SPE/IADC 79821

A New Downhole Tool for ECD Reduction

P. A. Bern, SPE, BP Exploration; Dave Hosie, SPE, Weatherford; R.K. Bansal, SPE, Weatherford; Donald Stewart,
Rotech Eng.; Bradley Lee, SPE, Weatherford
Copyright 2003, SPE/IADC Drilling Conference
This paper was prepared for presentation at the SPE/IADC Drilling Conference held in
Amsterdam, The Netherlands, 1921 February 2003.
This paper was selected for presentation by an SPE/IADC Program Committee following
review of information contained in an abstract submitted by the author(s). Contents of the
paper, as presented, have not been reviewed by the Society of Petroleum Engineers or the
International Association of Drilling Contractors and are subject to correction by the author(s).
The material, as presented, does not necessarily reflect any position of the SPE, IADC, their
officers, or members. Electronic reproduction, distribution, or storage of any part of this paper
for commercial purposes without the written consent of the Society of Petroleum Engineers or
the International Association of Drilling Contractors is prohibited. Permission to reproduce in
print is restricted to an abstract of not more than 300 words; illustrations may not be copied.
The abstract must contain conspicuous acknowledgment of where and by whom the paper was
presented. Write Librarian, SPE, P.O. Box 833836, Richardson, TX 75083-3836, U.S.A.,
fax 01-972-952-9435.

Abstract
Wellbore pressure management is a critical part of the drilling
process. In normal drilling practices, static and dynamic fluid
pressures are used to contain formation pressures and to assure
wellbore stability. Excessive fluid pressure while circulating
can create problems including reduced operating margins
between fracture and pore pressures and, in the extreme, lost
circulation.
To address these problems, an Equivalent
Circulation Density (ECD) Reduction Tool (RT) has
been developed.
The ECD RT is designed to counter the frictional pressure
effects that exist while circulating. The tool is expected to
have a broad range of drilling applications including; the
narrow pore/fracture pressure margin deepwater environment,
wellbores prone to instability, pressure depleted reservoirs,
and extended reach wells.
The tool has the potential to:
Improve wellbore stability
Extend hole intervals and reduce casing requirements
Improve well control
Reduce lost circulation
Reduce differential sticking
Improve hole cleaning in ERD wells through the use
of higher flow rates
This paper describes a new downhole tool for ECD
reduction, which is run as an integral part of the drill string. A
prototype tool has been built to operate inside 10-3/4" to 133/8" casing. This tool has undergone laboratory testing and
full-scale technology trials are in progress. The design
features of this prototype are discussed along with the
laboratory test results obtained to date.

Introduction
This paper describes the development of a novel system for
reducing the Equivalent Circulating Density (ECD ) of drilling
mud. The drive for reducing ECD has become apparent as the
industry is faced with increasingly difficult drilling challenges.
The initial focus and development for ECD reduction has
been directed towards applications in deepwater. Here the
issue is overcoming the significant hydrostatic pressure in the
riser when it is full of weighted mud (Reference 1). However
the concept affords potential benefits in a wide range of
drilling applications.
The work reported in this study covers the design and
testing of a prototype ECD RT that in principle can be applied
to a wide range of drilling opportunities (including both
onshore and offshore).
Benefits of ECD Reduction
As the industry has strived to recover hydrocarbons in
increasingly challenging areas, it has become apparent that
one of the major restrictions is maintaining downhole
pressures within the narrow window between pore pressure
and fracture gradient. In practice, the window may become
even narrower if the minimum required downhole pressure is
governed by wellbore stability issues rather than just pore
pressure (Reference 2). Since the size of this operating widow
dictates the maximum ECD that the well can tolerate, there is
clearly a big prize in reducing the magnitude of ECD.
The hydrostatic head of the mud column and the frictional
pressure loss in the annulus govern ECD. Therefore there are
many factors that influence ECD. Conventional well designs
often exploit the controlling parameters to ensure ECDs can
be minimized. Such optimization methods include: reducing
frictional losses through the use of low fluid rheologies; use of
casing strings with wider annular clearances; the application of
expandable tubulars to preserve hole size; use of drilling liners
rather than full casing strings and controlled penetration rates
to avoid overloading the annulus with cuttings. In addition,
there are more radical methods that can be employed to reduce
downhole pressures and hence ECDs. The industry has
pioneered underbalanced drilling as a successful method to
exploit low pressure and depleted reservoirs. Benefits in
penetration rate have also been realized by appropriate
application of underbalanced drilling.

SPE/IADC 79821

Systems that reduce ECD by either substituting the mud

hydrostatic for sea water or use pumping methods to overcome
hydrostatic are now being developed by the industry
(References 3-5). The method in floating drilling where mud is
returned to the sea bed, referred to as riserless drilling, has
enjoyed a great deal of success, particularly in the Gulf of
Mexico deepwater plays. The more technically innovative
methods that require pumping systems located on the seabed
are beginning to show promise (Reference 6). However such
systems will always require considerable capital expenditure
and are best suited to large developments where the cost of
installation can be offset against a large number of wells.
The objective of this work is to develop an ECD reduction
tool that is portable and can be applied to a wide range of well
types (both onshore and offshore). It is intended to be a low
cost alternative to dual mud gradient systems for deepwater
drilling. In extended reach drilling, the ECD RT could permit
the use of a heavier drilling fluid to improve wellbore stability
without increasing risks of fracturing formation and mud loss.
Successful application of the ECD RT will afford many
benefits. These include extending the capability of what is
currently available (e.g. ultra extended-reach drilling) as well
as applying ECD reduction as a performance enhancement
method. If the ECD RT can be made routinely available (i.e.
low cost and portable) the range of applications
become numerous.
Functional Specification
The ECD RT consists of three sections. At the top is a turbine
motor, which draws pressure energy from circulating fluid and
converts it into mechanical power. In the middle is a multistage mixed flow pump (part axial, part radial) driven by the
turbine motor. It pumps return fluid in the annulus. The lower
section consists of bearings and seals. The turbine is matched
to the pump duty, so no gearbox is required. A novel sealing
mechanism is employed to seal between the drillstring and the
annulus at very high speeds and pressures. This seal has a
back-up emergency seal, which is automatically activated at
high pressure differentials in a well control situation.
Basic features of the ECD RT are:

Up to 450-psi (30.6 bar) pressure boost in the annulus

at a flow rate of 550-gpm (2,080-liter/min). Actual
pressure boost in the annulus is a function of
circulation rate. A reduced fluid flow rate gives
correspondingly lower pressure boost.
Current design is suitable for running in 10-3/4
through 13-3/8 casings. ECD RT for other casing
sizes will be developed in 2003.
No need of a full trip to add or service the ECD RT.
The ECD RT is located in the vertical section of the
well. It is accessed by making a short trip.
Includes two packer-type seals to seal the pump body
inside the casing, which ensures that all returning
fluid passes through the pump.
No fluid leakage from the drill string to the annulus

throughout the length of the tool.

Motor outside diameter 6-3/4" (172mm) and the
pump outside diameter 8.200 (208mm).
Capable of handling drill cuttings carried by the fluid.
A grinding mechanism, located just below the pump,
helps break larger cuttings into smaller particles to
avoid plugging. The maximum spherical diameter
through the pump passages was designed to be
0.39" (10mm).
Provides wireline accessibility below the tool by
retrieving a flow diverter located in the turbine.
Tensile/torsional strength of the ECD RT is
comparable to that of new 5- 19.5 lb/ft S-135
drill pipe.

As evident from the above, the ECD RT has several

features intended to make it affordable and usable in both
offshore and land-based drilling operations. It is a much less
expensive choice when compared to dual-gradient drilling
systems in deep-water applications. It can be put in use with
minimal disruption on conventional drilling and telemetry
techniques. Unlike subsea pumps in dual-gradient drilling, the
ECD RT does not have to be installed on the well site. Instead
it is a portable device that can be added in the drill string when
needed simply by making a short trip.
Materials and methods for Lab Testing
A prototype ECD reduction tool was tested in a flow loop. The
main objectives of flow loop tests were: (a) to determine the
performance envelope of the ECD RT for a range of operating
conditions arising from variations of drilling fluid circulation
rate, mud weight and plastic viscosity, (b) to study cuttings
transport with fluid through the pump, and (c) to study surge
and swab effects during the trip. Performance of elastomer
seals and wear on internal components were evaluated after
completing lab tests in the flow loop.
A flow loop was specially designed for this test. The main
unit in the flow loop was a test chamber with an I.D. of 9.681"
(220mm) corresponding to 9-5/8 47 lb/ft casing. The ECD
RT was placed in the test chamber. Two triplex pumps were
used in tandem to obtain flow rates of up to 550-gpm. The
output from the pumps was fed into the turbine. After passing
through the turbine, the same fluid exhausted into the test
chamber and entered the ECD pump. There was a choke
upstream of the ECD pump to create a backpressure that
allowed measurement of pressure boost from the pump.
Pressure transducers were located at the inlet of the turbine
and at the inlet and outlet of the pump. Pressure at the turbine
outlet was the same as the pressure at the pump inlet. Fluid
circulation rate was measured from the pump units and
calibrated against a sonic flow meter in the pump flow loop.
Lab tests were conducted with fluid circulation rate varied
from 175 to 550-gpm (660 to 2080 liter/min).
The ability of the pump to handle cuttings was tested by
adding plastic balls to the pump flow loop. Plastic balls having
diameters of 0.24" (6mm), 0.31" (8mm), 3/8 and were
used in this study. The tests began with 0.24" balls and larger

SPE/IADC 79821

Results
Figure 1 shows the performance of the ECD RT with water in
terms of pressure boost obtained from the pump at different
flow rates. Three conclusions can be drawn from Fig. 1. First,
the pressure boost was a quadratic function of fluid circulation
rate, which means that the pump performed better when the
actual circulation rate approached the design circulation rate.
Second, there was virtually no pressure boost at a flow rate
below 200-gpm, which is indicative of a lower limit for
functioning of the ECD RT. Third, at 530-gpm (maximum
flow rate achieved in this test) ECD RT achieved a pressure
boost of 300-psi. Tests with heavier fluids were not complete
at the time this paper was written. Hence full potential of the
ECD RT has not yet been determined.
y = 0.0015x2 - 0.218x + 6.03
R2 = 0.99

Pressure boost (psi)

350
300
250
200
150
100
50
0
0

100

200

300

400

500

600

25

1600

20

1200

15
800
10
400

Pressure recovered (%)

Expected surge or swab pressure during the drill string trip

was measured in the flow loop by pumping water through the
ECD RT pump from the lower end. The ECD RT pump was
not turning during this test. Fluid flow rate was increased
steadily up to 275-gpm. Fluid pressure was measured at the
inlet and the outlet of the pump.

Pressure loss in the turbine (psi)

Pressure recovered in the pump (%)

Pressure loss (psi)

balls were progressively added to the flow stream. The fluid

containing plastic balls circulated through the pump for 45
minutes. The quantity of plastic balls in the flow stream was
approximately 1% by volume. This was equivalent to a 1
ft3/min cuttings load that would be experienced when drilling
an 8.5 hole at a ROP of 150 ft/h. The pump was dismantled
after running this test to check if there were any points where
plugging could occur. Functioning of crushing mechanism on
larger balls was also checked in this process.

0
0

100

200

300

400

500

600

Flow rate (gpm)

Fig. 2 Fluid pressure loss in the turbine and percentage

recovery in the pump.
The efficiency of the ECD RT in terms of pressure
recovered in the pump as a percentage of pressure lost in the
turbine is shown in Fig. 2. Pressure loss in the turbine
increased with increasing flow rate in a quadratic manner
similar to pressure boost from the pump. At a flow rate of 530gpm, pressure loss in the turbine was 1365-psi whereas
pressure boost from the pump was 300-psi. Thus the efficiency
of the system was about 22 percent. Fig. 3 shows that at low
flow rates, system efficiency was very low, which stabilized
between 18 and 22 per cent after reaching 300-gpm flow rate.
The cuttings transport test with plastic balls indicated no
problems. Plastic balls up to 0.31" (8mm) diameter passed
through the pump smoothly. Because of the closed loop
configuration, the plastic balls probably went through the
pump many times during 45 minutes of running, yet they were
generally in very good shape. On stripping the ECD RT pump
none of the internal components were found to have damage.
A total of eight 3/8 balls had lodged in three of the five
stators. Some 3/8 balls had splits and some had one, two or
three flat surfaces on them. Small fragments were also found
in the pump, mainly in the inlet area of the crusher. Most of
the balls were found near the inlet of the crusher
suggesting that perhaps balls did not go through the pump.

Flow rate (gpm)

Fig. 1 Pressure boost obtained from the pump at different

circulation rates of water.

Results from surge pressure tests are summarized in Fig.

3. There was considerable spread of data points on both sides
of the regression curve. Perhaps the highly variable flow cross
section area inside the pump caused surge pressure to fluctuate
to this degree.

SPE/IADC 79821

y = 0.243x - 13.1
R2 = 0.79

Surge pressure (psi)

80

of the ECD RT was very low when the flow rare was less than
300-gpm. It improved to the 18-22% range at higher
flow rates.
Tests with plastic balls showed that 0.31" (8mm) and
smaller size balls passed through the ECD pump unharmed.
Hence, typical drill cuttings are unlikely to cause plugging.
Preliminary tests showed that at a flow rate of 275-gpm,
corresponding to a trip speed of 50, 70 and 90 ft/min in 133/8, 11-3/4" and 10-3/4" casings, respectively, surge pressure
could vary between 40 - 60 psi.

60

40

20

0
0

50

100

150

200

250

300

Flow rate (gpm)

Acknowledgements
The authors wish to acknowledge the support and
encouragement of their respective companies. They also wish
to thank the teams of skilled design technicians and
manufacturers and the dedication of all the people involved
with the laboratory/field testing.

Fig. 3 Preliminary results from surge tests.

Surge pressure is a function of rate of fluid displacement
during tripping operation. The latter depends on casing size
and trip speed. For a given trip speed, surge will be higher in a
larger casing than in a smaller casing. Hence by slowing the
trip speed, surge pressure can be kept within the acceptable
limit. A flow rate of 275-gpm in this test was roughly
equivalent to a trip speed of 50, 70 and 90 ft/min in 13-3/8,
11-3/4" and 10-3/4" casings, respectively. At those trip speeds
surge pressure could be between 40 and 60-psi. These are
preliminary results from limited tests with water.
A comprehensive testing program for the ECD RT is in
progress at this time. Results from these tests will be made
available in the near future.
Conclusions
High ECD is a problem in deep water drilling causing
formation damage and mud loss. In extended-reach drilling
wells, high frictional losses increase ECD, forcing the use of
lighter drilling fluids that can compromise wellbore stability.
The ECD RT can potentially alleviate those problems in
both situations.
The limited test results available at the time of writing this
paper showed that, when using water as the circulating fluid,
at a very low circulation rate (less than 200-gpm), the ECD RT
had no effect on the ECD. As the circulation rate was
increased from 200-gpm to 530-gpm, pressure boost from the
ECD pump increased in a quadratic manner to 300-psi. This
indicated that this tool would provide maximum benefit in
terms of reduced ECD at the designed circulation rate of 550gpm. The ECD reduction with weighted drilling fluids is likely
to be higher than the 300-psi recorded with water. Efficiency

References
(1) Lopes, C.A. and Bourgoyne, A T.: Feasibility study
of a dual mud system for deepwater drilling
operations. OTC 84654 (1996).
(2) McLean, M.R. and Addis, M.A.: Wellbore stability
analysis: A review of current methods of analysis and
their field application. SPE Paper 19941 (1990).
(3) Eggemeyer, J.C. et al.: Subsea Mudlift Drilling:
Design and Implementation of a Dual mud Gradient
Drilling System. SPE Paper 71359 (2001).
(4) Smith, K.L. et al.: Dual-gradient drilling nearly ready
for field test. World Oil (October 2000).
(5) Johnson, M.B.: New mud supply process saves time
and expense in riserless deepwater drilling. World Oil
(September 2002).
(6) Witt, D.E. et al.: Drilling technique gets its feet wet.
E&P (March 2002).