Delivering an Innovative Active MPD Wellbore Sealing System for Field Operations

Abstract

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.