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Hollow Sphere Dual Gradient Drilling System

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Hollow Sphere Dual Gradient Drilling System. JIP Kickoff Meeting. Dr. William C. Maurer September 27, 2001. DOE Hollow Sphere Underbalanced Drilling Project. GAS. LIQUID. Types of Flow Regimes. AERATED. FOAM. MIST. LIQUID. Lightweight Mud. LIGHT WEIGHT. MUD. HOLLOW SPHERES. MUD.

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  1. Hollow SphereDual Gradient DrillingSystem JIP Kickoff Meeting Dr. William C. Maurer September 27, 2001

  2. DOE Hollow SphereUnderbalanced Drilling Project

  3. GAS LIQUID Types of Flow Regimes AERATED FOAM MIST LIQUID

  4. Lightweight Mud LIGHT WEIGHT MUD HOLLOW SPHERES MUD 1.02 S.G. 0.38 S.G. 0.70 S.G. 8.5 ppg 3.17 ppg 5.84 ppg

  5. Glass Beads

  6. Particle Sizes in Unweighted, Water-Based Mud(After Bourgoyne Jr. et al, 1986) MICRONS .01 0.1 1 10 100 1000 10,000 Drilled Solids Solids Percentage MESH Small Hollow Spheres Bentonite 200 100 20 60 SILT FINE SAND COARSE SAND GRAVEL

  7. Centrifuge Test

  8. Desilter Tests

  9. Oilfield Hydroclone(Moore et al., 1974) Overflow Opening (Hollow Spheres) Feed Inlet Feed Chamber Vortex Finder Vortex Underflow Discharge (Cuttings)

  10. Golden State Drilling Rig Mud System

  11. Mud Returns

  12. Dual Gradient Drilling Systems

  13. Hydrostatic Gradients for Conventional and Riserless Drilling(Snyder, 1998) Mud hydrostatic pressure (D) ( Riserless ) Mud hydrostatic pressure (C) Surface (Conventional) Casing Fracture (B) pressure Depth Seawater (E) hydrostatic Pore pressure (A) pressure Pressure

  14. Riserless Drilling System(Peterman, 1998) Mud Return and Pump Return Line Drillpipe Riser Diverter Mudlift Wellhead Pump and BOP BHA

  15. “DGD is estimated to save $9 million per well and increase the project value by $150 to $250 million at Crazy Horse” Andy Frazelle, BP (Wellconnected, Dec, 2000)

  16. “In an ultra-deepwater well, the savings could range from $5 - 15 million in casing running alone” Conoco, 2001 (Drilling Contractor, May/June)

  17. Mudlift System (Conoco/Hydril)

  18. Mudlift Pumping System

  19. Mudlift Subsea Diaphragm Pumps

  20. Mudlift Subfloor Module

  21. Mudlift Subsea Diverter

  22. Mudlift Drillstring Valve

  23. (Baker Hughes/Transocean) DEEPVISION System

  24. DEEPVISION Subsea Centrifugal Pump Electrical connections Pressure & volume compensator Motor cooling loop Strainer for compensator Filter for bearing pack Isolation valves for motor filters Isolation valves for Bearing pack filters Main filters Pump suction 6-Stage pump Pump discharge

  25. DEEPVISION Subsea Module 10,000 ft. Pump Station • 5-pump module station • Size: 15’ *17’ * 40’ • Weight: 350 kips • Max. available hhp 4050 • ANSI 2500 (6250 psi) rated • Standard riser joint connection • Independent of BOP MUX control system • Self contained power and control

  26. DEEPVISION Drillstring Valve VALVE SEAT & CONE VALVE PLUNGER DISC SPRING PACKAGE 4-3/4” Flow Stop Sub

  27. DGD Rock Removal Rates 12 12-1/4” Bit 8 Rock Removal Rate (tons/hr) 4 0 0 50 100 150 200 Drilling Rates (ft/hr)

  28. Shell SSPS System

  29. Shell SSPS DGD System(Offshore, June 2001) Existing Rig Pumps From Rig Power Power Control Mud Processing Water Depth 6 - Pumps Total Pump Section Nitrogen Tank Motor & Seal Control Module Level Sensor For Process Control Element Optional For Fluid Sep. Eductor Pump Check Valve

  30. SSPS Gumbo Slide & Mud/Gas Separation Nitrogen Tank Cut Away View Nitrogen Tank (Back-up) Gumbo Slide Mud/Gas Separator Cuttings Eductor Flowline Subsea BOP

  31. Dual Gradient Project Participation MUDLIFT • CONOCO* • HYDRIL* • BP • CHEVRON • TEXACO • DIAMOND OFFSHORE • GLOBAL MARINE • SCHLUMBERGER DEEPVISION • BAKER HUGHES* • TRANSOCEAN SEDCO FOREX* • BP • CHEVRON SSPS • SHELL

  32. Hollow SphereDual Gradient System

  33. Surface Hollow Sphere System Swivel Shale Shaker Mud Pump (Spheres) Spheres Mud Pump (Mud) Mud Drill Ship Mud Drillpipe Spheres & Mud Mud & Spheres Riser Wellhead and BOP Valve Mud Line Mud Drill String Valve Rock BHA

  34. Hollow Glass Sphere Technique Mixture Slurry Hollow Glass Spheres Mud

  35. New Seafloor Equipment DeepVision Mudlift Nothing Shell SSPS Maurer

  36. Sea Water Density Mud(50 % Spheres) LIGHT WEIGHT MUD HOLLOW SPHERES MUD 1.68 S.G. 0.38 S.G. 1.02 S.G. 14 ppg 3.17 ppg 8.56 ppg

  37. Mixture Density vs. Sphere Volume 18 Sphere Sp. Gr. = 0.38 16 14 12 Mixture Density, ppg 10 Mud Weight ppg 8 18 16 14 6 12 Sea Water 10 Water 4 0 10 20 30 40 50 60 70 Sphere Concentration (Volume %)

  38. Dual Gradient Mud Weights Sea Floor 10 12 14 Mud weight (ppg) 16 Fracture Gradient 18 Safe Zone Pore Pressure

  39. Single Injection Point Surface Mud & Spheres Mud & Spheres Riser Flow Line Valve Wellhead and BOP Sea Floor

  40. Multiple Injection Points Surface Valve 2,500’ Sea Water & Spheres 5,000’ Riser Flow Line 7,500’ 10,000’ Sea Floor

  41. Surface Sphere Separation Shale Shaker Hollow Spheres Seawater Mud Drill Cuttings

  42. Large and Small Hollow Glass Spheres

  43. Particle Sizes in Unweighted, Water-Based Mud(After Bourgoyne Jr. et al, 1986) MICRONS .01 0.1 1 10 100 1000 10,000 Drilled Solids Large Hollow Spheres Solids Percentage MESH Small Hollow Spheres Bentonite 200 100 20 60 SILT FINE SAND COARSE SAND GRAVEL

  44. Relative Particle Size (Microns) 50 Small Hollow Spheres 147 100 Mesh Screen 300 Large Hollow Spheres 1700 Frac Sand (12 mesh)

  45. Composite Hollow Spheres

  46. Composite Sphere Densities Foam System Density (g/cc) Water Depth (ft) Thermoplastic Macrospheres GRE Minispheres Carbon Fibre Minispheres PVC 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 11000 12000 13000 15000 0.25 0.36 0.28 0.34 0.36 0.39 0.43 0.44 0.48 0.53 0.53 0.40 0.41 0.45 0.48 0.51 0.55 0.60 0.62 0.65 0.43 0.45 0.46 0.48 0.50 0.53 0.56 0.59 0.61 0.66

  47. Riser Buoyancy Modules

  48. Solids Separation