Objectives/Scope This paper introduces an active wellbore sealing system for use in Managed Pressure Drilling (MPD) incorporating a wellbore seal condition monitoring system. The paper will discuss how finite element analysis which has previously been validated with full scale testing can be expanded to develop the condition monitoring system. Methods, Procedures, Process In contrast to a passive rotating control device, an active MPD wellbore sealing system requires hydraulic pressure to engage a sealing element and form a wellbore seal. The paper will investigate the relationship between wellbore sealing pressure and hydraulic fluid parameters using the results of finite element analysis on a sealing technology which has been previously operated offshore in addition to extensive full-scale testing in a lab environment. Results, Observations, Conclusions The paper will show how the required hydraulic fluid requirements to form a wellbore seal change over time due to sealing element wear. The information can be used to predict the remaining life of the existing sealing element as well as proactively alarm the driller of the need to replace a seal sleeve due to a sudden deviation from expected behavior. The implementation of a real-time, condition monitoring system for the MPD wellbore seal is intended to increase the rig's confidence toward using MPD for challenging hole sections as well as circulating out small influxes from the well without closing the SSBOP, further reducing the risk of stuck pipe events. Novel/Additive Information The active MPD wellbore sealing system is a non-rotating, offshore wellbore annular sealing device which is integrated into the riser. It contains a seal of elastomeric composition which seals against drill pipe during all tripping and drilling operations. As the seal wears, the hydraulic closing fluid requirement to maintain an annular seal changes, which indicates the amount of seal material remaining.

Objectives/Scope This paper shares results from the successful first use of an active sealing device in a narrow margin deepwater well in the Black Sea. The active sealing device is a clean-sheet design approach which is purpose built for deepwater Managed Pressure Drilling (MPD) operations. This paper shares highlights from design, testing, and first-use stages of the program. Methods, Procedures, Process This paper discusses the three key program phases from development to field operation. An overview of the detailed design phase introduces system elements and purposes. An overview of the fullscale prototype testing phase discusses design verification testing, system optimization testing, and systems integration testing measures taken prior to field deployment. Finally, an overview of the field deployment phase shares outcomes from the first deployment on a dynamically positioned deepwater rig drilling a narrow margin MPD well in the Black Sea. Results, Observations, Conclusions The paper shares conclusions from each of the active sealing device development program phases. Upscaling passive RCD technology for deepwater has had negative effects on performance. A nonrotating seal sleeve element design eliminates multiple high-wear RCD components. Elimination of bearings and rotary seals removes common system failure modes. Redundant, active seal elements ensure wellbore seal quality throughout the seal life. A lubrication system extends seal life and enables active seal condition monitoring. Active seal condition monitoring alerts the rig crew prior to failure to replace the seal assembly. Full-scale testing demonstrates the system under simulated drilling conditions. Seal life observed at over 200 rotating hours, outlasting most deepwater MPD hole sections. First active sealing device integrated into deepwater drillship. Multi-modal seal control system provides crew operational methods to reach the total depth. Consistent seal life enables rig crew to better plan and drill MPD sections with confidence. First deepwater MPD well drilled using the new active sealing device. Novel/Additive Information The project discusses other novel aspects such as drilling contractor ownership and integration of the MPD equipment. A design objective is to enable new models of MPD system fleet management to allow drilling contractors to share equipment between rigs. The integrated active wellbore sealing system allows communication between the rig drilling control system, subsea and topside equipment, and all 3rd party systems, while sharing commonality with other rigs in the fleet.

This paper shares results from the first year of deepwater operations using an active sealing device purpose built for deepwater Managed Pressure Drilling (MPD). The active sealing device is a clean-sheet design approach. The first use of the system was performed in a narrow margin deepwater well in the Black Sea with subsequent wells in the Gulf of Mexico. This paper shares lessons learned from first year of operations. This paper discusses field operations, lessons learned, and post run evaluation of system performance. An overview of the design introduces system elements and briefly discusses system testing measures taken prior to field deployment. An overview of operations from the first year is provided, highlighting lessons learned, action items taken, and solutions implemented between wells. Analysis of the link between the testing and field results demonstrates the novel approach to testing and validity of assumptions made during the testing phase. Furthermore, methods of evaluating seal performance are discussed. The paper shares conclusions from the first year of active sealing device deployment. A non-rotating seal sleeve element design eliminates multiple high-wear rotating control device (RCD) components such as bearings and rotary seal as well as their associated failure modes.Redundant, active seal elements ensure wellbore seal quality throughout the seal assembly life.Active seal condition monitoring alerts the rig crew prior to failure to replace the seal assembly.Multi-modal seal control provides crew methods to reach total depth in contingency mode.Full-scale simulated drilling testing included the use of client equipment prior to first use.Testing procedures were designed to simulate drilling to mirror system use in a live well.First MPD well completed in 2019 in the Black Sea with subsequent wells in the Gulf of Mexico.Lessons learned from operations to applied in continuous improvement program.Novel approaches to assessing performance have been developed in order to provide consistent metrics.Learnings have been applied in subsequent wells to improve technology transfer to drilling contractors. The paper discusses other aspects of the program such as drilling contractor ownership vs. use of third (3rd) party systems, integration of the MPD equipment into the rig, and network architecture. Further, an algorithm has been developed to analyze system performance from electronic drilling recorder data to better characterize the effect of usage patterns of seal wear. These data demonstrate the validity of assumptions made during the development of the test procedures.

Objectives/Scope This paper shares results from the first field deployment of an active sealing device in a narrow margin deepwater well in the Black Sea. The active sealing device represents a clean-sheet design approach purpose built for deepwater MPD operations. This paper shares highlights from the detailed design through the prototype testing to the first-use stages of the program. Methods, Procedures, Process This paper discusses three distinct program phases covering the overall process from concept development to field operation. First, the detailed design phase is discussed, introducing the reader to system components and functionalities. The second phase of full-scale testing is discussed from the design verification, system optimization, and systems integration testing perspectives. Finally, field results are shared detailing findings from the first deployment on a dynamically positioned deepwater rig drilling a narrow margin MPD well in the Black Sea. Results/Observations/Conclusions The paper shares findings, insights, and results from each of the phases of the active sealing device development program.Upscaling passive RCD technology for deepwater has negative effects on system performance.A non-rotating, externally functioned seal sleeve element eliminates multiple high wear components.Elimination of bearing assemblies and rotary seals removes common failure modes seen in deepwater.Redundant, actively controlled seal elements ensure wellbore seal quality throughout the seal life.A lubrication system injects mud between seal elements, enabling seal condition monitoring.Active seal condition monitoring alerts the rig crew when to replace the elements prior to failure.Full-scale testing has been completed demonstrating the system under simulated drilling conditions.Seal life demonstrated to outlast most deepwater MPD hole sections.Operational testing and integration testing reduce commissioning and testing time consumed on the rig.Active sealing device successfully integrated into the drilling riser and MPD specialty joint.Multi-modal system provides rig crew with distinct operational strategies to meet current parameters.Consistent seal life enables rig crew to drill MPD sections with confidence in the wellbore seal.Deepwater well with multiple MPD sections successfully drilled using new active sealing device. Novel/Additive Information The project includes secondary novel aspects such as drilling contractor ownership of the subsea and topside MPD equipment. The MPD system is integrated into the drilling control system allowing communication between the rig, subsea, MPD topsides, and all third-party systems, while also sharing commonality with other rigs in the fleet. An objective of the MPD system design is to enable new models of fleet management to meet drilling contractor operations.