the production zone is reached.
  • the production zone may be drilled through with a vertical section (as shown in FIG.4) or a horizontal section (as shown in FIG. 5). At this point, it may be desirable to drill with a light, clean drilling fluid to prevent contamination of the reservoir or damage to the formation.
  • the well in this section may be drilled in a near-balanced (i.e., slightly underbalanced or slightly overbalanced) or underbalanced state such that the drilling fluid does not penetrate the formation.
  • the mud control system includes a BOP 31 connected to a wellhead injection apparatus 32.
  • a riser 80 is provided to establish communication between the surface and the wellbore 40.
  • a drill bit 90 is mounted on the end of the drill string 70.
  • a riser charging line (or booster line) 100 runs from the surface to the well head injection apparatus 32.
  • the mud recirculation system of the present invention can also be employed for any offshore operation (shallow, deep, or ultra deep) and even land-based drilling operations.
  • a light, clean drilling fluid is pumped downward into the drill string 70 to rum the drill bit 90 and circulate into the borehole 40.
  • the drilling fluid then flows into the annulus defined by the outer wall of the drill string 70 and the formation 40.
  • the production zone section of the wellbore is near-balanced or underbalanced such that the drilling fluid does not penetrate or contaminate the reservoir.
  • the drilling fluid picks up the cuttings or particles loosened by the drill bit 90 and carries them upward toward the surface.
  • a fluid having a density greater than the light drilling fluid is injected into the return mud to create a sufficiently dense combination fluid.
  • This combination fluid may then pass into the riser 80 and return to the surface for treatment and separation without damaging the wellhead and thus impairing the safety of the well. While this system is described above for use once the production zone is reached, the light drilling fluid with heavy fluid injection system may also be used for sand screen zones, multi-lateral sections, extended reach sections, horizontal sections, or any occasion where slightly underbalanced (or near balanced) drilling is desired. With respect to FIG.
  • another embodiment of the mud control system of the present invention includes a rotating head 33 for closing around the drill string 70 and containing the pressure in the wellbore 40 under controlled conditions.
  • the rotating head 33 controls the direction of the return mud stream as it flows to the surface by making a rotating seal around the drill string when actuated. This seal forces the return mud away from the riser 80.
  • This system may be used in both the drilling of vertical well sections 40 A and horizontal well sections 40B.
  • This embodiment of the mud control system further includes a booster line (or charging line) 100 for delivering the light fluid to the well and a return line (or choke line) 104 for delivering the return mud to the surface when the rotating head 33 is actuated.
  • the booster line 100 includes: (1) a first valve-controlled section 100A for delivering a light fluid directly to the riser 80 under the rotating head 33 to lighten the return mud flowing through the return line 104 when the rotating head is actuated, and a second valve-controlled section 100B for delivering a light fluid (if drilling overbalanced above the production zone) or a heavy fluid (if drilling underbalanced or near- balanced through the production zone) to the borehole annulus.
  • a first valve-controlled section 100A for delivering a light fluid directly to the riser 80 under the rotating head 33 to lighten the return mud flowing through the return line 104 when the rotating head is actuated
  • a second valve-controlled section 100B for delivering a light fluid (if drilling overbalanced above the production zone) or a heavy fluid (if drilling underbalanced or near- balanced through the production zone) to the borehole annulus.
  • each valve may be moved between an open position to facilitate light fluid injection or a closed position to block injection.
  • the drill string used to deliver drilling fluid to the drill bit and the bottom of the hole may comprise a string of oversized drill pipes to increase the annular velocity of the return fluid.
  • prior art drill pipes 70A have an outer diameter ranging from 2 7 / 8 " to 6 5 / 8 ". These drill pipes are run through a surface casing borehole 40 having a diameter ranging from 12" to 18". With respect to FIGS .
  • a drill string comprising a string of oversized drill pipes (i.e., having a diameter ranging from 6 3 / " to 9 7 / 8 ") would provide a smaller annular space between the borehole 40 and the drill string 70B.
  • a higher annular velocity for the return mud can be achieved.
  • the diameter of oversized drill pipe used in the drillmg application will depend on the borehole size and the target annular velocity.
  • the target annular velocity should be greater than the slip velocity of the suspended cuttings and debris in the return mud.
  • the slip velocity of the cuttings and debris is generally determined to be approximately 25 FPM.
  • the minimum target annular velocity would therefore be approximately 100 FPM, with an optimum target annular velocity of 150 FPM.
  • a concentric drill string comprises an inner string of drill pipe 70C arranged within an outer string of drill pipe 70D.
  • the inner drill string 70C may comprise a string of drill pipes having an outer diameter of 2 7 / 8 " and the outer drill pipe 70D may comprise a string of drill pipes having an outer diameter of 5 V 2 ".
  • the size of the inner drill string 70C and outer drill string 70D may vary from 2 7 / 8 " to 9 7 / 8 " depending on the requirements of the well.
  • the concentric drill string may be used to both (1) deliver drilling fluid to the drill bit 90 and bottom of borehole 40 via the inner drill string 70C, and (2) inject light fluid into the return mud stream via a set of ports 71 formed in the outer drill string 70D.
  • the light fluid is actually injected from the surface drilling rig 10 into the annular space between the inner drill string 70C and the outer drill string 70D.
  • the combination return mud is then returned to the surface via the riser 80.
  • the concentric drill string of the present invention is described as being used to circulate drilling fluid to the bottom of the hole via the inner drill pipe and to inject a light fluid into the return mud stream via a set of ports in the outer drill pipe, it is intended that the present invention includes another embodiment where the drilling fluid is circulated to the bottom of the hole via the outer drill pipe and the light fluid is injected into the return mud stream via a set of ports which establish communication between the borehole and the inner drill pipe by spanning the outer drill pipe.
  • a concentric drill string of the present invention includes only one injection point, it is intended that a concentric drill string may include a plurality of axially spaced injection points which may be regulated by valves controlled at the surface or by convention drop ball actuation. Each valve may be moved between an open position to facilitate light fluid injection or a closed position to block injection.
  • FIGS. 10-12 An example of the advantages achieved using the dual density mud system (light fluid injection) of the present invention is shown in the graphs of FIGS. 10-12.
  • the graph of FIG. 10 depicts casing setting depths with single gradient mud
  • the graph of FIG. 11 depicts casing setting depths with dual gradient mud (light fluid injection) inserted at the seabed
  • FIGS. 12 depicts casing setting depths with dual gradient mud (light fluid injection) inserted below the seabed.
  • the graphs of FIGS. 10-12 demonstrate the advantages of using a dual gradient mud (light fluid injection) over a single gradient mud.
  • the vertical axis of each graph represents depth and shows the seabed or sea floor at approximately 6,000 feet.
  • the horizontal axis represents mud weight in pounds per gallon or "PPG".
  • the solid line represents the "equivalent circulating density" (ECD) in PPG.
  • the diamonds represents formation frac pressure.
  • the triangles represent pore pressure.
  • the bold vertical lines on the far left side of the graph depict the number and depth of casings required to drill the well with the corresponding drilling mud at a well depth of approximately 23,500 feet.
  • FIG. 13 depicts casing setting depths with injecting a light fluid into the return mud stream before the production zone (or sand screen or horizontal section) is reached, and then drilling with a light drilling fluid and injecting a heavy fluid once the production zone (or sand screen or horizontal section) is reached.
  • the vertical axis of the graph represents depth and the horizontal axis represents mud weight in pounds per gallon or "PPG".
  • PPG pounds per gallon
  • overbalanced drilling operations include maintaining a hydrostatic pressure on the formation equal to or slightly greater than the pore pressure of the formation
  • underbalanced drilling operations include maintaining a hydrostatic pressure at least slightly lower than the pore pressure of the formation.
  • hydrostatic pressure at the bottom of the wellbore likewise increases which may result in a formation fluid influx into the wellbore (called a "kick").
  • the invading formation liquid and/or gas may "cut" or decrease the density of the drilling fluid in the wellbore. If the kick is not contained and more formation fluid enters the wellbore, then hydrostatic control of the wellbore could be lost.
  • Constant Bottom Hole Pressure method There are two variations of the Constant Bottom Hole Pressure method ⁇ the "Driller's method” and the “Engineer's method” (also called the “Weight and Wait” method).
  • the original mud weight is used to circulate the contaminating formation fluid from the wellbore. Thereafter, kill weight mud is circulated through the drill and into the wellbore.
  • the kill weight mud is calculated and prepared and then circulated through the drill string and into the wellbore to remove the contaminating formation fluid from the wellbore and to kill the well.
  • the mud recirculation system includes a treatment system located at the surface for: (1) receiving the return combined mud (with density Mr), (2) removing the drill cuttings from the mud, and (3) stripping the lighter fluid (with density Mb) from the return mud to achieve the initial heavier drilling fluid (with density Mi).
  • a treatment system located at the surface for: (1) receiving the return combined mud (with density Mr), (2) removing the drill cuttings from the mud, and (3) stripping the lighter fluid (with density Mb) from the return mud to achieve the initial heavier drilling fluid (with density Mi).
  • the treatment system of the present invention includes: (1) a shaker device for separating drill cuttings from the return mud, (2) a set of riser fluid tanks or pits for receiving the cleansed return mud from the shaker, (3) a separation skid located on the deck of the drilling rig — which comprises a centrifuge, a set of return mud pumps, a light fluid collection tank and a drilling fluid collection tank — for receiving the cleansed return mud and separating the mud into a drilling fluid component and a light fluid component, (4) a set of holding tanks (e.g.
  • the return mud flows from the riser into the shaker device having an inlet for receiving the return mud via a flow line connecting the shaker inlet to the riser.
  • the shaker device separates the drill cuttings from the return mud producing a cleansed return mud.
  • the cleansed return mud flows out of the shaker device via a first outlet, and the cuttings are collected in a chute and bourn out of the shaker device via a second outlet. Depending on environmental constraints, the cuttings may be dried and stored for eventual off-rig disposal or discarded overboard.
  • the cleansed return mud exits the shaker device and enters the set of riser mud tanks/pits via a first inlet.
  • the set of riser mud tanks/pits holds the cleansed return mud until it is ready to be separated into its basic components — drilling fluid and light fluid.
  • the riser mud tanks/pits include a first outlet through which the cleansed mud is pumped out.
  • the cleansed return mud is pumped out of the set of riser mud tanks/pits and into the centrifuge device of the separation skid by a set of mud pumps. While the preferred embodiment includes a set of six pumps, it is intended that the number of return mud pumps used may vary depending upon on drilling constraints and requirements. Also, the method of delivering mud to each separator may be by a number of centrifugal pumps and distribution through a manifold and valve system.
  • the separation skid includes the set of return mud pumps, the centrifuge device, a light fluid collection tank for gathering the lighter fluid, and a drilling fluid collection tank to gather the heavier drilling mud. As shown in FIG.
  • the centrifuge device 500 includes: (1) a bowl 510 having a tapered end 510A with an outlet port 511 for collecting the high-density fluid 520 and a non-tapered end 510B having an adjustable weir plate 512 and an outlet port 513 for collecting the low-density fluid 530, (2) a helical (or “screw") conveyor 540 for pushing the heavier density fluid 520 to the tapered end 510A of the bowl 510 and out of the outlet port 511, and (3) a feed tube 550 for inserting the return mud into the bowl 510.
  • the conveyor 540 rotates along a horizontal axis of rotation 560 at a first selected rate and the bowl 510 rotates along the same axis at a second rate which is relative to but generally faster or slower than the rotation rate of the conveyor.
  • the cleansed return mud enters the rotating bowl 510 of the centrifuge device 500 via the feed tube 550 and is separated into layers 520, 530 of varying density by centrifugal forces such that the high-density layer 520 (i.e., the drilling fluid with density Mi) is located radially outward relative to the axis of rotation 560 and the low-density layer 530 (i.e., the light fluid with density Mb) is located radially inward relative to the high-density layer.
  • the high-density layer 520 i.e., the drilling fluid with density Mi
  • the low-density layer 530 i.e., the light fluid with density Mb
  • the weir plate 512 of the bowl is set at a selected depth (or "weir depth") such that the drilling fluid 520 cannot pass over the weir and instead is pushed to the tapered end 510 A of the bowl 510 and through the outlet port 511 by the rotating conveyor 540.
  • the light fluid 530 flows over the weir plate 512 and through the outlet 513 of the non-tapered end 510B of the bowl 510.
  • the return mud is separated into its two components: the light fluid with density Mb and the drilling fluid with density Mi.
  • the light fluid is collected in the light fluid collection tank and the drilling fluid is collected in the drilling fluid collection tank.
  • both the light fluid collection tank and the drilling fluid collection tank include a set of circulating jets to circulate the fluid inside the tanks to prevent settling of solids.
  • the separation skid includes a mixing pump which allows a predetermined volume of light fluid from the light fluid collection tank to be added to the drilling fluid collection tank to dilute and lower the density of the drilling fluid.
  • the light fluid collection tank includes a first outlet for moving the light fluid into the set of holding tanks and a second outlet for moving the light fluid back into the set of riser mud tanks/pits if further separation is required. If valve VI is open and valve V2 is closed, the light fluid will feed into the set of holding tanks for storage.
  • each of the holding tanks includes an inlet for receiving the light fluid and an outlet.
  • the light fluid can be pumped from the set of holding tanks through the outlet and re- injected into the riser mud at a location at or below the seabed via the riser charging lines using the set of light fluid pumps.
  • the drilling fluid collection tank includes a first outlet for moving the drilling fluid into the set of conditioning tanks and a second outlet for moving the drilling fluid back into the set of riser mud tanks/pits if further separation is required.
  • valve V3 If valve V3 is open and valve V4 is closed, the drilling fluid will feed back into the set of riser fluid tanks/pits to be run back through the centrifuge device. If valve V3 is closed and valve V4 is open, the drilling fluid will feed into the set of conditioning tanks.
  • Each of the active mud conditioning tanks includes an inlet for receiving the drilling fluid component of the return mud and an outlet for the conditioned drilling fluid to flow to the set of active tanks.
  • mud conditioning agents may be added to the drilling fluid. Mud conditioning agents (or “thinners”) are generally added to the drilling fluid to reduce flow resistance and gel development in clay-water muds.
  • these agents may include, but are not limited to, plant tannins, polyphosphates, lignitic materials, and lignosulphates.
  • these mud conditioning agents may be added to the drillmg fluid for other functions including, but not limited to, reducing filtration and cake thickness, countering the effects of salt, minimizing the effect of water on the formations drilled, emulsifying oil in water, and stabilizing mud properties at elevated temperatures.
  • the drillmg fluid is fed into a set of active tanks for storage. Each of the active tanks includes an inlet for receiving the drilling fluid and an outlet. When required, the drilling fluid can be pumped from the set of active tanks through the outlet and into the drill string via the mud manifold using a set of mud pumps.
  • treatment system of the present invention is described with respect to stripping a fluid from the return mud, it is intended that treatment system can be used to strip any material — fluid or solid ⁇ having a density different than the density of the drilling fluid from the return mud.
  • drilling mud in a single density drilling fluid system or "total mud system" comprising a light fluid with barite can be separated into a light fluid component and a barite component using the treatment system of the present invention.
  • total mud system each section of the well is drilled using a drilling mud having a single, constant density.
  • the shallower sections of the well may be drilled using a drilling mud having a density of 10 PPG, while the deeper sections of the well may require a drilling mud having a density of 12 PPG.
  • a drilling mud having a density of 10 PPG In previous operations, once the shallower sections of the well were drilled with 10 PPG mud, barite is added to form a denser 12 PPG mud. After completion, the mud would be shipped on shore for separation and retreatment and then back to the drilling unit.
  • the treatment system of the present invention may be used to treat the 10 PPG density mud to obtain the 12 PPG density mud without having to add barite and without the delay and expense of sending the mud to and from a land-based treatment facility between wells.
  • the treatment system of the present invention is described with respect to stripping the light density fluid from the combination return mud to obtain the original drilling fluid to be recirculated through the drill bit and the light fluid to be reinjected into the return mud stream (as shown in FIGS. 1 -2), it is intended that the treatment system of the present invention can be used to strip the light drilling fluid from a combination return mud to obtain the original light drilling fluid to be recirculated through the drill bit and the heavy fluid to be reinjected into the return mud column (as shown in FIGS. 4-6).
  • the treatment system includes a circulation line for boosting the riser fluid with drilling fluid of the same density in order to circulate cuttings out the riser. As shown in FIG.
  • the mud recirculation system includes a multi-purpose software-driven control unit for manipulating drilling fluid systems and displaying drilling and drilling fluid data.
  • the control unit is used for manipulating system devices such as: (1) opening and closing the switch valves 101 (FIGS. 1 and2) or lOOAand 100B (FIG.
  • control unit may be used to adjust centrifuge variables including feed rate, bowl rotation speed, conveyor speed, and weir depth in order to manipulate the heavy fluid discharge.
  • control unit is used for receiving and displaying key drilling and drilling fluid data such as: (1) the level in the set of holding tanks and set of active tanks, (2) readings from a measurement-while-drilling (or “MWD”) instrument, (3) readings from a pressure-while-drilling (or “PWD”) instrument, and (4) mud logging data.
  • MWD measurement-while-drilling
  • PWD pressure-while-drilling
  • mud logging data e.g., resistivity, natural gamma ray, porosity
  • wellbore geometry e.g., inclination and azimuth
  • drilling system orientation e.g., toolface
  • mechanical properties of the drilling process e.g., toolface
  • a PWD instrument is used to measure the well fluid pressure in the annulus between the instrument and the wellbore both while drilling mud is being circulated in the wellbore and static pressure.
  • a PWD unit provides real-time data at the surface of the well indicative of the pressure drop across the bottom hole assembly for monitoring motor and MWD performance.
  • Mud logging is used to gather data from a mud logging unit which records and analyzes drilling mud data as the drilling mud returns from the wellbore.
  • a mud logging unit is used for analyzing the return mud for entrained oil and gas, and for examining drill cuttings for reservoir quality and formation identification.
  • tubular member is intended to embrace “any tubular good used in well drilling operations” including, but not limited to, "a casing”, “a subsea casing”, “a surface casing”, “a conductor casing”, “an intermediate liner”, “an intermediate casing”, “a production casing”, “a production liner”, “a casing liner”, or “a riser”;
  • the term “drill tube” is intended to embrace “any drilling member used to transport a drilling fluid from the surface to the wellbore” including, but not limited to, “a drill pipe”, “a string of drill pipes”, or “a drill string”;
  • the terms “connected”, “connecting”, “connection”, and “operatively connected” are intended to embrace “in direct connection with” or “in connection with via another element”;
  • set is intended to embrace

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Abstract

L'invention concerne un système de contrôle de la densité de la boue de forage dans un emplacement situé au niveau du fond marin (ou juste au-dessus du fond marin) ou, en variante, en dessous du fond marin des puits d'applications de forage au large et à terre. La présente invention combine un fluide de base de densité inférieure/supérieure au fluide de forage nécessaire au niveau de l'outil de forage pour forer le puits, afin d'obtenir une boue de retour combinée dans la colonne montante. La combinaison de quantités appropriées de boue de forage avec un fluide léger permet d'obtenir une densité de boue dans la colonne montante identique ou proche de la densité de l'eau de mer, afin de faciliter le transport de la boue de retour à la surface. En variante, l'injection de quantités appropriées d'un fluide lourd dans une boue de retour légère permet d'équilibrer suffisamment la colonne de boue de retour pour protéger la tête du puits. A la surface, la boue de retour combinée passe dans un système de traitement pour nettoyer la boue des déblais de forage et pour séparer le fluide de forage du fluide de base. La présente invention comprend également une unité de commande de manipulation des systèmes fluidiques de forage, et d'affichage de données de forage et de données concernant le fluide de forage.
PCT/US2004/036328 2003-10-29 2004-10-29 Systeme de forage de petrole et puits de gaz pourvus d'un train de forage surdimensionne permettant d'atteindre des vitesses de retour annulaires superieures WO2005042911A2 (fr)

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US10/696,094 2003-10-29
US10/696,094 US20040084213A1 (en) 2001-02-15 2003-10-29 System for drilling oil and gas wells using oversized drill string to achieve increased annular return velocities

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US7651420B1 (en) * 2008-07-25 2010-01-26 Wilson Sporting Goods Co. Injection-molded ball bat
CA2771095C (fr) 2009-08-18 2017-11-07 Pilot Drilling Control Limited Soupape d'arret d'ecoulement
US9328575B2 (en) * 2012-01-31 2016-05-03 Weatherford Technology Holdings, Llc Dual gradient managed pressure drilling
US9249637B2 (en) * 2012-10-15 2016-02-02 National Oilwell Varco, L.P. Dual gradient drilling system
RU2524228C1 (ru) * 2013-04-23 2014-07-27 Федеральное государственное бюджетное образовательное учреждение высшего профессионального образования "Кубанский государственный технологический университет" (ФГБОУ ВПО "КубГТУ") Способ очистки наклонных и горизонтальных стволов скважин
CN110374528B (zh) * 2019-07-29 2023-09-29 中海石油(中国)有限公司湛江分公司 一种深水钻井中降低ecd钻井液喷射装置
CN115288625B (zh) * 2022-10-08 2023-03-24 廊坊开发区森德石油设备有限公司 一种冲砂打捞设备

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US20040084213A1 (en) 2004-05-06

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