Managed Pressure Drilling

SPE Advanced Drilling Technology & Well Construction Textbook

Chapter 9, Novel Drilling Methods, Section 10 – MPD

Don M. Hannegan, P.E., Weatherford International

MPD is a technology that offers more precise pressure

This draft reflects the results of two peer-review management throughout the open hole with fewer
processes: IADC UB & MPD Committee and selected interruptions to drilling ahead. MPD technology is synergistic
Operator “Champions” of MPD, February 8, 2005. with and compliments several other technologies, such as
Drilling with Casing (DwC).
Introduction The predominance of the text speaks to drilling for
Managed Pressure Drilling (MPD) is an advanced form of conventional oil and gas. However, MPD technology has
primary well control usually employing a closed and unique applications to coalbed methane, geothermal resources,
pressurizable drilling fluid system that allows greater and and drilling for commercial quantities of methane hydrates.
more precise control of the wellbore pressure profiles than
mud weight adjustments alone. The primary objective of MPD Background – Closed, Pressurizable Fluids Systems
is to optimize drilling processes by decreasing non-productive A closed and pressurizable circulating mud system, in its
time (NPT) and mitigating drilling hazards. most basic configuration, includes a Rotating Control Device
MPD specialized equipment and the techniques to practice (RCD), Drilling Choke, and drill string Floats (non-return
its various methods safely and effectively have evolved since valves). The RCD is considered the key-enabling tool.
the mid-sixties on U.S. land drilling programs to a point of Onshore and shallow water applications of RCDs use
status quo. Although the focus of this discussion will be MPD “surface models” that are typically mounted atop or on the
in marine environments, many of the methods presented have head of a typical Blowout Prevention (BOP) stack. Thus the
been well proven on land drilling programs, particularly in the common label, rotating control head.
United States. Deepwater designs may be configured to be atop a typical
It was not until 2003 that the enabling characteristics of the marine riser in the moon pool area of a floating rig. The
technology began to be more fully appreciated by offshore deepwater rig may have a subsea or surface BOP stack. If a
drilling decision-makers. MPD is a technology that addresses surface BOP is used drilling in deep water, the tool is typically
a growing number of offshore challenges associated with atop the surface annular within the moon pool. Another
drilling through “trouble zones”. Because primary objectives deepwater application involves a subsea BOP, marine riser,
of MPD are most often drilling cost related, such as reduction and one or two Annular BOP’s in the moon pool. In this
of non-productive time, the potential savings are much greater configuration, the RCD is mounted atop the Annular BOP in
when practiced in marine environments than onshore. the moon pool. Subsea RCD’s designs are applicable to
Therefore, this Section (9.10) will focus primarily upon riserless drilling and several variations of dual gradient deep
offshore applications of MPD tools and methods. A precursor water drilling.
to MPD technology is Section 9.2, Underbalanced Drilling In the 1960’s RCD’s enabled the practice of drilling with
(UBD). Many of the tools required for the practice of MPD are compressible fluids (gas, air, mist, foam) to flourish. Now
illustrated in the Section speaking to UBD. referred to as Performance Drilling (PD), value was realized in
the form of improved penetration rates and longer life of
Abstract drilling bits.
Drilling-related issues such as excessive mud cost, In the 1990’s, a relatively wide range of sizes, designs, and
differentially stuck pipe and resulting well control issues pressure-containment capabilities of RCDs evolved to meet
associated with lost circulation situations contribute to growing industry demand. Their usage became a key enabler
defining the offshore industry need for MPD technology. of UBD with mud and nitrified fluids and where the benefits
Kick-loss scenarios that frequently occur when drilling into are improved productivity from easily damaged reservoirs.
narrow downhole pressure environments also define a Over time, other uses of the tool evolved – uses other than
requirement to deviate from conventional methods. Excessive “air drilling” and “underbalanced operations”. The drilling
drilling flat time and HSE issues further indicate the necessity industry has learned to use the RCD and other “specialized”
for a technology that enables more precise wellbore pressure tools associated with UBD technology to more precisely
management, containment, and control. manipulate the annular hydraulic pressure profile when
These challenges to economic drill-ability apply to a drilling overbalanced. An influx of hydrocarbons during the
growing percentage of offshore prospects for oil and gas, drilling process is not invited. The assortment of techniques
becoming more troublesome and costly with water depth. that evolved is now referred to as Managed Pressure Drilling.
Most “drilling hazards” have one thing in common; they all Benefits include fewer incidents of lost circulation, less
may be addressed to some degree or other with more precise drilling non-productive time, reduced mud cost, less negative
wellbore pressure management.
2 [AUTHOR NAMES] [Paper Number]

environmental impact and enhanced control of the well during Today, many thousands of onshore drilling programs and a
the drilling process. rapidly growing number of offshore programs have proven
Today, about 50% of all wells drilled onshore in the U.S. that drilling with a closed and pressurizable mud returns
employ PD or UBD techniques to improve drilling system enables more precise wellbore pressure management.
performance or well productivity. MPD techniques are In recognition of the fact that interest in the various MPD
employed on another approximately 25 percent of all wells techniques was growing quickly, a Sub-Committee of the
drilled onshore in the U.S. In other words, three of every four IADC UBO (Underbalanced Operations) Committee was
land drilling programs drill at least one section of the wellbore established in 2003 as a technology transference vehicle. In
utilizing a Rotating Control Device. 2004, the name of the committee was changed to IADC
Underbalanced Operations and Managed Pressure Drilling
Performance, Underbalanced and Managed Pressure Committee (IADC UBO & MPD). The committee remains
Drilling – The differences comprised of several industry experts. An early deliverable of
the committee was to define Managed Pressure Drilling:
As mentioned - Closed, pressurizable mud returns systems
are required to practice UBD, PD and MPD. This “MPD is an adaptive drilling process used to more
commonality has naturally resulted in some asking - precisely control the annular pressure profile throughout the
specifically how do these three technologies differ? wellbore. The objectives are to ascertain the downhole
UnderBalanced Drilling (UBD) is drilling with bottomhole pressure environment limits and to manage the annular
annulus pressures intentionally designed and maintained hydraulic pressure profile accordingly.”
below adjacent wellbore reservoir pressures to invite fluid Technical Notes
influx. The primary objective of UBD is to enhance well  MPD processes employ a collection of tools and
economics and asset exploitation strategies by reducing techniques which may mitigate the risks and costs
drilling induced formation impairment, and by providing associated with drilling wells that have narrow
reservoir characterization. Typically a full surface complement downhole environmental limits, by proactively
of separation and flaring equipment is required to properly managing the annular hydraulic pressure profile.
handle hydrocarbons produced during the drilling process.  MPD may include control of backpressure, fluid
Performance Drilling (PD) is applying air, mist, or foam density, fluid rheology, annular fluid level,
drilling fluid systems to drill with sub-hydrostatic wellbore circulating friction, and hole geometry, or
pressures to increase drilling rate of penetration (ROP) and combinations thereof.
extend bit life. The primary objective of PD is to optimize  MPD may allow faster corrective action to deal with
drilling economics. observed pressure variations. The ability to
Managed Pressure Drilling (MPD) does not invite influx, dynamically control annular pressures facilitates
but one is equipped to contain any that may be incidental to drilling of what might otherwise be economically
the operation. The objective is to benefit from strengths of unattainable prospects.
UBD technology to more precisely manage the pressure “MPD techniques may be used to avoid formation influx.
profile throughout the wellbore and where the benefits are Any flow incidental to the operation will be safely contained
focused upon optimizing drilling processes by decreasing non- using an appropriate process.”
productive (NPT) and mitigating drilling hazards.
 Avoid exceeding the wellbore fracture gradient by drilling Methane Hydrates Drilling Applications of MPD
with a lighter-than-conventional wisdom drilling fluid.
 Maintain effective bottom hole pressures at or above It is perhaps an oversight that temperature management
formation pressures in the entire open hole. was not mentioned in the above definition of MPD.
 Perhaps apply backpressure when shut in to make jointed For example, MPD technology may be uniquely applicable
pipe connections, e.g., shut in BHP very close if not to drilling for commercial quantities of methane hydrates.
identical to the BHP when circulating and drilling ahead. Methane hydrates drilling is governed by Boyles Law, the
 Contain and control any influx that may be incidental to pressure and temperature relationships of gases.
the operation with a closed and pressurizable mud returns Methane hydrates or clathrates exist in huge quantities on
system and perhaps with other tools developed for UBD the slopes of continental shelves where pressures and
such as Wireline Retrievable Drill String Floats and temperatures are suitable and methane and water co-exist.
Downhole Deployment Valves (casing isolation valve). They are also found onshore in permafrost regions. They exist
In summary, a primary objective of UBD is to avoid naturally as a frozen crystalline lattice structure consisting of
damaging a pay zone’s ability to produce. UBD is generally molecules of water that have formed an open, cage-like lattice
reservoir-issue related. A primary objective of MPD is to that encloses molecules of methane. Depending upon the
address a litany of drilling-related problems or barriers to purity of the methane hydrate, it can contain between 70 and
economic drill-ability. MPD is generally drilling-issue 164 times the volume of free gas at standard temperature and
related. PD is UBD for the primary purpose of improving pressure vs. the volume of the hydrate prior to dissociation.
penetration rate. PD is generally drilling performance Methane hydrates must therefore not be allowed to
related. dissociate downhole during the drilling process. Temperature
management plus precise pressure management is required to
IADC Definition of MPD
[Paper Number] [PAPER TITLE] 3

drill for commercial quantities of methane hydrates without a

CONVENTIONAL CIRCULATION
well control incident.
Note: Ideally, static and dynamic
Categories of MPD pressures are comfortably
within formation pressure and
There are two Categories of MPD: fraction pressure windows
Figure 1
Reactive MPD – When planning to drill with
conventional-wisdom casing set points and fluids program, the
rig is equipped with at least with an RCD, choke, and perhaps
drill string float(s) as a means to more safely and efficiently T
deal with, for example, unexpected downhole pressure V
environmental limits, e.g., lower or higher pore or fracture D DYNAMIC
pressure than expected. For example, of the one-in-four U.S. BHP = HH(MW) + AFP
land drilling programs practicing MPD, most are practicing STATIC
Reactive MPD. As a means of preparing for unexpected BHP = HH(MW)
developments, the drilling program is equipped or “tooled up”
from the beginning to deal more efficiently and safely with
downhole surprises. This, in part, explains why some
underwriters require wells they insure be drilled with a closed BHP
and pressurizable mud returns system. psi
AFP
Proactive MPD – The drilling plan is designed from
the beginning with a casing, fluids, and open-hole program
that takes full advantage of the ability to more precisely Figure 2 illustrates that when drilling within narrow
manage the pressure profile throughout the wellbore. This formation pore pressure and fracture gradient margins, kick-
“walk the line” category of MPD technology is expected to loss scenarios often occur. Shutting the rig’s mud pumps off to
offer the greatest benefits to offshore drilling of conventional make a jointed pipe connection permits an influx of
oil, gas, and methane hydrates. Total depth objectives may be hydrocarbons into the wellbore, a “kick” that must then be
reached with fewer casing strings, less drilling non-productive circulated out. The hydrostatic head alone results in a BHP
time, fewer mud density changes and enhanced control of the that is less than the pore pressure of the formation at that
well. depth. Alternatively, when the hydrostatic BHP is near the
fracture pressure; starting the rig’s mud pumps to regain
MPD System Components circulation results in the additive of annulus friction pressure.
A conventional mud returns system typically consists of an HH + AFP results in a BHP that exceeds the fracture pressure.
open-to-the-atmosphere drilling or bell nipple, from where Mud losses, differential sticking, well control issues and/or
mud returns gravity flow away from the rig floor. loss of hole may occur.
At the essence of MPD technology is the ability to drill With the weight of the mud in the hole at the time, the only
ahead with closed and pressurizable mud returns. adjustment that can easily be made to BHP is pumping rate,
At the very minimum, such a system consists of a Rotating pumps on or pumps off.
Control Device (RCD) and drilling choke. The RCD contains CONVENTIONAL CIRCULATION – TIGHT MARGINS
and/or diverts pressurized mud returns to the choke manifold
and its Bearing and Drill String Seal assembly permits drilling Note: In tight margins, well can
ahead, tripping, etc. The RCD, choke, perhaps drill string Figure 2
flow statically, and lose returns
non-return valves (floats) and other specialized tools that may when circulating.
have been developed primarily for the practice of
underbalanced drilling (UBD) have unique application to
MPD. Reference: Section 9.2, Underbalanced Drilling.
T
Conventional - Hydraulics and Hydraulics Manipulation V
D
DYNAMIC
In conventional drilling, bottom hole pressure (BHP) is BHP = HH(MW) + AFP
determined by the sum of the mud weight (MW) hydrostatic STATIC
head (HH) and circulating annulus friction pressures (AFP). BHP = HH(MW)

BHP = HH(MW) + AFP

AFP is present when drilling ahead (rig’s mud pumps on) psi
AFP
and ceases to exist when shut down to make jointed pipe
connections (mud pumps off). See Figure 1.

MPD – Hydraulics and Hydraulics Manipulation

4 [AUTHOR NAMES] [Paper Number]

required for the practice MPD in marine environments will be

When practicing MPD with a closed and pressurizable illustrated.
mud returns system, another important variable can be added
to the equation for determining BHP. That variable is the The Offshore Environment
ability to apply a desired amount of backpressure (BP). When Today, at least half of all offshore drilling “prospects” are
drilling with an essentially incompressible fluid, surface economically undrillable with conventional drilling equipment
backpressure adjustments result in an almost instant change in and methods. The percentage is destined to increase over time
effective BHP. as reservoir pressures deplete and as requirements to drill in
deeper water increase.
BHP = HH(MW) + AFP + BP A major contributor to “economically un-drillable
prospects” is excessive costs stemming from drilling-related
In practice, one would not ordinarily desire to simply issues, problems, or barriers. Drilling-related situations such as
impose backpressure on a wellbore without benefit. In part, lost circulation, occurrences of differentially stuck pipe, twist-
this is why applications of MPD often combine a number of off’s, many mud density changes to T.D., kick-loss situations
variables when manipulating the annular pressure profile. See associated with narrow pore-fracture pressure margins
Figure 3. contribute significantly to a growing number of prospects that
are destined to exceed the drilling programs Authorization For
Expenditure.
All of the aforementioned drilling-related challenges have
MANAGED PRESSURE DRILLING CIRCULATION one thing in common – they indicate a requirement for more
BP Note: Backpressure is added at precise wellbore pressure management, containment, and
the surface. In this case, it would control with fewer interruptions to drilling ahead. Drilling in
Figure 3 cause lost returns at the shoe. marine environments with more precise pressure management
throughout the wellbore can address to varying degrees a
DYNAMIC significant amount of these conventional challenges.
BHP = HH(MW) + AFP + BP What is the “size of the prize”? A recent study has
quantified the causes of drilling-related non-productive time in
T the U.S. Gulf of Mexico (GoM) in water depths less than 600’.
V Approximately 22% of total days on a GoM location are non-
D
productive time. Lost circulation, resulting differentially stuck
pipe and twist off’s, kick-loss issues associated with narrow
downhole environmental limits, and flat time associated with
interrupting the drilling program to increase or decrease the
STATIC mud weight numerous times account for almost half of the
BHP = HH(MW) total number of days on average lost to NPT when drilling in
the GoM’s shallow water.
psi AFP + BP
To varying degrees, the lost drilling days in the GoM are
mirrored globally. In deep water, the cost of NPT is more
foreboding.
Perhaps as much as 10 to 15% of “borderline” drilling
Demand for Managed Pressure Drilling
prospects could be drilled economically if this 40% of the
In the U.S., drilling with a closed and pressurizable mud
NPT could be addressed with offshore application of managed
returns systems has been an evolving technique on land
pressure drilling technology. It would lead to more precise
drilling programs the last two decades. Less drilling flat time,
pressure management while drilling ahead, resulting in
less cost and enhanced well control have been the key drivers
enhanced well control and less frequent adjustments to mud
for land drilling programs to perfect the technique.
density. Additionally, overall productive time would be
Today, only about one-fourth of all U.S. land drilling
improved through faster ROP, and deeper casing set points. In
programs drill without such a system. One fourth use a closed
some cases, MPD would enable a well to be drilled to the total
and pressurizable mud returns system to practice true-state
depth (TD) objective with large enough hole diameter to
UBD for reservoir enhancement. One fourth require such a
assure economic success.
system for drilling with compressible fluids (air, gas, foam,
mist) for PD, and one fourth of the U.S. land rigs today are
Opportunities with MPD
practicing one of the several variations of what the industry
All variations of MPD involve the management of one or
has now defined as MPD.
more of the following:
Well-proven on land, the size of the prize for practicing
 Abrupt changes in pressure in the hydrostatic
MPD is greatest when applied to offshore drilling. The
column: The vast majority of this is done with the
purpose of this section is to further define MPD and outline its
RCH and choke. Backpressure can be imposed on
several variations in play today. “Early adopters” are
the wellbore in a controlled manner. Another method
practicing MPD today from all types of rigs, in shallow and
is to place a pump in the wellbore downhole, where
deep water. Offshore designs of specialized equipment
the pressure is boosted.
[Paper Number] [PAPER TITLE] 5

 Friction losses: The annular friction losses are  Dual Gradient and Deepwater Dual Gradient MPD.
additive to the hydrostatic column when circulating. When a wellbore is exposed to two different fluid
The magnitude is manipulated by altering the fluid density gradients, it is referred to as “Dual Gradient
rheology, the circulation rate and the annular MPD”. This is typically accomplished by injecting a
clearances (generally the outside diameter and length less dense fluid, into a parasite string attached to the
of the drilling assembly). casing or marine riser. Introducing air, inert gas, light
 Altering the fluid density: This can be done as a liquids or solids at this point decreases the fluid
change in mud density altogether or coupled with, for density from that point to the surface. Offshore, this
example, a surface choke and RCH to compensate for can be accomplished in one of two ways. First, a less
the loss in total BHP. Dual density gradients are also dense medium can be injected at some predetermined
common, as examples, using a parasitic string depth into the marine riser as a means to adjust BHP
strapped to the outside of surface casing into which a without changing base mud weight. Less dense
gas is injected, lightening the mud column above that mediums may include inert gas, light but separable
point. True riserless drilling, where mud returns to fluids, glass beads, or light solids such as plastic
the seabed, is also a form of dual density drilling. pellets. Another method of achieving a deepwater
 Wellbore strengthening is emerging as a new form of dual gradient is to actively pump the mud and cuttings
MPD. This process consists of manipulation of fluid returns from the seabed back to the surface through
temperature or solids content for the purpose of returns lines external to the drilling riser. In this case,
strengthening the wellbore, effectively widening the the drilling riser is filled with seawater. The intent is
window between fracture pressure and pore pressure, not to reduce the equivalent mud weight or effective
and making “walking the line” easier to do. BHP to a point less than formation pore pressure.
Instead, the intent is most often to avoid gross
Variations of MPD overbalance, and not exceed the fracture gradient. In
 Returns Flow Control (HSE) MPD. The objective is both cases, the wellbore is exposed to two fluid
to drill with a closed annulus returns system vs. an densities: one below the point of injection or
open-to-the-atmosphere drilling or bell nipple. For pumping, and one above that point. This form of MPD
example, a conventional production platform drilling can be run with or without a subsea RCH, although
operation may otherwise trigger atmospheric monitors there are advantages to having the subsea RCH. In the
and/or automatically shut down on-going production. case of gas injection into the riser, a surface RCH
 Constant BHP MPD, or “ECD Management” or must be run. See Figure 5.
“Low Head”. The objective is to drill with a slightly
DEEPWATER DUAL GRADIENT MPD
lighter-than-conventional-wisdom fluids program,
nearer balanced. When shut in to make jointed pipe Note: Dual gradient systems
connections, surface backpressure maintains a desired open margins in low overburden
or quickly increasing pore
degree of BHP overbalance, controlling influx. Note Figure 5
pressure environments.
the application of surface backpressure (BP), upper
left, in the illustration below. See Figure 4.

CONSTANT BHP MPD SINGLE DENSITY

T GRADIENT
V
Note: Ideally, AFP = BP, so BHP D
Figure 4 remains constant, and pressure
at weak zone is reduced.

DUAL DENSITY
GRADIENT
T
V
D BHP
STATIC psi
BHP = HH(MW) +BP
DYNAMIC
BHP = HH(MW) + AFP

Pressurized Mud Cap MPD. A method of dealing with risk of

psi severe loss circulation. A predetermined column-height of
AFP
heavy mud, perhaps the rig’s kill fluid, is pumped down the
“backside” via the rotating head. This “mud cap” serves as an
annulus barrier. Typically a lighter and non-damaging fluid,
perhaps seawater, is used to drill into the zone of depleted
pressure. Mud and cuttings are “single passed” or forced into
the otherwise troublesome zone. Result: lighter drilling fluid
results in an increase in rate of penetration (ROP). Mud
Figure 7
6 [AUTHOR NAMES] [Paper Number]

sacrificed into the depleted zone is less expensive than  Zero Discharge Riserless MPD, also known as “dual
conventional. Well control with total or near total losses. In gradient riserless drilling”. A subsea pump is used in
the reservoir, less invasive damage to the well’s ultimate conjunction with a subsea RCD. Result: Mud and
productivity. See Figure 6. cuttings are returned to the rig for proper disposal.
Effective BHP may be adjusted via subsea annulus
PRESSURIZED MUDCAP MPD backpressure and speed of both the rigs and subsea
pump(s). See Figure 8.
Figure 6 BP
HIGH DENSITY ZERO DISCHARGE RISERLESS MPD
FLUID
SINGLE DENSITY
Figure 8 GRADIENT EQUIVALENT
ALL RETURNS
INJECTED INTO
LOSS ZONE
T Pump
V Head
D
T FP
EQUIVALENT SINGLE V
D
DENSITY GRADIENT
MUDLINE

LOW DENSITY
FLUID, E.G., SEAWATER
BHP
psi
psi

 Riserless MPD. A subsea rotating device and remote

operated vehicle (ROV) is used when establishing a
subsea location via riserless drilling with seawater.  Compressible Fluids MPD. The concept of more
This is done prior to running the subsea BOP. A ROV precise wellbore pressure management has application
or subsea automatic choke adjusts backpressure at the to air, mist, foarm, and gas drilling mediums. An
mudline. Closing the subsea choke increases BHP, example is a downhole air diverter subbed into the
virtually as if the subsea location was being drilled drill string. The tool responds to a pre-set differential
with a marine riser filled with mud and cuttings. between drill string and annulus pressure. An amount
Result: a degree of overbalance greater than the of cuttings-free compressed air is diverterted into the
drilling fluid itself would impart, useful to control annulus. Improved hole cleaning in the upper hole and
shallow geohazards such as shallow water flow a corresponding decrease in annulus BHP results in a
 hazards. See Figure 7. greater differential pressure across a percussion
hammer. ROP increases. ROP increases and in some
cases allows drilling to a deeper depth in a “wet hole”
RISERLESS MPD than otherwise possible.
SINGLE DENSITY
 Deepwater Surface BOP Application of MPD. The
GRADIENT EQUIVALENT
SEAWATER initial purpose of drilling from a moored semi
GRADIENT submersible or dynamically positioned drill ship with
a surface BOP (SBOP) was to enable wells to be
drilled in water depths deeper than the depth rating of
BP the rig when utilizing a subsea BOP stack. However,
T AFP drilling with a SBOP enables many of the same MPD
V technologies otherwise available only to fixed rigs to
Figure 7 D
be exploited in deep water.
MUDLINE
 Continuous Circulating Concentric Casing (CCCC)
MPD. This process involves more precise and almost
instantaneous BHP management by utilizing hydraulic
friction control on the return annulus through
continuous annular fluid circulation. By pumping
additional volumes of drilling fluid through a
psi
concentric casing or drill pipe string, the bottom hole
annulus friction pressure is manipulated into seeing a
more steady state condition. By increasing the annular
fluid rate down the concentric casing during
connections by a volume equal to the normal stand
pipe rate, the down hole environment in the wellbore
 [Paper Number] [PAPER TITLE] 7

sees a more constant annulus friction pressure. pressure at the point of the pump, reducing the impact
Pressure spikes typically associated with making of the friction pressures on the bottom hole pressure.
jointed pipe connections may be eliminated or reduced See Figure 10.
significantly with this method. See Figure 9.

CONTINUOUS CIRCULATING CONCENTRIC CASING

DOWNHOLE PUMPING MPD
Note: Using less-than-conventional
mud density, well will be
Note: Ideally, BHP pressure would
dynamically dead, but may be
statically under-balanced
remain constant, either while static
or while pumping.
DYNAMIC
BHP = HH(MW) + AFP - Ppump
T
V
D T
DYNAMIC V
BHP = HH(MW) + AFP D

Ppump
STATIC
BHP = HH(MW)
STATIC
BHP = HH(MW)
psi
AFP

psi BHP

Advancing into the Offshore Environment:

Most associate the use of a RCD with underbalanced
drilling and air/mist/foam drilling and where a requirement for
such a tool is fairly obvious. In part, this explains why
 Wellbore strengthening MPD. In the early 1990’s, offshore drilling decision-makers have paid little attention to
work was done to investigate the impact of the tool: primarily due to a lack of interest in air drilling or
strengthening the wellbore by maintaining a sized inviting influx (UBD) when drilling in marine environments.
solids content in the mud which effectively plugged However, MPD does not invite influx during the drilling
the micro-fractures that occurred in weaker formations process. Instead, the ability to apply varying degrees of
as the mud density was increased. While this is not backpressure with a closed and pressurizable mud returns
MPD in the sense of requiring a closed and system is key enabling technology to contain and safely
pressurizable mud returns system, it achieves similar control any influx that may be incidental to the MPD
goals by widening the margin between pore pressure operation.
and fracture pressure in the wellbore. At the time of Use of a RCD, choke manifold, and drill string floats have,
this writing, there is renewed interest in this technique. more or less, become status quo in onshore operations. The
practice has increased from 15% of drilling programs in 1996
Figure 9 to 75% today. A positive HSE track record has been firmly
Figure 10 established and in fact, a properly executed MPD program
actually has less potential for hydrocarbons to surface than a
conventional open-to-the-atmosphere (bell nipple, drilling
nipple) mud returns system.
This sets the stage for drilling in marine environments with
closed and pressurizable mud returns systems.

 Downhole pumping MPD. A newly emerging Examples of MPD in Marine Environments

variation of MPD is through the use of a drilling fluid
powered pump in the drill string that adds energy to  The world’s first practice of Pressurized Mud Cap
the annulus fluid returns. Such an “ECD Reduction Drilling from a floating rig, July 2004. Drilling in
Tool” has the effect of creating an abrupt change in deep water into a formation that historically has
8 [AUTHOR NAMES] [Paper Number]

experienced gross loss of drilling fluid, excessive water, this variation of MPD was drilled using a
mud cost, well control issues, and significant drilling subsea RCD to divert the mud and cuttings to subsea
flat time, a major operator practiced the Pressurized pumps on top of the BOPs to return the fluids to the
Mud Cap Drilling (PMCD) variation of MPD. rig through lines external to the drilling riser. This
Several previous offset wells experienced significant well was drilled as the test well to a joint industry
mud cost and failed to reach the TD objective. A project. The objective was to prove that the
RCD enabled pressurized mud returns and its flexible technology worked to maintain a dual gradient profile
flowlines compensated for vessel heave. Result: The for all drilling, tripping, casing running, cementing
PMCD-MPD program avoided loss of costly and well control operations. (Proactive MPD,
conventional drilling fluid, reduced significantly NPT Deepwater Dual Gradient, rig with subsea BOP,
and achieved the TD objective. (Proactive MPD, subsea pumps, subsea RCD and flow-stop valve in
offshore Sarawak, East Malaysia, PMCD variation, the drill string.)
moored semi submersible with a subsea BOP and  The world’s first application of a process control
marine riser.) computer to maintain constant bottomhole pressure.
Process industries (chemical, refineries, pulp &
 Reactive MPD in shallow water, 2003, 2004. paper, etc.) have benefited from the use of closed and
Drilling from jackup rigs w/surface BOP offshore pressurizable systems for many decades. Today, few
Viet Nam and Denmark into formations that are found to be operating those systems without the
historically have initiated well control issues aid of process control (PC) computers. Greatly
associated with loss circulation and narrow pore- improved safety, more consistent product quality,
fracture margins. Although equipped to practice reduction of waste, lower energy consumption, and a
MPD, the expected and historical drilling-related more positive environmental impact have resulted.
problems did not occur on the first two wells in the A closed and pressurizable system is a key
operators’ drilling programs. However, the third characteristic of MPD. The previously mentioned
drilling program required the practice of drilling “worlds first” deepwater dual gradient drilling system
ahead with a closed and pressurizable mud returns field trials used a PC to assist in accomplishing a
system. Drilling ahead with a Marine Diverter more constant bottomhole pressure, pumps on and
Converter Rotating Control Device, typical drilling- drilling ahead or pumps off, say to make a jointed
related problems were avoided by being able to pipe connection.
quickly react to unexpected downhole pressure There is a strong argument that the use of PC
environmental limits. In this case, Reactive MPD operated choke manifolds will enable several
served as a type of insurance policy with cost- variations of MPD to offer the most complete
effective premiums. (Reactive MPD, Returns Flow benefits.
Control, HSE variation, jackup rigs with surface
BOP.).
Conclusion
 The world’s first practice of pressurized mud cap
drilling from a jackup rig with surface BOP, August At some point in the future, all wells, onshore and
2004. Offshore Angola, this variation of MPD offshore, will have to be drilled underbalanced. Today, a
enabled the operator to escape drilling and mud cost growing percentage of prospects are economically un-drillable
issues associated with drilling into a zone of depleted with conventional technology. Managed Pressure Drilling
pore pressure. (Proactive MPD, mud cap variation, offers a means to increase economic drill-ability and do so
jackup rig with surface BOP). short of inviting hydrocarbons influx. The practice of MPD
will increase recoverable offshore assets. MPD has a
 The first practice of MPD in the U.S. Gulf of commendable onshore track record that is being repeated in
Mexico, Outer Continental Shelf, December, 2004. marine environments.
South of Galveston, Texas in 940’ of water depth the
operator’s objectives were to: MPD technology is a more readily acceptable step-
~Significantly reduce lost drilling days due change towards the inevitable requirement to drill
to drilling within narrow fracture-pore margins. underbalanced. The closed and pressurizaable circulating mud
(kick-loss scenario) system characteristics of MPD is a necessary enabler of
~Simplify fluids program to only three base process control computer operated pressure management.
fluid densities to TD.
~Reduce ballooning. References
(Proactive MPD, Constant BHP variation, rig with Subsea MudLift Drilling Joint Industry Project: Delivering
surface BOP). Dual Gradient Drilling Technology to Industry, Ken L. Smith,
A. D. Gault, D. E. Witt and C. E. Weddle, SPE #71357, SPE
 The world’s first deepwater dual gradient well was ATCE, 30 September, 2001.
successfully drilled from a semi submersible rig in
the U.S. Gulf of Mexico, October 2001. In 810’ of
[Paper Number] [PAPER TITLE] 9

Pressurized Mud Cap Drilling from a Semi-Submersible SubSea MudLift Drilling: Design and Implementation of a
Drilling Unit, J. Terwogt, Shell Malaysia, George H. Medley, Dual Gradient Drilling System, J.C. Eggemeyer, M.E. Akins,
Signa Engineering, 2004 SPE/IADC Drilling Conference R.R. Brainard, R. Judge, C. Peterman, R. Theti, L.J. Scavone,
Application of an Automated Choke Manifold for SPE #71359.
Maintaining a Constant Bottomhole Pressure while Drilling,
Don Reitsma, Shell SIEP, 2004 SPE/IADC Drilling
Conference
New Downhole Isolation Valve Technology Reduces Costs
and Increases Capabilities of Underbalanced Drilling and
Completion Programs in the Southern North Sea, I. C.
Sutherland, Weatherford Drilling & Well Services, Brian
Grayson, Weatherford International, Inc., 2004 SPE/IADC
Drilling Conference
Well Control Considerations for Underbalanced Drilling,
Adam Ted Bourgoyne, Jr., SPE #38594, Distinguished
Lecturer Series
Pressurized Mud Cap Drilling: Efficient Drilling of High-
Pressure Fractured Reservoirs, R. Urselmann, J. Cummings,
R. N. Worral, & G. House, 1999 SPE/IADC Drilling
Conference # 52828
Deep Water Drilling Using Dual Gradient Mud System,
Neil Forrest, Tom Bailey, Don Hannegan, 2001 SPE/IADC
Drilling Conference, #67707
Redefining the Environmental Envelope for Surface BOPS
on a Semi-Submersible Drilling Unit, Kevin T. Gallagher,
David F. Bond, 2001 SPE/IADC Drilling Conference # 67709
Design of a Drilling Rig for 10,000’ Water Depth using a
Pressured Riser, Colin Leach, K. Dupal, C. Hakulin, B. Fossli,
J. Dech, 2002 SPE # 74533
Underbalanced Drilling Tools and Technology Solve
Conventional Offshore Drilling Problems, D. M. Hannegan,
Weatherford International, Inc., 2001, AADE #01-NC-HO-01
Petrobras Looks To A Smarter Future, Article by Rick
Von Flatern, p. 27-32, Offshore Engineer, October 2001
Practical Underbalanced Drilling and Workover, Bill
Rehm, University of Texas Petroleum Engineering Extension
Service textbook, 2002
IADC UBO Glossary of UBD and MPD terms,
[Link]
Rotary Drilling with Casing-A Field Proven Method of
Reducing Wellbore Constructions Cost, Greg Galloway,
Weatherford International, Inc., WOCD-0306-03, March 6-7,
2003
The 1999 LSU/MMS Well Control Workshop: An
Overview, John Rogers Smith, World Oil, June 1999
UBD Technology Offers Pathway to Solving Complex
Reservoir Problems, D. Brant Bennion, The American Oil &
Gas Reporter, February 1999
Well Control Consideration of UB Technology in marine
environments, Don Hannegan, Weatherford International, Inc.,
Glen Wanzer, University of Oklahoma Blowout Prevention
School, 2003 SPE/IADC Drilling Conference #79854
Problem Incidents Database, GoM Shelf Gas Wells, 1993-
2002; water depth <600’, James K. Dodson Company Study
IADC UBO MPD Sub-committee Meeting Minutes, Leiden,
The Netherlands, March 13, 2004
American Petroleum Institute Specification for Rotating
Control Devices, API-16RCD, 2005
IADC UBO & MPD Committee meeting minutes, Houston,
Texas, December 13-14, 2004