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Continuous Circulation
Drilling
Improved
safety & production
Pressure
Connections
etc
Temporary
surge
Temporary
swab
Depth
Circulating
pressure
Static
pressure
Clearly, the solution is to keep the circulation of drilling fluids steady and
continuous, throughout the drilling of each section, or to try to compensate
for these wild pressure variations each time circulation is stopped.
Until recently, continuous circulation was not commercially available. As a
result several competing Managed Pressure Drilling (MPD) technologies
came on the market to try to maintain a steady/constant downhole pressure,
while circulation was stopped to make connections.
However, none of these commercially developed MPD techniques,
completely compensate for the pressure variations when circulation is
stopped, as will be explained later.
The solution
Pressure
Connections
etc
.
Depth
Circulating
pressure
Top Drive
Pressure
Mud
in
Mud
out
Coupler
Mud
Subsea BOP
Pressure in
drill string
Cased
Hole
Fracture
Pressure
Last
Hydrostatic
Pressure
Pressure in
annulus
Pore
Pressure
Exposed
Formation
Bi
Depth
Pressure in
annulus, when
circulating
Pore
Pressure
Static Annulus
When circulation stops, the static mud
pressure gradient across the exposed
formation is lower than the dynamic
pressure gradient.
In this situation, most MPD providers aim
to keep the bottom hole pressure steady
(at d), by imposing pressure on the
annulus at the surface, resulting in the
pressure at, or near, the last casing shoe
(at Y) being greater than when circulating
and may enter the frac pressure zone.
Fracture
Pressure
Pressure in
annulus, when
static & back
pressured
Pore
Pressure
Fracture
Pressure
Pressure in
annulus, when
static & back
pressured
Pore
Pressure
d
Z
Drilling problems
minimised or eliminated
Improved
safety & production
Eliminated Problems:
Formation Fracturing
Lost circulation
Differential Sticking
ECD variations
Stuck Pipe
Connection Kicks
Conventional Drilling
The solution
Pressure
Pressure
Connections
Connections
etc
etc
Temporary
surge
Temporary
swab
Depth
Circulating
pressure
Depth
Static
pressure
Circulating
pressure
The solution
The downhole steady state fluid dynamics established while drilling, is best
left undisturbed. Stopping and re-starting circulation take the dynamics
through many changes in turbulence (quantity and location) and, in unstable
formations, inevitably erode the exposed formation wall, more than if
circulation is continuous and steady.
Continuous circulation therefore, provides the best conditions for establishing
a minimum filter cake and minimising erosion of the exposed formation.
The steady pressure, throughout the drilling of the section, is most likely to
minimise the loss of mud to the formation. The continuous return flow means
that any variation can be taken as an early sign of lost circulation or a kick
and the response can be quicker and therefore more effective.
P2
P1
P2
P3
P3
Initial sticking
P2
P3
P1
P2
P3
The solution
Continuous Circulation allows the differential between the mud pressure and
the pore pressure to be kept continuously at the optimum pressure for drilling
the particular formation.
The lower continuous circulation differential pressure, reduces the lateral
force on the drill string; and, provided the drill string is in tension before
rotation is stopped, the possibility of differential sticking is greatly reduced.
If, while drilling with continuous circulation the drill string still becomes stuck,
the differential pressure can be temporarily adjusted to underbalance the
formation, reverse the sticking force and free the pipe, allowing drilling to be
resumed without undue delay.
Opinions vary on the effect of circulation and rotation on differential sticking
and, certainly, the longer a stuck pipe is left without taking remedial steps the
more stuck the pipe becomes.
The general agreement is that the following actions minimise the possibility
of differential sticking - in order of importance:
a) Maintain a low differential (balance) pressure, while drilling.
(Possible with Continuous Circulation or Stop/Start Circulation + MPD)
b) Avoid pumping up the formation with stop/start circulation.
(There are no pressure changes at all, with Continuous Circulation Drilling)
c) Maximise lubricity and minimise gel in the drilling fluid.
(This is achievable with Continuous Circulation Drilling)
d) Raise bit off bottom to ensure drill string is in tension, before stopping
rotation. (Continuous Circulation turbulence helps to keep the drill string
loose while stationary); and re-start rotation before returning to bottom.
e) Rotate drill string, slowly, at rotary table level, while it is disconnected for
lengthy periods of time. (Likely development for the CCS in future).
If differential sticking occurs while drilling, be prepared to go temporarily
underbalanced, to reverse the sticking force, and pull out of hole, without any
rotational torque. (Much easier to perform safely with mud continuously
circulating, in Continuous Circulation Drilling.)
10
The solution
By using a CCS, circulation is uninterrupted and the transport of cuttings and
debris continuous with no opportunity to settle and build up. The continuous
mud flow keeps cuttings moving and the hole clean while connections are
being made.
Continuous circulation does not pump up the formation, or change the down
hole pressure dynamics, both of which can damage the borehole wall and
make it increasingly unstable.
The steady state downhole pressure and flow conditions, maintained by
continuous circulation, are the best way to construct boreholes in sensitive
formations and will minimise the chances of stuck pipe.
11
The solution
When circulating continuously, the transport of cuttings and debris is
continuous back to the shale shakers, with a steady temperature, minimal
density changes and no slugging.
Mud flow continues at a steady flow and temperature during tool joint
connections, cleaning the hole and increasing the efficiency of cuttings
separation across the shale shakers and the mud treatment process.
Since the mud flow is continuous, the gel strength can be reduced and the
chemical composition optimised to provide a thin, tough filter cake.
12
The solution
By maintaining continuous circulation, during tool joint connections, the
circulating pressure in the borehole can be carefully set and controlled to
remain steady across the whole exposed formation from the bit to the last
shoe.
Additionally, because there is no change in the downhole pressure regime,
(static plus dynamic head and an established turbulent flow) the borehole
fluid dynamic situation can therefore be called truly steady state. This
enables an extended length of the each hole section to be drilled through
narrow frac pressure / pore pressure windows.
13
The solution
By maintaining continuous circulation, during tool joint connections, the mud
pressure in the borehole can be carefully set and controlled to remain
steady across the whole exposed formation from the bit to the last casing
shoe.
In long laterals and ERD wells, continuous circulation allows each nearhorizontal section to be extended. As above, each section length will be
limited by the difference between the Pore and Frac pressure. Utilising
continuous circulation drilling, this only has to exceed the dynamic pressure
drop from bit to the last casing shoe. Consequently the section can be much
longer before casing is required, which is most valuable.
Continuous circulation allows the continuous transportation of cuttings
throughout the making of connections, eliminating any time for stagnation
and minimising cuttings settlement.
In lateral boreholes, the continuous steady state mud pressure, flow,
temperature and density, provide the best means of constructing and
maintaining a long and stable open hole, before committing casing.
14
The Solution
Continuous circulation provides a steady state down hole pressure and flow
regime, which greatly reduces the possibility of damage to the wellbore.
Continuous hole cleaning avoids settlement or accumulation of cuttings and
debris, allowing the bit to be returned directly to bottom to restart drilling
following connections.
The steady state, down hole, allows the circulating pressure to be controlled
by flow rate alone, at the optimum low differential pressure for the formation
being drilled, which generally allows the bit to penetrate faster.
By keeping the circulation continuous throughout the tripping operation, the
drill string can be tripped faster without the damaging swab and surge effects
on the wellbore. Additionally, the well remains under continuous control with
circulation connected and flowing at all times.
15
The solution
Maintain continuous circulation.
The most simple, effective and safe MPD solution is to circulate
continuously.
As new wells are drilled in increasingly difficult pressure regimes and old or
depleted wells are re-entered and deepened, the pressure variations due to
stopping/starting circulation are increasingly unacceptable.
16
The solution
Establish continuous circulation and avoid any significant pressure variations
to be compensated for with alternative MPD methods. The rightful use of
MPD can then be focussed on controlling the Continuous Circulation
pressure at the optimum for the formation being drilled.
The steady state, maintained by a CCS (Continuous Circulation System),
provides the calm setting for reading downhole pressure variations more
meaningfully, since any variations in pressure, or flow, will be due to the
formation being drilled, which should also improve well control and safety.
17
The solution
Maintain continuous circulation with a CCS and achieve all the benefits of a
constant ECD. Of all of the MPD methods, continuous circulation, is the
simplest and most effective and is the only method that maintains the steady
and unchanged down hole pressure regime, across the entire exposed
formation, while making connections.
.
18
The solution
Maintaining continuous circulation, allows the ECD to be kept constant and
the underbalance, balance or near balance pressure, to be more easily
controlled.
By circulating continuously during connections, there are no accumulated
fluids to circulate out and the steady state down hole pressure regime is
maintained throughout, allowing drilling to recommence without delay.
Furthermore, with reservoir fluids flowing into the wellbore, it is intrinsically
safer to have uninterrupted circulation, particularly, while making
connections.
19
The solution
Using the CCS to circulate continuously, the mud is never static and settling
is avoided as the circulating fluid continues to clean the hole during
connections. The uninterrupted flow of drilling fluid in lateral wells minimises
settlement and reduces the build up of solids at intervals or weirs in the
annulus.
20
The solution
With continuous circulation connection kicks are eliminated.
Continuous circulation maintains the established steady dynamic state,
across the exposed formation from bit to the last casing shoe, in terms of
both pressure and flow regime, such that there should be no induced flow
from the formation.
If during or after a connection, any change in pressure or flow occurs, it can
be interpreted as an exchange between the annulus and the formation,
providing a more sensitive and immediate signal of what is happening
downhole.
21
The solution
Using a CCS to provide continuous circulation while making connections,
facilitates continuous and improved well control.
The valves which control the mud flow between Top Drive and CCS are
standard, accessible and safe proven equipment. No additional valves or
components are required in the drill string itself.
Continuous mud connection to the drill string allows steady running of the
mud pumps, which is preferable and the continuous flow over the shale
shakers, allows a higher separation efficiency, and circulation while making
connections improved hole cleaning.
-------------------------------------------------------------------------------------------------------------------------
22
The solution
Using continuous circulation, an uninterrupted steady state flow of mud is
established with uniform parameters throughout the system making the
hydraulics consistent and easier to calculate.
With continuous circulation, high dynamic pressure drops in the annulus can
be accommodated since these are not lost during connections.
23
Continuous Circulation
Drilling
Improved
safety & production
24
25
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