"Continuous Circulation" Drilling

Maris International Ltd.
Continuous Circulation Drilling

Continuous Circulation Drilling Drilling problems minimised or eliminated Improved safety & production
1. Continuous Circulation Drilling

compared with Stop/Start circulation + MPD
The circulating mud pressure (or Equivalent Circulating Density ECD) in the well bore between the bit and the last shoe is intentionally kept below the Fracture Pressure and above the Pore Pressure of the exposed formation. (This Frac Pressure/Pore Pressure window is discussed under section 2.6). For offshore wells, particularly in deep water, the circulating mud pressure in the well bore at, or near, the last casing shoe can approach the formation Fracture Pressure as the circulating mud pressure at, or near, the bit approaches the Pore Pressure, requiring casing to be run before drilling further. When drilling conventionally, before each connection is made, the mud circulation is stopped and the mud pressure in the uncased borehole, drops rapidly, generally overshooting balance by several hundred psi before rising to the static level. This negative pressure surge, or swab, may induce flow from the formation if it falls below the formation pore pressure. After a connection is made, circulation is re-started and the mud pressure in the borehole, rises rapidly, generally overshooting by several hundred psi, before decreasing to the circulating level. This surge pressure may exceed the fracture pressure anywhere in the exposed wellbore
Pressure
Connections etc
Temporary surge
Temporary swab Depth Static pressure
Circulating pressure
Stop/start circulation drilling
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.
L.Ayling ITF JIP Director July 2009.
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
Mud in Mud out Coupler
Pressure a
Mud
Subsea BOP
Pressure in drill string
Cased Hole
Fracture Pressure
Last
Hydrostatic Pressure Exposed Formation Pore Pressure
e
Pressure in annulus
Pressure in drill string and annulus due to static pressure only
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.
Downhole Pressure Maintenance

If the section has been drilled to its limit, the circulating annular pressure, (d to e), is, typically, already close to the frac pressure near the last casing shoe (e) and close to the pore pressure near the bit (d). Static Annulus When circulation stops, the static mud pressure gradient across the exposed formation is lower than the dynamic pressure gradient. In this situation, most MPD providers aim to keep the bottom hole pressure steady (at d), by imposing pressure on the annulus at the surface, resulting in the pressure at, or near, the last casing shoe (at Y) being greater than when circulating and may enter the frac pressure zone. Alternatively, if the pressure at the last casing shoe is kept steady, the pressure at, or near, the bit (at Z) will be less than when circulating and may enter the pore pressure zone. Although the dynamic pressure loss up the annulus, across the exposed formation, when circulating, is small, it is nevertheless quite significant and, generally, beneficial. MPD methods do partially compensate for pressure loss, if and when circulation is stopped; and so assist in minimising the occurrence of several drilling problems But MPD methods do not compensate for many of the disadvantages of stop/start circulation, including reduced safety.
e
Fracture Pressure
Pressure in annulus, when circulating
Pore Pressure
Fracture Pressure
Pressure in annulus, when static & back pressured
Pore Pressure
Fracture Pressure
Pressure in annulus, when static & back pressured
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.

16 Drilling Problems :Minimised or Eliminated by Continuous Circulation Minimised Problems:

Formation Fracturing Lost circulation Differential Sticking Stuck Pipe Slugging of Cuttings Returns Narrow Pore/Frac pressure windows Lengths of sections in ERD wells Bit wear / ROP / Surge & swab
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.
2.0 Introduction to Drilling Problems

Caused by Stop/start Circulation
NPT (Non Productive Time) Much drilling NPT is attributable to Lost Circulation, Kicks, Sloughing, Stuck Pipe and Differential Sticking, all of which are largely caused by stopping/starting the circulation of drilling fluids. Continuous Circulation Drilling or Stop/start circulation + MPD MPD (equipment, techniques and real time computer modelling) compensate partially for the loss in downhole pressure, when circulation is stopped. However, MPD does not compensate for the other disadvantages of stop/start circulation such as:- loss of steady state dynamics, adverse decrease in annular pressure, cuttings settlement, rising temperature and reducing density of the static drilling fluid and time taken to circulate out cuttings from the uncased hole, before stopping circulation. Also, after making a connection, circulating out the potentially unstable 3 phase annular accumulations of gas, produced fluids or slugs of cuttings and debris, before re-commencing drilling. Adding MPD (Rotating BoP/annulus chokes) to Continuous Circulation Drilling Produces the additional benefit of being able to throttle the returning mud in the annulus to maintain downhole pressure, whenever tripping out of the hole. This avoids having to increase the circulation rate as the drill string is withdrawn, or displace to heavier mud, to achieve the same result. The most trouble free drilling is achieved, when the downhole steady state fluid dynamic regime, which has been well established while drilling, is left undisturbed throughout the drilling of each section. The hole is cleaned continuously and the only variations detected in flow, pressure, temperature and density, will be due to the formation being drilled. The feedback, to the drillers, is therefore far more sensitive to downhole changes and is safer.
2.1 Formation Fracturing

Minimised by Continuous Circulation The problem
Formation fracture occurs when the pressure in the well bore exceeds the Fracture Pressure of the formation. The Fracture Pressure can be defined as the hydraulic pressure imposed by the fluid in the wellbore at which the formation breaks down and the fluid penetrates the surrounding formation. Once fractured, the formation can absorb mud at a lower pressure than the initial Fracture Pressure. Controlling the circulating pressure in the annulus between the bit and last casing shoe to navigate down a narrow frac pressure / pore pressure corridor, is challenging; particularly, when stop/start circulation produces such static and transient pressure variations as shown below.
Conventional Drilling
The solution
Pressure
Pressure
Connections etc
Connections etc
Temporary surge
Temporary swab Depth Static pressure
Circulating pressure Depth Circulating pressure
Stop/start Circulation drilling
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.
2.2 Lost Circulation

If circulation fluid flows into the formation, this is experienced as a drop in the returning mud flow termed Lost Circulation. Lost circulation, as the result of formation fracture or drilling into a porous formation, is largely proportional to the positive differential pressure of the circulating fluid over the formation pressure. Near wellbore damage to the recently drilled hole is often caused by pumping up the formation with significant changes in annular pressure. This can turn a reasonably circular small diameter hole into a larger irregular cavity, which is more vulnerable to further collapse. Lost Circulation is expensive in mud usage and because of consequent circulation pressure reduction, can induce a kick elsewhere in the borehole.
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.
2.3 Differential Sticking

Differential Pressure Sticking A condition wherein the drill string becomes stuck against the wall of the hole and will not rotate. Conditions normally include a permeable formation, a nearly impermeable (thick) filter cake and a relatively high pressure differential across the filter cake between the well bore and the formation. Once the pipe is embedded in the filter cake, it is forcibly held there. Differentially stuck pipe is a major cost, involving significant NPT (Non Productive Time) on the rig. Attempts to free a stuck pipe can result in parting the drill string, followed by fishing or side tracking, adding many days to the well construction operation. During such attempts, any mud pressure reduction may induce a kick, which may be difficult to contain if circulation is interrupted during connections. The lower section of the drill string usually the drill collars, is under compression and in vertical wells is picked up off bottom to place the whole drill string in tension before ceasing rotation. This minimises the possibility of contact with the wall of the hole.
P2
P3
P3
P2
P1
Initial sticking
P2
P3
P1 P2 P3
Increased sticking a period of time
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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2.4 Stuck Pipe

Stuck Pipe is another major cost in certain drilling formations, involving significant NPT (Non Productive Time). Stuck Pipe can refer to the bit, collars, BHA (bottom Hole Assembly), or the drill pipe itself, all of which become stuck for several different reasons: Attempts to free stuck pipe can result in parting the drill string or backing off intentionally and then having to fish or side track, adding many days to the well construction operation. Stuck Pipe may be caused by: The borehole wall collapsing in friable or unconsolidated formations or plastically deforming inwards and reducing the hole size, both of which are encouraged by stopping/starting mud circulation, causing step changes in the downhole pressure with surges in both directions. Cuttings and debris settle in near vertical holes, when circulation stops unless high gel strength drilling fluid is employed. However this can impose even higher initial surge pressure on the well bore when circulation is resumed. In long laterals, the cuttings have only to settle a few inches to the lower side of the hole when circulation and rotation cease. Re-starting circulation and rotation only moves some of the accumulated cuttings up the hole before stopping for the next connection. This results in the formation of piles of debris or weirs at intervals, reducing the effective diameter and increasing the potential for stuck drill collars, BHA or Bit. The prime cause is insufficient and inefficient hole cleaning, aggravated by stopping the circulation during connections.
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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2.5 Slugging of Cuttings Return

Stopping/starting the mud circulation, inevitably causes significant variations in mud density and content across the shale shakers, after restarting circulation This is mainly due to cuttings and debris settling and the mud heating up down hole when circulation stops. To minimise this, cuttings are normally circulated back in the annulus above the drill collars after drilling has stopped and before circulation is interrupted. On restarting circulation the accumulated cuttings and debris have to be mobilised before restarting drilling.
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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2.6 Narrow Frac/Pore pressure windows

Pore Pressure and Fracture Pressure convergence can leave a very small operating window, which is a major issue for MPD (Managed Pressure Drilling). However all MPD techniques, computer programs and equipment aim to keep the down hole pressure steady as circulation is stopped. Unfortunately, the very nature of circulation is that there is a dynamic pressure drop in the annulus between the bit and the last casing shoe. There is therefore no MPD method that can maintain a constant pressure across the exposed formation between the bit and the last casing shoe, except continuous circulation. The challenge is not just to keep the dynamic circulating pressure within the Frac pressure/Pore pressure window. The gradient within the window is typically different from the circulating pressure gradient, particularly offshore and in deeper waters. As the circulating pressure gradient moves from close to the Frac Pressure at the last casing shoe, to close to the Pore Pressure at the bit, (rarely vice versa) the stage is reached where the section has to be cased. The casing programme, particularly in deep water can involve an inconveniently large number of cased sections, starting with overly large conductors and ending with uneconomically small production strings.
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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2.7 Lengths of sections in ERD wells problem

In lateral wells and Extended Reach Drilling (ERD) wells in particular, the increase in circulating pressure at the bit, can be solely due to the increasing dynamic (or friction) pressure component as the section extends horizontally. The Pore and Fracture pressure may not vary much from the last shoe to the bit but the circulating pressure at the bit increases with the length of the section. When circulation ceases, the mud pressure at the last casing shoe (and at the bit) may be close to the pore pressure. When circulating, the mud pressure at the bit will be approaching the frac pressure. The section length will be limited by the difference between the Pore and Frac pressure. This, in stop/start circulation, has to exceed the entire dynamic pressure drop from bit to surface. On long laterals, the settlement of cutting on the low side of the hole when circulation ceases, can, in some formations, cause serious problems. In such conditions, cuttings have to be circulated out of the uncased section, after stopping drilling to make a connection.
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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2.8 Bit wear / ROP / Surge & swab problems

An extensive range of bits has been developed to drill a wide variety of formations from clay to granite. However, a particular bit does not perform well in circumstances for which it was not designed. Excessive bit wear can occur when it is required to drill through debris accumulated during lengthy periods without circulation, or re-enter a hole that has been pumped up by stop/start circulation, during the tripping out, and in. Rate of Penetration (ROP) is generally reduced by a high overbalance between the circulating and formation pressures. In practise the mud weight/density is calculated to provide a small overbalance on formation pressure when circulation ceases, to control the possibility of influx from the formation, or kicks. With circulation stopped during tripping, axial motion of the pipe out of and into the well, produces negative and positive pressure fluctuations, swabbing and surging, which can cause hole damage, including the possibility of an influx of formation fluid or gas. Either way, some pumping up of the formation is inevitable.
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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2.9 Surging on stop / start circulation

Eliminated by Continuous Circulation The problem
Each time circulation is started, the normal pump pressure is exceeded by a dynamic pressure increment required to shear the gel of the static mud column and start it moving. This relatively sudden increase in pressure produces a surge which can fracture and/or weaken the exposed formation. Each time circulation is stopped, the down hole pressure momentarily decreases below the normal static mud pressure. This relatively sudden decrease in pressure produces a negative surge (or swab) which can initiate formation collapse or an influx of fluid (or kick) from the exposed formation. Either way, stopping/starting circulation effectively pressurises or depressurises the exposed formation. This has been happening ever since rotary drilling commenced some one hundred years ago. This pumping of the formation and stopping/starting circulation is the main contributor to most drilling problems caused by weakening of the exposed formation and is evidenced by the considerable current interest in MPD (Managed Pressure Drilling), which aims to compensate for the interruption of circulation to the wellbore.
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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2.10 Formation pumping & Balooning

Formation pumping is the undesirable effect of varying the downhole mud pressure up and down repeatedly. This has been considered as inevitable for many years and only recently has MPD (Managed Pressure Drilling) become an acceptable drilling technique At the upper extreme, the surge pressure on starting circulation can charge up a permeable formation and inject drilling fluid into the formation or even fracture it. Balooning is the ability of the formation to return this fluid to the wellbore when the circulating pressure drops and stabilises, giving the impression of a kick initiating. Over an open hole of several thousand meters, this can be a considerable and misleading volume.
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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2.11 ECD variations

Many drilling engineers use ECD (Equivalent Circulating Density), instead of circulating pressure when planning how to drill through a particular formation. Controlling the ECD is a main objective for the drilling team. The ECD is the sum of the density of the mud in the hole plus the density equivalent of the dynamic pressure drop generated by circulating. To be able to maintain a steady, unchanging ECD, would greatly assist the drilling of formations with narrow pore/frac pressure windows and minimise differential pressure to increase ROP. Controlling the ECD has the potential to minimise or eliminate a range of drilling problems, allowing a longer hole section to be drilled before running casing.
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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2.12 Well de-stabilisation in UBD

Underbalanced Drilling (UBD) can be defined as a drilling activity employing appropriate equipment and controls where the pressure exerted in the wellbore is intentionally less than the pore pressure in any part of the exposed formation with the intention of bringing formation fluids to the surface. The wellbore pressure must be maintained as near constant as possible, which is difficult when making connections; not just because of the loss of ECD when circulation is stopped, but because formation fluids, gas in particular, accumulate in the annulus, upsetting the pressure balance and have to be circulated out before resuming drilling Circulating out the formation fluids and re-establishing a steady state down hole can take up several hours of Non Productive Time (NPT) per connection.
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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2.13 Static Cuttings Settlement

When circulation is interrupted to make a connection, cuttings in the wellbore annulus start to fall even in high gel strength mud. In near vertical holes, cuttings and debris could accumulate sufficiently to trap the collars, BHA or bit. In lateral holes, the solids need only sink a few inches to settle on the low side and potentially trap the drill string when drilling recommences. This is minimised by taking extra time to circulate solids out of the uncased hole before stopping circulation.
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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2.14 Connection Kicks

Connection kicks are those influxes of formation fluids into the wellbore, which occur during conventional connection operations, caused by the drop in downhole pressure when circulation of drilling fluid is stopped. The downhole mud pressure, at the exposed formation in the annulus, is the sum of the hydrostatic mud pressure and the dynamic (or friction) pressure generated to move the mud back up the annulus to the surface; plus any back pressure imposed at the surface, on the returning mud. Until now, the Top Drive (or Kelly) could not be disconnected without first stopping the mud circulation. With stop/start circulation, the dynamic pressure is lost when circulation stops every time a connection is made. Additionally, on stopping circulation, the pressure drops temporarily below the static mud pressure which can initiate a kick when the safety margin on the static mud column is small. Furthermore, a connection kick may not be detected immediately and a tool joint in the drill string at rig floor level may have been disconnected, when the influx of formation fluids is detected. With the mud disconnected, circulation cannot be immediately started to limit the kick. The drill pipe BoP must be made up and a connection made before the mud pumps are re-started. This has been the situation on all rotary drilling rigs for over a hundred years
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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2.15 Disconnecting mud from the drill string

Stopping circulation and disconnecting the mud supply from the drill string while drilling is intrinsically unsafe. In rotary drilling with jointed pipe, it was inevitable when making a connection to add or remove drill pipe to/from the drill string. Intrinsically unsafe, as evidenced historically by the number of occasions when a kick has been initiated during a connection and developed into a blow out situation before drill pipe could be re-connected and circulation reestablished. Even with MPD techniques that try to compensate for the drop in pressure when circulation is stopped, making a connection during a drilling operation, is still not without a measure of risk, requiring both a sensitivity to detect down hole changes and an ability to respond quickly.
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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2.16 P & T variations in HPHT wells

Increasingly, wells have to be drilled to access hydrocarbons in HPHT fields. In these conditions when circulation is stopped to make a connection, the static mud column heats up and can change its properties. This change in properties can significantly affect the accuracy of hydraulic calculations; circulation rate, pressure, etc. In HPHT wells, pressure surges on stopping/starting circulation can be significant, potentially causing well-bore ballooning on start up, and fluid influx and formation collapse when the pumps are stopped. Stabilising the mud column before and after making a connection can be time consuming and add to NPT.
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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3. Improved Safety and Production

Facilitated by Continuous Circulation Drilling
3.1 Improved Safety

Conventional practice
While drilling ahead, the downhole pressure, temperature and dynamic flow regime, settle down to a near steady state, affected only by the formation being drilled. When stopping drilling, to add another stand of drill pipe, the mud pumps are stopped, usually after first circulating mud and cuttings away from the collars and BHA or back to the last shoe in lateral wells. As the circulation reduces to zero, the steady state is lost and the dynamic flow regime passes through several turbulent and laminar flow patterns, which encourage additional scouring and debris production. As the circulation shuts down, a negative surge temporarily reduces the downhole pressure to below the static mud pressure. This occurs across the whole of the exposed formation from the bit to the last shoe and may encourage an influx of fluid from the formation, a kick, or it may allow fluid to be relieved from the formation from being charged by the higher drilling pressure or ballooning. Both the changes in flow and pressure tend to damage the uncased hole. Having upset the downhole steady state regime and significantly lowered the downhole pressure often causing a fluid influx, the mud supply, which is the primary means of well control, is not only shut off by breaking the tool joint between the top drive and the drill string but disconnected completely. While making connections, the downhole mud heats up, cuttings sink and settle (depending on the gel strength), formation fluids accumulate (gas being a major concern), the shale shakers are out of use and the mud remains disconnected from the drill string. The ability of the driller to interpret the signs of what is happening down hole is significantly compromised.
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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.

By continuously circulating, the downhole pressure, temperature and dynamic flow regime, remain in a steady state, affected only by the formation just drilled. There are no pressure surges, no accumulated formation fluids, no static settlement of cuttings, no pumping of the formation and, above all, the mud is connected and flowing at all times. The connection operation is simplified and the exposed formation is not only treated with more respect, but the well remains under better control. The driller is able to respond to any well situation without having to first reconnect the mud supply and start up the mud pumps. With continuous circulation maintaining a steady state throughout the connection operation, any variation in downhole mud pressure or flow will be due to the formation and can be more easily and quickly interpreted as such. The CCS is constructed from recognised, standard BOP components and the connection operation is safely contained entirely within this assembly. The drill string is conventional without the necessity to introduce any valves or other mechanical items. In the event of any difficulty with the connection, the CCS allows remedial action to take place safely under pressure, while keeping the well under control at all times.
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3.2 Improved Production

Conventional practice
The drilling team construct wells to produce oil and gas from pay zones that are increasingly difficult to reach but, having done so, the ability of the pay zone to produce fluids is largely dependant on the extent to which drilling fluid has been squeezed into or lost to the formation. Fracturing and/or lost circulation within the pay zone may decrease the subsequent flow rate of production fluids Even if this is avoided, a major factor in subsequent productivity will be the extent of over balance pressure that existed during the drilling of the pay zone. Generally, this incremental over balance is set to ensure that the static mud pressure is in excess of the formation pore pressure to prevent a kick occurring. Increasingly, MPD techniques are used to allow NBD (near balance drilling) or UBD (under balance drilling). The circulating, or drilling, pressure exceeds this static pressure by the dynamic, or friction, pressure required to push the mud back to surface. Hence the balance when drilling is usually several times the balance when circulation stops. It is this drilling circulation pressure which forces drilling fluids into the formation. The drilling fluid includes barites to increase density, gelling additives to support cuttings when static, bit lubricant and additives to produce mud filter cake to reduce fluid loss to the formation. The subsequent production rate of hydrocarbons achievable from the well is fundamental to the well economics.

By maintaining a continuous circulation flow, the circulating pressure and balance, ECD, can be set at the optimum to control the well and maximise bit RoP, the static mud density can be reduced as can the fluid loss into the producing formation. With steady state pressure, temperature and mud flow, throughout the drilling of the pay zone, the chances of exposing a cleaner, undamaged production formation are greatly enhanced. Generally, the higher production rate will be very worth while.
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"Continuous Circulation" Drilling

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