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Casing Drilling

CBHP MPD

Pruitt recently expanded their range of Constant Bottomhole Pressure (CBHP) Managed Pressure Drilling (MPD) solutions to include 'MPD - Casing while Drilling' when they provided unconventional CBHP MPD solution to two different operators in North America. These operators had to set aside their plans to drill on these multi-well pads for over a decade because of extreme faulting and fracturing associated with these formations, practically eliminating any drilling window before reaching the Target Depth.

Challenges/Problems

Extreme fracturing and faulting in the formation resulted in several failed attempts to reach TD forcing different operators to wait for more than a decade to drill in these formations. Non-existing drilling pressure window to reach TD with CBHP MPD setup using conventional drillpipe and BHA, due to drilling issues related to extremely narrow pressure windows, such as: surge-swab cycles, kick and loss cycles, casing running and cementing issues.

Action/Solution

Design, plan, and execute CBHP MPD in 2 phases – (1) drill with conventional drillpipe & BHA using CBHP MPD until drilling window ceases to exist, (2) drill with CBHP MPD Drilling with casing to TD.

Execution/Results

Successfully drilled to Target Depth and completed multiple wells by staying within the pressure window. Any influx volume was limited to less than the maximum allowable limit using Pruitt’s advanced kick detection system and was circulated out safely using Pruitt’s CBHP MPD equipment.

Details

• On these wells losses were seen very early. Drilling continued with Anchor Point MPD (100 ±50 psi hydrodynamic/circulating and 800 ± 200 psi hydrostatic) followed by drilling with casing with similar backpressures.
• The drilling, connections, trips and fluid displacements, casing running and drilling, and cementing operations were simulated using advanced drilling software and executed with the required amount of hydrostatic and/or hydrodynamic backpressures.

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Unsticking Differentially Stuck Pipe

An operator in Canada utilized Managed Pressure Drilling (MPD) to successfully unstick differentially stuck pipe. A constant bottom hole pressure (CBHP) MPD solution was designed and executed by optimizing the static and dynamic surface backpressures. MPD provided enough flexibility for the operator to safely reduce the wellbore pressure below pore-pressure and decrease the differential pressure to free the pipe.

Action/Solution

Design, plan, and execute CBHP MPD to lower differential pressure and work pipe to free it.

Execution/Results

Successfully released pipe by reducing the wellbore pressure below the pore-pressure to reduce the differential pressure and pulling on the pipe. The influx volume was limited to less than the maximum allowable limit, and was circulated out with MPD.

Details

• Drillpipe stuck differentially and the pore pressure gradient was very close to the mud density used.
• Using CBHP MPD and applying 5500 kPa surface backpressure, 36m3 of .90 SG base oil was placed in the annulus which diluted to 1.37 SG equivalent BHP. Base oil was displaced by 1.67 SG mud.
• When the rig was ready to work pipe, backpressure was released and the pipe was pulled four times, then torqued and pulled twice again to get it free. A total of 2.2 m3 was introduced into the annulus in 18 minutes of operation.
• The 5500 kPa backpressure was re-applied while the influx was circulated out using MPD equipment.

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MPD Cementing

Cementing Solution for Problem Formations

'Managed Pressure Cementing' or 'MPC' is a cementing solution for narrow and ultra narrow pressure windows that cannot be cemented using conventional methods. MPC is a variation of Managed Pressure Drilling (MPD) technology and works on the same principles as MPD.

Challenge/Problem

Cementing pipe in formations that have narrow/ultra narrow pressure windows and challenges such as (a) severe loss of circulation, (b) low formation leak-off, (c) low formation strength, (d) highly faulted and fractured formations, (e) high pressure fluid flows, (f) formation stability issues, etc.

Action/Solution

Perform MPC by using Constant Bottomhole Pressure (CBHP) MPD principles to minimize losses and avoid formation fluid gains, and to place cement at desired depth(s).

Execution/Results

Pruitt Optimal has successfully planned and executed MPC on multiple projects (10+) in USA to cement pipe using static and dynamic Surface Backpressure.

Details

• An operator in US cemented several wells on a multi well pad using MPC on their production openhole section. MPD was used for drilling the openhole on both intermediate and production sections on 8 wells, while MPC was used on 5 of these wells (≤ 0.5 ppge pressure window).
• Another operator in US had multiple wells with a very high permeability and communication across multiple formation layers in the production hole. The objective was to stay within a 0.5 ppge window while cementing entire production hole section using multiple density cementing fluids.

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Curing Losses

Managed Pressure Drilling (MPD) helps drill through conventionally un-drillable severe lost-circulation zones and highly fractured and faulted formations with minimal losses. Constant Bottomhole Pressure (CBHP) and Region of Controlled Pressure (RoCP) sub-variations of MPD, successfully designed and executed by optimizing the surface backpressure in static and dynamic conditions, come to the rescue.

Challenges/Problems

Drilling through highly fractured and faulted formations or formations with lower leak-off / fracture gradient minimizing losses and without inducing any kicks.

Action/Solution

Use CBHP MPD and its sub-variations to drill through the formations by optimizing the surface backpressure.

Execution/Results

Multiple wells (20+) in US and Canada were drilled using MPD minimizing the loss and avoiding kicks. MPD enabled faster reaction because of the info gathered through Coriolis meter.

Details

• One operator in WY drilled multiple wells through faults that had a very high permeability and communication across multiple formation layers. The wells were using CBHP and RoCP to reach the target depth. The operator minimized losses and TD all wells. This operator waited several years (>5) to drill in this part of their lease because of severity of losses anticipated.
• Another operator in WY drilled multiple wells with MPD and used MPD for cementing the production casing. The objective of the operator was to avoid formation losses when circulating the high density cement.
• Another major in Canada minimized losses when drilling through narrow pressure windows, and avoided kick-loss catch 22.

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Modular MPD Flexibility

Two operators: One in Canada, the other one in the USA have utilized the flexibility of Pruitt MPD Lite™ Modular system to meet their changing MPD requirements onsite.

Challenges/Problems

Changing formations and unknown regional geology leads to cautions MPD planning.

Action/Solution

Flexible MPD Modular system easily can be tailored to a client’s needs in MPD designing phase or onsite.

Execution/Results

Two operators in separate countries (Canada and USA) have now fully utilized the flexibility of Pruitt’s MPD Lite™ Modular system, made operational cost savings and time.

Details

An Operator in Canada and in the USA used Gen-2 package of Pruitt MPD services and configured the same package to meet their changing well requirements.

• Both a Canadian and USA based land operators have started off with a full dual automated MPD choke system, complete with IPRV and bypass manifold.
• During their drilling programs, based on their perceived drilling risk they have customized the MPD system to suit their well knowledge based on the previous operations.
• The Canadian Operator started operation with a full system. They initially dropped both IPRV’s and switched from dual chokes to single choke system onsite. After realizing that they had a potential for exceeding the fracture gradient, they settled on using single automated choke, IPRV and bypass.
• The US Operator started off with a full MPD system as well and based on previous operations data they dropped full MPD system down to a single automated choke with bypass system onsite.

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Successful Results

Managed Pressure Drilling has a growing acceptance in the drilling industry as a means by which to mitigate certain drilling related problems such as narrow drilling windows or wellbore stability issues, among others. Benefits of MPD include enhanced primary well control, mitigating ballooning events, increased ROP, reducing drilling mud costs, mitigating differential sticking events, and better cementing operations in loss zones.

When faced with these drilling related issues, successful results require a service oriented MPD well engineering approach along with dependable equipment and good field personnel.

Action/Solution

Pruitt MPD Services’ business model is to provide a strong client-focused well engineering team, highly competent and trained MPD personnel, industry leading equipment, cradle to grave asset management, and a robust maintenance inspection plan.

Execution/Results

In the past two years, Pruitt MPD Services has executed MPD operations on nearly one hundred wells in the USA and Canada with a 96% average Client Satisfaction Rating.

Challenge/Problem

The challenge, especially in North American land drilling business units, is for operators to have engineers or subject matter experts who know and understand how to best utilize MPD to manage drilling related problems.

Conclusion

How do we attain high client satisfaction rating job after job? We plan and work with PRIDE! Great people, planning, preparation, and equipment lead to successful operations.

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MPD Solution: PRCD 1509 Casing Tripping

Pruitt PRCD 1509 tripped over 20,450 ft of 5 ½ inch TENARIS BLUE casing with surface mud temperature and pressure averaging 130° F and 630 psi on a single RCD element. Evidence on raising industry standards for performance.

Equipment Details

The PRCD 1509 is a single or dual element, drill through bearing assembly with a static pressure rating of 1500 PSI. This model has been designed with a 9-1/32 inch drill through bore to allow for large drill pipe as well as smaller casing and other drill string components.

The PRCD 1509 comes equipped with a recirculating hydraulic power unit and clamp operating stand. The recirculating power unit is designed to circulate, cool, and filter the lubricating oil used in the closed-loop lubrication system. This added feature ensures longer life and durability of the bearing assembly.

Operational Success

Pruitt MPD Services recently completed an HPHT MPD drilling operation for a valued client. After drilling was completed, a total of 20,471ft of 5 ½” TENARIS BLUE casing was tripped in the hole using only one RCD element. This was achieved using the PRCD 1509 with its 9-1/32 inch pass through bearing bore.

While running the casing, surface back pressure averaged 630psi with pressures up to 710psi in OBM with surface temperatures of 130° F.

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