DGD The System Dea 2011

Dual Gradient Drilling The System
David Dowell Chevron North America Exploration and Production Company
DEA Presentation June 23, 2011
2011 Chevron U.S.A. Inc. All Rights Reserved.
Dual Gradient Drilling: Working WITH Nature, Not Against Her With DGD, We Literally Replace the Mud in the Drilling Riser with a SeawaterDensity Fluid and Use a Denser Mud Below the Mudline.
Conventional
Dual Gradient
Single Mud Weight
Heavier Mud w/ Seawater Density Above Mudline
Same Bottom Hole Pressure
Impact in Deepwater: Casing Point Reduction
5 Casing Points Conventionally
Seafloor
Single Gradient Density at TD
Depth
Fracture Pressure Seawater Hydrostatic
TD
Pore Pressure
Pressure
Casing Points Dual Gradient
3 Casing Points
Seafloor Dual Gradient Density at TD
Depth
Fracture Pressure
Seawater Hydrostatic
TD
Pore Pressure
Pressure
Dual Gradient Drilling Defined Major Components
Mud Return Line
Subsea Rotating Device (SRD)
Solids Processing Unit (SPU)
MudLift Pump (MLP)
Drill String Valve (DSV)
Normal Drilling The U-tube Is Balanced
Sea Level Drillstring Annulus
Mud Line
Bit
Bottom Hole
DGD Drilling The U-tube Is Unbalanced
Sea Level Drillstring Annulus
Mud Line
Bit
Bottom Hole
The Drill String Valve Arrests the Natural U-Tube
Valve in BHA 3 Sizes Evaluating two Major Companies Designs Will be Tested in Top-hole Operations
(JIP Design)
About the Drill String Valve

Not essential
Makes operations easier Arrests the U-tube
Faster connections More certainty in kick detection
Easier to stop the MLP

Helpful in flow rate management Helpful in well control pressure reading
Run above the BHA, you cant wireline through it

Two builders Mechanism of operation, not intuitive
9
DGD Subsea Component Stack-Up

(Not to Scale)
Subsea Rotating Device (SRD) Solids Processing Unit (SPU) MudLift Pump (MLP) Subsea Manifold Standard BOP Stack
10
The Worlds First DGD-Ready Rig, the Pacific Santa Ana, will be Delivered in 1Q12.
11
Surface Changes
Six rig pumps
Three for power fluid and Three for mud One back-up for each fluid stream
Additional trip tank (riser fluid) More piping for handing up to 3 fluids at once
Pits divided for multiple fluids
12
Two trip tank systems

Riser Fluid Trip Tank
Two trip tank systems One for riser fluid One for mud in the hole below Both are circulating trip tanks
MUD TRIP TANK
Mud Return Line (MRL)
Choke Line
MUDLINE
13
Return Line Manifold And A Drilling Choke

Provides a way to divert mud to: The pits MGS Rig choke Drilling Choke Drilling Choke prevents uncontrolled expansion of return line gas
Riser Fluid Trip Tank Pit System MUD TRIP TANK Drilling Choke MGS System To Pits
To Rig Choke
Choke Line
MUDLINE
Tripping and Displacement Manifold

Mud from Line A Mud from Line B Mud from Line C Mud from Trip Tank Kill Line
Allows for management of fluids in: Choke and Kill Line Returns Riser
Choke Line
MUDLINE
The Drilling Riser is Modified
MudLift Pump is SeawaterPowered, so Riser Modifications are Needed Two Six inch Lines Seawater Power Mud Return No Boost Line 3.5MM lb Flange rating Standard 15K C&K lines
Flange End of Riser

Seawater Power Line
Hydraulic Line
Choke Line
Drill Pipe
Kill Line Hydraulic Line Mud Return Line
16

(Not to Scale)
17
The Subsea Rotation Device (SRD)

Provides a interface between riser and the wellbore
Has the SRD Bypass built into it

Mechanical latching mechanism on the Bearing insert
Rated for: Pressure from below - 2,000 psi Static 1,000 psi rotating Pressure from above - 1,000 psi static and rotating Controlled by the MLP control system
Choke and Kill lines pass through it
SRD Joint and Insert
19
Subsea Rotating Device Separates Mud from Riser Fluid
Located above the Solids Processing Unit in the DGD System The Active guts: seals and bearings are retrievable Seals pressure from both below and above, typically 50 psi, up to 1000 psi WP Maintains the gradient interface Allows for rapid Managed Pressure Drilling type operations
20
SRD and SPU Must Fit Through the Rotary
Santa Ana has a 72 rotary
2011 Chevron U.S.A. Inc. All Rights Reserved. This material is proprietary information of Chevron U.S.A. Inc. and is Confidential Restricted Access to specific, authorized individuals only. Unauthorized modification, duplication or distribution of this material is expressly forbidden.
21

(Not to Scale)
22
The Solids Processing Unit (SPU)
Part of a riser specialty joint Provides feed of mud to MLP Sizes solids to 1-1/2 or smaller Controlled and powered by the MLP control system Choke and Kill lines pass through it
23
Tears Everything to Pumpable Sizes

Sits in Riser below SRD
Two separate feed paths

Can be flushed in multiple ways
24

(Not to Scale)
25
The Heart: GEs MudLift Pump Delivery in 3Q2011

(2) Triplex modules
80 gallon chambers 1800 gpm max rate
10,000 WD rating
18.5 ppg mud
PUMP SECTION
HYDRAULICS
VALVE MANIFOLD
26
About the MLP

Built by GE/ Hydril Made the original unit that was field tested Modernized About 18 x 18 x 30 high
About 450,000 lbs

MULTIPLE redundancies Operates with six cylinders, five, four, three or even two in a pinch Powered by SEAWATER
Emergency Disconnect
BOPE systems are NOT changed

Disconnect is at the LMRP and MLP comes with the LMRP
Disconnected dynamics are similar to conventional
28
Pump Modularization
Pump can be broken into separate lifts for initial lift onto rig
Triplex Modules are Interchangeable Mirror Images
29
Reliability -Initial Endurance Testing Complete. Second Phase Starting

Pumping Continuously
Pumped 500,000 Cycles
The equivalent of 3 wells/~1 year!

Tear Down and Xrays revealed NO CHANGES in Diaphragms Phase II Testing Underway
30

(Not to Scale)
31
Subsea Manifold
Most Valves are 5K
Provides Versatility
Most operations conducted offline Redundant Flow Paths
32
DGD Subsea Component Stack-Up (Not to Scale)
33
Subsea Stack
The BOP Stack is unchanged

Once extra valve placed in the Choke line for improved operations Still have complete conventional Well Control available.
34
People Preparation is Extensive
Drilling Engineers: How to Design DGD Wells and Secure Permits Drill Site Managers, Field Drilling Engineers, FDEs and Rig Crews: How to Perform DGD Operations (Routine and Well Control) Offshore Support Personnel: How to maintain, troubleshoot and repair equipment
People Preparation Starts with HAZOPS
HAZOPS
JIP Drilling Procedures Well Control Procedures
FORMS BASIS FOR: New detailed procedures, Well design tools/software, Revised training material, Improved simulator Valve manifold layout, Specialized drilling equipment mods, DGD System Control philosophy and screen layouts, etc.
Simulator
Training
Permits
Initial HAZOPS Were Completed in 2010
9 months Effort Feb 10 Oct 10 ~ 22 All-Day HAZOPS covering nearly 50 DGD operations and well control procedures have occurred.
Tremendously valuable learning exercise.
Total Man-years to date: ~20!
37
Were Building Well Design Tools to Facilitate Well Design for our New DGD Drilling Engineers
38
Control Philosophies are Agreed and Drillers Panel Layouts are the Result
Setting Level Alarms
Recording Trends
Monitoring Trends Picking Mode of Operation
39
All of these Things are Incorporated into Training Programs and the Pre-Spud Meeting
DGD Project Schedule
4Q09
1Q10
2Q10
3Q10
4Q10
1Q11
2Q11
3Q11
4Q11
1Q12
Pacific Santa Ana Ship Fabrication
Select Rig
Fabrication at Samsung Heavy Industries, S. Korea Sail
MudLift Pump
Procedures/Plans Training/Pre-spud Commission DGD Begin Ops
HAZOPS
Procure/Fabricate
FAT/SIT
Well Plans
Train/Pre-spud
HUC
41
DGD: The Future is Here! Its Only Just Beginning!
2011 Chevron
42

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Dual Gradient Drilling The System

David Dowell Chevron North America Exploration and Production Company

DEA Presentation June 23, 2011

2011 Chevron U.S.A. Inc. All Rights Reserved.

Single Mud Weight

Heavier Mud w/ Seawater Density Above Mudline

Same Bottom Hole Pressure

2011 Chevron U.S.A. Inc. All Rights Reserved.

Impact in Deepwater: Casing Point Reduction

5 Casing Points Conventionally

Single Gradient Density at TD

Fracture Pressure Seawater Hydrostatic

Casing Points Dual Gradient

Dual Gradient Drilling Defined Major Components

Mud Return Line

Subsea Rotating Device (SRD)

Solids Processing Unit (SPU)

MudLift Pump (MLP)

Drill String Valve (DSV)

2011 Chevron U.S.A. Inc. All Rights Reserved.

Normal Drilling The U-tube Is Balanced

Sea Level Drillstring Annulus

2011 Chevron U.S.A. Inc. All Rights Reserved.

DGD Drilling The U-tube Is Unbalanced

Sea Level Drillstring Annulus

2011 Chevron U.S.A. Inc. All Rights Reserved.

The Drill String Valve Arrests the Natural U-Tube

2011 Chevron U.S.A. Inc. All Rights Reserved.

About the Drill String Valve

Easier to stop the MLP

Run above the BHA, you cant wireline through it

DGD Subsea Component Stack-Up

2011 Chevron U.S.A. Inc. All Rights Reserved.

2011 Chevron U.S.A. Inc. All Rights Reserved.

Pits divided for multiple fluids

2011 Chevron U.S.A. Inc. All Rights Reserved.

Two trip tank systems

MUD TRIP TANK

Mud Return Line (MRL)

2011 Chevron U.S.A. Inc. All Rights Reserved.

Return Line Manifold And A Drilling Choke

2011 Chevron U.S.A. Inc. All Rights Reserved.

Tripping and Displacement Manifold

Mud Return Line (MRL)

2011 Chevron U.S.A. Inc. All Rights Reserved.

The Drilling Riser is Modified

Flange End of Riser

Kill Line Hydraulic Line Mud Return Line

2011 Chevron U.S.A. Inc. All Rights Reserved.

DGD Subsea Component Stack-Up

2011 Chevron U.S.A. Inc. All Rights Reserved.

The Subsea Rotation Device (SRD)

Has the SRD Bypass built into it

2011 Chevron U.S.A. Inc. All Rights Reserved.

SRD Joint and Insert

2011 Chevron U.S.A. Inc. All Rights Reserved.

Subsea Rotating Device Separates Mud from Riser Fluid

2011 Chevron U.S.A. Inc. All Rights Reserved.

SRD and SPU Must Fit Through the Rotary

Santa Ana has a 72 rotary

DGD Subsea Component Stack-Up

2011 Chevron U.S.A. Inc. All Rights Reserved.