dgd the system dea 2011
TRANSCRIPT
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Dual Gradient Drilling
The System
DEA Presentation
June 23, 2011
David Dowell
Chevron North America Exploration andProduction Company
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With DGD, We
Literally Replace
the Mud in the
Drilling Riser witha Seawater-
Density Fluid and
Use a Denser
Mud Below the
Mudline.
2
Same Bottom
Hole Pressure
Dual Gradient Drilling:
Working WITH Nature,
Not Against Her
Dual Gradient
Heavier Mud w/
Seawater Density
Above MudlineSingle
MudWeight
Conventional
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Impact in Deepwater: Casing Point Reduction
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Seawater
Hydrostatic
Single Gradient
Density at TD
Seafloor
Depth
Pressure
Fracture
Pressure
5 Casing Points Conventionally
TD
Pore Pressure
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Fracture Pressure
Seawater
Hydrostatic
Seafloor
Depth
Pore Pressure
Pressure
3 Casing Points
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TD
Dual Gradient
Density at TD
Casing Points Dual Gradient
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Dual Gradient Drilling
Defined Major Components
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Subsea Rotating Device (SRD)
MudLift Pump (MLP)
Mud Return Line
Drill String Valve (DSV)
Solids Processing Unit (SPU)
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Normal Drilling The U-tube Is Balanced
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Sea Level
Mud Line
Drillstring Annulus
Bottom HoleBit
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DGD Drilling The U-tube Is Unbalanced
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Sea Level
Mud Line
Drillstring Annulus
Bottom HoleBit
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The Drill String Valve Arrests the Natural U-Tube
Valve in BHA
3 Sizes
Evaluating two Major
Companies Designs
Will be Tested in
Top-hole Operations (JIP Design)
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About the Drill String Valve
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Not essential
Makes operations easier
Arrests the U-tube
Faster connections
More certainty in kick detection
Easier to stop the MLP
Helpful in flow rate management
Helpful in well control pressure reading
Run above the BHA, you cant wireline through it
Two builders
Mechanism of operation, not intuitive
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DGD Subsea Component Stack-Up(Not to Scale)
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Subsea Rotating Device (SRD)
Solids Processing Unit (SPU)
MudLift Pump (MLP)
Subsea Manifold
Standard BOP Stack
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The Worlds First DGD-Ready Rig, the Pacific Santa
Ana, will be Delivered in 1Q12.
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Surface Changes
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Six rig pumps
Three for power fluid and Three for mud
One back-up for each fluid stream
Additional trip tank (riser fluid)
More piping for handing up to 3 fluids at once
Pits divided for multiple fluids
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Return Line Manifold And A Drilling Choke
Provides a way to
divert mud to: The pits
MGS
Rig choke
Drilling Choke
Drilling Choke
prevents uncontrolled
expansion of return
line gas
Riser FluidTrip Tank
ChokeLine
MUD TRIPTANK
MUDLINE
Pit System
MGS
System
Drilling
Choke
To Rig ChokeTo Pits
Mud
ReturnLine
(MRL)
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Tripping and Displacement Manifold
Returns
Mud from Line A
Mud from Line B
Mud from Line C
Mud from Trip Tank
Choke
Line
MUDLINE
Kill
Line
Mud
Return
Line(MRL)
Allows for management of fluids in:
Choke and Kill Line
Riser
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The Drilling Riser is Modified
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MudLift Pump is Seawater-Powered, so Riser Modifications
are Needed
Two Six inch Lines
Seawater Power Mud Return
No Boost Line
3.5MM lb Flange rating
Standard 15K C&K lines
ChokeLine
Kill
Line
Hydraulic
Line
Mud Return
Line
Seawater
Power
Line
Drill Pipe
Hydraulic
Line
Flange End of Riser
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DGD Subsea Component Stack-Up(Not to Scale)
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Subsea Rotating Device (SRD)
Solids Processing Unit (SPU)
MudLift Pump (MLP)
Subsea Manifold
Standard BOP Stack
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The Subsea Rotation Device (SRD)
Provides a interface between riser and the wellbore
Has the SRD Bypass built into it
Mechanical latching mechanism on the Bearing insert
Rated for: Pressure from below - 2,000 psi Static 1,000 psi rotating
Pressure from above - 1,000 psi static and rotating
Controlled by the MLP control system
Choke and Kill lines pass through it
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SRD Joint and Insert
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Subsea Rotating Device Separates Mud from Riser Fluid
Located above the Solids Processing
Unit in the DGD System
The Active guts: seals and bearings
are retrievable
Seals pressure from both below and
above, typically 50 psi, up to 1000 psiWP
Maintains the gradient interface
Allows for rapid Managed Pressure
Drilling type operations
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2011 Chevron U.S.A. Inc. All Rights Reserved.
This material is proprietary information of Chevron U.S.A. Inc. and is Confidential Restricted Access to specific,
authorized individuals only. Unauthorized modification, duplication or distribution of this material is expressly
forbidden.
SRD and SPU Must Fit Through the Rotary
Santa Ana has a 72 rotary
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DGD Subsea Component Stack-Up(Not to Scale)
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Subsea Rotating Device (SRD)
Solids Processing Unit (SPU)
MudLift Pump (MLP)
Subsea Manifold
Standard BOP Stack
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The Solids Processing Unit (SPU)
Part of a riser specialty joint
Provides feed of mud to MLP
Sizes solids to 1-1/2 or smaller
Controlled and powered by the MLP
control system
Choke and Kill lines pass through it
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Tears Everything to Pumpable Sizes
Sits in Riser below SRD Two separate feed paths
Can be flushed in multiple ways
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DGD Subsea Component Stack-Up(Not to Scale)
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Subsea Rotating Device (SRD)
Solids Processing Unit (SPU)
MudLift Pump (MLP)
Subsea Manifold
Standard BOP Stack
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The Heart: GEs MudLift Pump
Delivery in 3Q2011
(2) Triplex modules
80 gallon chambers
1800 gpm max rate
10,000 WD rating
18.5 ppg mud
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PUMP SECTION
HYDRAULICS
VALVEMANIFOLD
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About the MLP
Built by GE/ Hydril
Made the original unit that was field
tested
Modernized
About 18 x 18 x 30 high About 450,000 lbs
MULTIPLE redundancies
Operates with six cylinders, five,
four, three or even two in a pinch
Powered by SEAWATER
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Emergency Disconnect
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BOPE systems are NOT changed
Disconnect is at the LMRP and MLP comes with the
LMRP
Disconnected dynamics are similar to conventional
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Pump Modularization
Pump can be broken into
separate lifts for initial lift onto
rig
Triplex Modules are
Interchangeable Mirror Images
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Reliability -Initial Endurance Testing
Complete.
Second Phase Starting Pumping
Continuously
Pumped 500,000Cycles
The equivalent of 3wells/~1 year!
Tear Down and X-rays revealed NOCHANGES inDiaphragms
Phase II TestingUnderway
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http://localhost/var/www/apps/conversion/tmp/scratch_3/MudliftPump_Function_Lg_Prog_001.wmvhttp://localhost/var/www/apps/conversion/tmp/scratch_3/MudliftPump_Function_Lg_Prog_001.wmv -
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DGD Subsea Component Stack-Up(Not to Scale)
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Subsea Rotating Device (SRD)
Solids Processing Unit (SPU)
MudLift Pump (MLP)
Subsea Manifold
Standard BOP Stack
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Subsea Manifold
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Most Valves are5K
Provides
Versatility
Most operations
conducted offline
Redundant Flow
Paths
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DGD Subsea Component Stack-Up
(Not to Scale)
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Subsea Rotating Device (SRD)
Solids Processing Unit (SPU)
MudLift Pump (MLP)
Subsea Manifold
Standard BOP Stack
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Subsea Stack
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The BOP Stack is
unchanged
Once extra valve placed in
the Choke line for
improved operations Still have complete
conventional Well Control
available.
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People Preparation is Extensive
Drilling Engineers: How to Design DGD Wells and
Secure Permits
Drill Site Managers, Field Drilling Engineers, FDEs and
Rig Crews: How to Perform DGD Operations (Routine
and Well Control)
Offshore Support Personnel: How to maintain, trouble-
shoot and repair equipment
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People Preparation Starts with HAZOPS
HAZOPS
JIP Drilling
Procedures
Well Control
Procedures
TrainingSimulator
Permits
FORMS BASIS FOR:
New detailed procedures,
Well design tools/software,
Revised training material,
Improved simulator
Valve manifold layout,
Specialized drilling equipment mods,
DGD System Control philosophy andscreen layouts, etc.
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Initial HAZOPS Were Completed in 2010
9 months Effort
Feb 10 Oct 10
~ 22 All-Day HAZOPS
covering nearly 50 DGD
operations and wellcontrol procedures have
occurred.
Tremendously valuable
learning exercise.
Total Man-years todate: ~20!
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W B ildi W ll D i T l t F ilit t W ll D i f
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Were Building Well Design Tools to Facilitate Well Design for
our New DGD Drilling Engineers
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Control Philosophies are Agreed and Drillers Panel
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Control Philosophies are Agreed and Drillers Panel
Layouts are the Result
Setting Level
Alarms
Recording
Trends
Monitoring
Trends
Picking Mode
of Operation
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All f th Thi I t d i t T i i
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All of these Things are Incorporated into Training
Programs and the Pre-Spud Meeting
DGD P j t S h d l
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DGD Project Schedule
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Procure/Fabricate FAT/SITMudLift Pump
Procedures/Plans
Select Rig
HUC
Ship Fabrication
Pacific Santa Ana
Training/Pre-spud
Begin Ops
HAZOPS
Train/Pre-spud
Well Plans
SailFabrication at Samsung Heavy Industries, S. Korea
Commission DGD
4Q09 1Q10 2Q10 3Q10 4Q10 1Q11 2Q11 3Q11 4Q11 1Q12
DGD: The Future is Here!
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DGD: The Future is Here!
Its Only Just Beginning!