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Pressure
Connections etc
Temporary surge
Circulating pressure
In conventional drilling, this stop/start cycling of pressure across the full length of the exposed formation, occurs every 30, 60 or 90 ft of hole being drilled. With each connection the exposed formation is repeatedly depressured before being pumped up or supercharged before normal circulation pressure is re-established.
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
Ideally when drilling, circulation of the drilling fluid should be continuous. This is now commercially possible with the Continuous Circulation System (CCS). Located on the rig floor, the CCS safely maintains uninterrupted circulation to the drill string, at up to 5,000psi, while the Top Drive is disconnected. Connections are made or broken within a pressure chamber constructed from conventional blow out preventer components, using Iron Roughneck technology With Continuous Circulation, the circulating pressure in the borehole (the ECD) can be carefully controlled to stay within narrow Frac Pressure / Pore Pressure windows.
Pressure
Connections etc .
Depth
Circulating pressure
Additionally, with uninterrupted flow, the fluid dynamic regime established while drilling, is kept Steady State. The annular flow, mud temperature and density, hole cleaning, mud processing and cuttings mobility are all constant and stable. Consequently any small change in the returning flowrate, caused by fracturing, or the beginning of lost circulation, or a kick, is far easier to detect and respond to. For the driller, this improved well control and safety is significant.
Top Drive
Pressure a
Mud
Subsea BOP
Cased Hole
Fracture Pressure
Last
Hydrostatic Pressure Exposed Formation Pore Pressure
e
Pressure in annulus
Bi
Depth
Stable Pressure Gradient across the Exposed Formation when Drilling with Continuous Circulation
Steady State pressure, flow, turbulence, ECD, hole cleaning, cuttings mobility, temperature and density, plus increased safety and subsequent production.
Managed Pressure Drilling (MPD) techniques may be used to partially compensate for the loss of pressure and ECD, when circulation is stopped. To maintain the down hole pressure, drilling fluid has to be pumped into the annulus against a closed drill string, and the annulus has to be modelled to calculate how much to pump. The accuracy and reliability of the computer model, which has to be continuously built in real time, is a significant challenge. Circulating continuously avoids most of these complications and has several other important benefits.
L.Ayling ITF JIP Director July 2009.
Fracture Pressure
Pore Pressure
Fracture Pressure
Pore Pressure
Fracture Pressure
Pore Pressure
d
Z
Stopping and re-starting circulation, when making connections, has been a major cause of most typical drilling problems, ever since rotary drilling with jointed tubing, replaced cable drilling.
Eliminated Problems:
Surging on stop / start circulation Formation pumping & Balooning ECD variations Well de-stabilisation in UBD Static Cuttings Settlement Connection Kicks Disconnecting mud from drill string P & T variations in HPHT wells
Why on earth, for a hundred years, we stopped the circulation of drilling fluids, every time we wanted to make a connection; and disconnected the mud from the drill string just when connection kicks could occur, is an enigma. The answer is that we had no means of maintaining circulation; until now, when the technologies of BOPs, Iron Roughnecks, Snubbing and Programming have come together to give us a commercially viable, reliable and safe mechanised system to maintain continuous circulation throughout the drilling of each section.
Conventional Drilling
The solution
Pressure
Pressure
Connections etc
Connections etc
Temporary surge
Continuous Circulation maintains a steady ECD and pressure gradient across the exposed formation surface. With the best MPD technique the pressure gradient is supplemented by the applied annulus pressure at the surface which can cause wellbore instability.
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
P3
P3
P2
P1
Initial sticking
P2
P3
P1 P2 P3
Where P1 is the Annular pressure and P3 is close to the pore pressure and P1 > P2 > P3.
The prime cause, though, is the effective differential (balance) pressure, which includes both the mud hydrostatic pressure and the dynamic circulation pressure head. Conventionally, this is set sufficient high to allow the static pressure alone to control the well when circulation is stopped.
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.)
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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. .
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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.
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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.
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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.
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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.
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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.
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On reconnecting the drill string and restarting circulation, the downhole pressure surges temporarily above the steady circulating pressure and changing flow patterns further damage the formation wall. Accumulated cuttings, debris, and formation fluids then have to be circulated out of the well, before a steady state for drilling can be re-established.
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