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Abstract
The application of managed pressure drilling (MPD) is
becoming more widely spread throughout the world. It is
well known that MPD has less hydrostatic head during
drilling therefore the rate of penetration (ROP) is
increased. This is due to the reduced rock confinement and
chip hold down effects. By simulating the conventional
drilling and MPD of a well in advance the benefits of
MPD can be quantified in terms of increase in ROP and
therefore the economical benefits. Applying a
commercially available drilling simulator (1). meter by
meter drilling performance is analyzed, first simulating
and optimizing a conventional drilling operation and then
performing the same procedure for a MPD operation in
Western Canada. The additional costs of the MPD
operation are integrated into the economical analysis. The
analysis shows that the ROP during MPD in the higher
mud weight regime of the well is improved from 60 to 80
percent. In addition to the faster drilling during MPD the
drill bits last longer due to the lesser hardness of the rock
being less confined and therefore also reducing the amount
of bit wear and the number of bits required and tripping
time. Overall the results indicate that the MPD operation
reduce the drilling cost of gas wells in Central Alberta
more then 20 percent and due to the reduced time at the
location less environmental impact is seen.
Introduction
The first objective of this exercise was to develop a base
case drilling simulation from which subsequent
optimization simulations could be run. An apparent rock
strength log (ARSL) was developed based on actual
drilling data and formed the backbone of all subsequent
calculations. The second objective of the exercise was to
compare the non-optimized base case (as above) with an
optimized base case. Based on previous experience,
drilling economics should improve by approximately 25%.
The third and primary objective of this exercise was to
compare the optimized base case with an optimized
Managed Pressure drilling (MPD) case and, if possible, to
justify the additional cost of implementing MPD
technology.
Executive Summary
The well under study was broken into 5 discreet 200 mm
diameter sections: section 1 (443 m to 447 m) was drilled
with a type 4-1-7 tricone bit (due to its short interval,
section 1 did not account into subsequent simulation runs),
section 2 (447 m to 1944 m), section 3 (1944 m to 2805
m) and section 4 (2805 m to 3149 m) were all drilled with
PDC bits. Because of the presence of chert nodules in the
lowest section, Section 5 (3149 m to 3218 m) was drilled
with a type 5-4-7 insert tricone bit. The first simulation run
for the entire 2771 m section established a benchmark
drilling cost of $237.50/m or $658,110. After optimizing
hydraulics then optimizing bit runs progressively
downward, it was found that the optimized non-MPD Case
showed a decrease in drilling cost to $183.50/m or
$508,295 (a decrease of 23%- as anticipated). The next
step in meeting the aforementioned objectives was to
optimize the MPD Case. First, mud density was changed
from the existing optimized non-MPD profile to a constant
0.9 S.G. for the entire wellbore. The simulation was re-run
and it was found that drilling costs increased to
$199.60/m. It is interesting to note that the decrease in
mud density and therefore increased ROP was offset by
the additional +/- $15,000/day estimated cost of MPD
equipment/services. The new meterage cost of $199.60/m
formed the datum from which subsequent optimized MPD
calculations were compared against. Again, hydraulics and
bit runs were progressively optimized to establish a new
cost per meter of $168.90/m (a further decrease of 15%).
Finally, sections 3 and 4 were merged and an optimized
suite of simulations (based on 1 bit) were run. It was found
that drilling cost decreased to $150.40/m or a total of
$416,750 (18% less than the optimized non-MPD case). A
final suite of simulations were run which sections 3, 4 and
5 were merged and drilled with 1 bit. It was found that
drilling costs decreased a further $9/m ($141.50/m) to a
total of $392,095 (22% less than the optimized non-MPD
case). It should be noted that the costs to move the MPD
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Drilling Mud
It was assumed that the system volume (including surface
or active) was +/- 200 m3. Given this volume, cost of the
mud system for the conventionally drilled well with a
90/10 invert mud system was formulated as following:
$75/m3/well fluid rental
$400/day system maintenance
$20,000 system refurbishment cost at end of well
$2000 centrifuge cost at end of well strip system back
from 1.4 S.G. to 0.90 S.G.
The cost of the mud system for the MPD drilled well
was formulated as following:
$75/m3/well fluid rental
$400/day system maintenance
Well Profiles
The different drilling programs for conventional and MPD
can be found in the comparative Figure 1. In this figure
the different schemes studied and simulated for the present
study are shown.
MPD Equipment Layout
Bit Types
The subject 200 mm section was originally drilled with 5
bits. The first section (443 to 447 m) was drilled with a
type 4-1-7 insert bit. Sections 2 through 4 (447 to 1944 m,
1944 to 2805 m, 2805 to 3149 m) were drilled with PDC
bits. Due to the presence of chert nodules, the final section
(3149 to 3218 m) was drilled with a type 5-3-7 insert bit.
Rotating Control Head
Specific information regarding the rotating control head
was unavailable at the time of writing. However, given the
depth of the well and the source of the cost data
(Weatherford) it can reasonably assumed that a Williams
Series 7100 dual element 5000 psi (static) 2500 psi
(working) rotating control head (RCH) would be used.
Separation Package
Again, specific information regarding the actual separation
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References
1. Pason System Corp, Optimizer Version 1.20, 2007.
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